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Toray Waterless Plate
Automatic Processor
TWL-650F
Instruction Manual
2003.4
Introduction
Introduction
Thank you for your purchasing Toray’s waterless plate automatic processor.
This document is the instruction manual describing functions and operation/work procedures and cautions for using/safety in order to use Toray’s waterless plate automatic
processor safely and fully utilizing its functions. Before using this machine, please read
this manual and understand the operation/work procedures thoroughly.
The items described in "For Safe Use" of this instruction manual and those
marked
in the procedure explanation sentences are cautions for safe use and
must be observed.
As to the MSDS of the treating solutions to be used together with the automatic processor, it should be obtained from the dealer and read prior to use.
Cautions in Using This Document
1 No part of this manual can be reproduced in any form without permission.
2 The contents of this manual are subject to change without notice when this product
is improved.
3 Do not operate/work using methods other than those described in this manual.
There is a possibility that unexpected failures or accidents are caused with
undescribed operate/work using methods.
We may not responsible for the accident with undescribed operate/work methods.
4 If there are any unknown points, errors, or omissions in this manual, please let us
know.
TWL-650F Instruction Manual i
Contents
1
2
3
Prior to Use
1
For Safe Use
2
For Maintaining Performance
4
For Protecting Environment
5
Appearance/Names of Portions and Safety Devices
6
Names and Functions of Operating Portion
8
How to Operate Automatic Processor
9
How to Operate Automatic Processor
10
Daily Check Points and Maintenance Works
12
Maintenance
15
How to Check Pre-treatment Solution Level and Replenish
16
How to Check Developing/After-treatment Solution
Level and Replenish
18
How to Control Shower Flow Rate
20
How to Clean Shower Pipe
22
How to Grease
24
How to Clean Pre-treatment Strainer
26
How to Replace Filter of Developing Portion
28
How to Clean Pre-treatment Strainer
30
How to Replace Filter of After-treatment Portion
32
How to Replace Filter of Washing Portion
34
How to Adjust Roller Nip Pressure
36
How to Replace Delivery Roller Molton
34
How to Change Treatment Solution
38
How to Change Developing/Washing Water
38
How to Measure and Adjust Brush Pressure
42
ii TWL-650F Instruction Manual
Contents
4
5
6
Troubleshooting of Automatic Processor/Plate
45
Unusual Machine Condition(Before Requesting Repair)
46
Causes and Measures for Plate Processing Fault
48
How to Change Installation of Automatic Processor Specifications
51
How to Install Automatic Processor
52
Changing Specifications of Automatic Processor
(Negative Positive)
56
Wiring Diagram/Specifications
59
TWL-650F Wiring Diagram
60
TWL-650F Specification
63
TWL-650F Instruction Manual iii
Composition of
Instruction Manual
How to Use
Instruction Manual
Be sure to use this instruction manual before operating the automatic processor.
Detailed work procedures and important information for preventing accidents
are described therein.
Procedure
The procedures for operating the automatic
processor and maintenance works are
described in accordance with actual works.
The works should be correctly done in
sequence. The marks in the procedure explanation indicate the following contents.
Tools necessary
8
+
4
The outline of this item is explained.
Caution for Safety
Procedure
Important points for safe work are described.
The safety instructions must be checked
before work is started.
1
2
3
Caution for Operation
Work check items and work-related cautions
are described.
P
Supplementary Item
Conditions of the automatic processor and
more detailed information during work are
described for your reference.
Check items and remedial methods when the
conditions are not improved through maintenance are described
iv TWL-650F Instruction Manual
P
indicates reference page
1
Prior to Use
Important matters about this processor are described. Be sure to read them before
operating the automatic processor.
Especially as to the safety-related matters, safety education must be given to those responsible for and in charge of the operation by the controller of the automatic processor.
TWL-650F Instruction Manual
1
Prior to Use
For Safe Use
Be sure to read
Matters which must be observed for safe work are described. The controller of the
automatic processor must give safety education to those responsible for and in
charge of the operation.
Explanation of Caution/Warning Marks
WARNING
Wrong handling may lead to serious injury or death.
CAUTION
Wrong handling may lead to injury or property damage.
PROHIBITION
Prohibition items. The instructions must be observed.
INSTRUCTION
Instructions which must be observed. The instructions must be observed.
WARNING
Earth Connection
Be sure to connect the ground. If the connection is incomplete, there is a possibility of electric shock.
Power Supply
Capacity
The receptacle of 100V AC rating 20A or higher should be used for the automatic
processor alone. If the capacity is insufficient or extension cord is used, there is a
possibility of electric shock, heating, or fire.
Machine Modification
Prohibited
Do not disassemble, repair or modify the machine. There is a possibility of losing
the safety functions and machine functions.
2TWL-650F Instruction Manual
For Safe Use
Prohibiting Removal
of Safety Device
Function
Do not remove the functions of the emergency stop button and side cover limit
switch. There is a possibility of leading to a serious accident.
No Touching of
Control Panel Wirings
Do not touch the control panel interior with bare hands. There is a possibility of
electric shock.
Caution
Power OFF prior to
Maintenance Working
Be sure to turn off power before removing the cover and starting adjusting works.
For working procedures, read and follow the instruction manual.
Wearing Protectors
When Handling Plate
Material
Since there is a possibility of cutting hands with the plate edges or damaging eyes
when handling the plate, protective goggles and gloves must be worn.
Wearing Protectors
When Handling Treatment Solution
Wear protective goggles and gloves when replenishing the treatment solution. Prior to work, be sure to read the MSDS of the treatment solution. If the MSDS is
missing, obtain it from the dealer.
Closing Top Cover
When Operating
During operation, there is a possibility of eye damage due to sprashing of the treatment solution or being caught in the brush, so the top cover must be closed.
No Touching of Rollers
and Brushes
Do not touch the rollers and brushes during operation because there is a possibility of your hand being caught by them.
Referring to Procedures
in Instruction Manual
The maintenance works must be correctly done in accordance with the procedures described in the instruction manual. The safety cautions must be observed.
Wearing Protective
Goggles for Adjusting
Flow Rate of the Shower
For checking the flow rate of shower , wear the protective goggles to prevent
splashing solution from entering your eyes because the checking is done when the
power is supplied. Especially when the top cover of the negative type pre-treatment solution, protective goggles must worn to prevent mist from entering your
eyes.
Remove contact lenses because there is a possibility of them being deformed.
TWL-650F Instruction Manual
3
Prior to Use
For Maintaining Performance
Be sure to read.
Items necessary for maintaining the machine performance are described. Periodical machine maintenance must be carried out.
Important Items
Contents necessary for maintaining the performance of the machine are shown
below.
Periodical Greasing
of Bearing
If greasing is neglected, bearing and shaft wear out may be caused.
Checking Treatment
Solution Level
If the treatment solution becomes lower than minimum level, the machine operation will be stopped by float switch in tanks. The replenishing solution should be
more than minimum level.
Checking Shower
Flow Rate
If the shower flow rate is low, abnormal plates may be made.
Checking Plate Edge
before Inserting
Before inserting the plate into the processor, check if the plate is bent. Bending
plates may cause jamming probrem.
Periodical Replacement
of Filter
If filter replacement is neglected, Insufficient shower flow may be caused, and this
will cause plate faults.
Periodical Replacement
of Brush
The brush attached to the machine is consumable, and worned brush may cause
underdevelopment. It is necessary to replace it either every 2 years or 20,000
plates to maintain the developing performance.
Periodical Replacement
of Roller
If transporting roller is deteriorated, slippage, bending or solution cutting fault
may occur, resulting in plate faults. It is necessary to replace it either every 2 years
or 20,000 plates to maintain the performance.
After-Sale Service
The after-sale service will be done in accordance with the attached sheet of aftersale service rules. Contact the dealer.
4TWL-650F Instruction Manual
For Protecting Environment
For Protecting Environment
Be sure to read
The following describes the methods of disposing of waste/waste solution produced in the waterless plate processing and automatic processor operation. They
should be disposed of in a correct method.
Methods of Disposing of Waste Solution/Waste
The following shows how to dispose of waste solution/waste produced.
Unprocessed Plate
Case/Slip Sheet
Request for the disposal should be made to a wastepaper recovery firm.
Cover Film
This should be disposed of as waste plastics. (Material: positive type PET, negative
type PP)
Unprocessed Plate/Processed Plate
Request for the disposal should be made to an aluminium recovery firm. (Same as
for the conventional PS plate)
Unnecessary Treatment
Solution/Waste Solution
Basically replenishment is made for loss and no waste solution is produced, but if
waste solution is produced for some reason, it should be disposed of in accordance with the MSDS of each treatment solution.
Draining Developing
Water
Please consult our Sales Representative, if the water can be drained into the sewerage (only during automatic water supply), because each area has different Water
Pollution Control Law and Sewage Water Law.
Filter
It should be disposed of as waste plastics (material PET, PP + silicone rubber residue).
TWL-650F Instruction Manual
5
Prior to Use
Appearance/Names of Portions
and Safety Devices
Toray Waterless Plate
Automatic Processor
For inquiry about the machine, please inform us of the following model name and
production No.
Model name
Processor: TWL-650F
Appearance and Names of Portions
Sketch Drawing
Top cover
Emergency
stop button
Plate inserting
limit switch
tic
oma or
Autrocess
p
it
ter
Wa ing un
h
s
a
w
Level
gauge
Left side cover
Developing water
Level gauge
Operation
portion
Power breaker
After-treatment
Level gauge
Right side cover
Right Side View
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Side cover
limit switch
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
6TWL-650F Instruction Manual
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
Water washing shower
drain valve
recovery valve
flow rate control valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
Appearance/Names of Portions and Safety Devices
Safety Devices
Emergency
Stop Button
It is provided on the right/left side cover of the automatic processor.
ON (push in): Electricity is cut off by the breaker, and the button is locked.
OFF (release): Turn the button in the arrow direction until it stops.
TWL-650F
Side Cover
Limit Switch
It is provided within the right/left side cover of the processor/water washing unit.
TWL-650F
Warning Labels Shown
on Equipment
On operation portion
CAUTION
Read instruction manual
before operating switch.
On each top cover
On each side cover
CAUTION
Open gears
Will cause severe
personal injury.
On each top cover
CAUTION
CAUTION
Open rollers.
Can cause severe
personal injury.
Chemical splash or
vapor.
Can burn eyes.
Control box
On each brush cover
CAUTION
DANGER
Hazardous voltage.
Will cause severe
injury or damage
transformer.
Open rollers.
Can cause severe
personal injury.
TWL-650F Instruction Manual
7
Appearance/Names of Portions and Safety Devices
Names and Functions of Operating Portion
COUNTER
1 Counter
The number of plates processed is counted.
0001
1
2 Power indicating lamp
MAIN: It is lit with the processor breaker and select switch AUTO
2
MAIN
3
OK
3 Ready lamp
AUTO
STOP
(it is extinguished by pressing STOP).
CHECK
OK: This lights when the automatic processor becomes ready to process (plate is not accepted when it is dark).
4
4 Operation select switch
STOP: To stop the operation of the automatic processor.
AUTO: The automatic processor is automatically operated.
CHECK: Used for measuring the brush pressure.
SPEED
5
5 Speed setting volume switch
SPEED: For setting the transporting speed.
TWL-650F
Changing Setting of Transporting Speed
Setting Changing
Procedure
The setting is done with the speed control volume switch of the operation portion.
1
Unlock by turning the lock knob of the volume unclockwise.
SPEED
Unlock
Lock
2
Turn the black knob of the volume (the digit is not in agreement with the actual speed).
SPEED
Down
Speed
Up
You may need to find actual speed by using ruler.
(See Speed conversion table.)
3
8TWL-650F Instruction Manual
Lock by turning the lock knob of the volume switch clockwise.
2
How to Operate
Before operating the automatic processor, be sure to check prior to work and then
turn on the power. During operation, always check that the machine is operating
normally.
TWL-650F Instruction Manual
9
How to Operate
How to Operate
Automatic Processor
Prior to Operation
Before operating the automatic processor, carefully read this instruction and correctly operate in accordance with the procedure.
Procedure
Checking Work prior to Operation
1
Is the power cord plug inserted in the receptacle?
Is the receptacle capacity sufficient?
Is the power source of the receptacle turned on?
2
In the case of automatic supply of developing water, is the
valve open?
3
Is the quantity of each treatment solution sufficient?
Preparation for Operation
4
Turn ON the breaker of the processor, and set the select
switch of the operation panel to AUTO.
AUTO
ON
CHECK
OF
F
TRI
PP
ED
STOP
If the breaker cannot be turned on, check the following items.
1) The emergency stop switch is locked.
2) The side cover is not closed.
The red lamp (MAIN lamp) to confirm that power is supplied lights
and the temperature control of the pre-treatment solution starts.
MAIN
10TWL-650F Instruction Manual
OK
How to Operate Automatic Processor
When the temperature of the pre-treatment solution reaches
the set temperature, the OK lamp (green) lights and the preparation for operation is completed
5
.
MAIN
OK
Automatic Operation
6
Remove the cover film of the plate already exposed and insert
the plate.
The machine does not operate unless the plate is inserted and the
limit switch works.
Correct the plate end if bent. The limit switch installed to the inserting board works, the transporting roller rotates, the plate is
pulled into the processor, and automatic developing is done.
7
A while after the plate is carried out, the operation automatically stops.
The stop time is set with the PC of the control panel.
Stopping Operation
8
At the completion of work, set the operation switch to STOP
and processor breaker to OFF.
TWL-650F Instruction Manual
11
How to Operate
Daily Check Points
and Maintenance Works
Daily checking and
maintenance
In order to maintain the machine performance, the checking and maintenance
works must be done. Please prepare/stock consumables necessary for the maintenance works.
Check Points and Maintenance Works
Checking (daily) before
power is turned on
1-1 Is oil leaking around the automatic processor?
Visual checking of the floor surface
1-2 Is the pre-treatment solution level proper?
Checking the level gauge in the pre-treatment solution tank
Replenish if insufficient.
P
16
1-3 Is the developing/washing water level proper?
Checking the developing /washingwater level gauge on the right side
face
P
18
Replenish if insufficient.
1-4 Is the after-treatment solution level proper?
P
Checking the after-treatment solution level gauge on the right side face
18
Replenish if insufficient.
Check levels before power is turned on.
Level will go down after pewer is turned on.
Checking (daily) during
operation and action
(as required) at trouble
2-1 Are the shower pipe holes of each tank clogged?
Visual checking of uniformity
Clean the pipe if clogged.
P
22
2-2 Is the flow from the pre-treatment shower pipe sufficient?
Visual checking of flow
Adjust the flow rate if insufficient.
P
20
Insufficient even when the valve is fully opened
Clean the pre-treatment strainer.
P
26
2-3 Is the solution flow from the developing/after-treatment /washing shower pipe
sufficient?
P
Visual checking of flow
20
Adjust the flow if insufficient.
Insufficient even when the valve is fully opened
Replace the filter .
Clean the after-treatment strainer.
2-4 Is liquid squeeze/transportation good?
Visual checking of transportation
Adjust the roller nip pressure
if insufficient.
Still wrong even after adjustment
Replace the roller (consult the dealer).
12TWL-650F Instruction Manual
P
28-35
P
36
Daily Check Points and Maintenance Works
Periodical work
(weekly/monthly/yearly)
3-1 Changing developing water (in case of batch system)
Once/week
P
40
3-2 Greasing portions of automatic processor
Once/month
P
24
3-3 Changing whole quantity of treatment solution
(Pre-treatment :Once / 3-6 month, After-treatment :Once / year)
Checking development
of plate processed
P
38
4-1 Is the degree of exposure proper?
Checking the degree of exposure with the step guide
Adjust the exposure time if outside the standard range.
4-2 Are the dots reproduced as the film?
Visual checking of plate dot reproduction
Measure the brush pressure if some dots are lost.
Brush pressure is low
Adjust the brush pressure.
P
42
P
43
Not fixed by adjusting
Replace the developing brush (consult the dealer).
P
14
TWL-650F Instruction Manual
13
Daily Check Points and Maintenance Works
After-Sale Service
The following maintenance works are done charged by the manufacturer. Contact
the dealer.
1. Roller replacing (rubber changing)
The warranty period is 2 years or 20,000 plates passing whichever is shorter.
2. Brush replacing (brush changing)
The warranty period is 2 years or 20,000 plates passing whichever is shorter.
3. Repairing failure parts
The warranty period for parts is 1 year. If the failure is attributable to faulty maintenance, the repairing cost is charged even within the warranty period.
For the details, read the attached after-sale service rule for
TorayÕs waterless plate equipment.
Consumables
Pre-treatment solution (for replenishing)
Always stock recommended
After-treatment solution (for replenishing)
Always stock recommended
Filter (for replacement)
Always stock recommended
Transporting roller (rubber changing)
Request when required
Developing brush (brush changing)
Request when required
After-treatment brush (brush changing)
Request when required
Warranty of Plate Materials
Should any plate quality trouble occur which seems to be attributable to our manufacturing, attach to the products the trouble detail and production lot No. written
on the plate material case and contact the dealer or our company. If the cause is
recognized to be our manufacturing fault, materials will be replaced with the same
number of new products, and no other responsibilities will be taken by our company.
Plate Material Case Label
TAP: positive type
TAN: negative type
TAN E
24
Plate thickness
14TWL-650F Instruction Manual
Plate size
670 mm X 560 mm
50 SHEETS
Product type
Plant control No.
T06 025343
512507 D
Production lot No.
3
Maintenance
The checking and maintenance works to maintain the machine performance must be
carried out for maintaining good machine condition. Please prepare/stock consumables necessary for the maintenance works.
TWL-650F Instruction Manual
15
Maintenance
How to Check Pre-treatment
Solution Level and Replenish
Solution level checking
and replenishing
Since the treatment solution consumes as it is used, daily checking must be done.
When the solution level approaches the lower limit, the solution should be replenished in accordance with the following procedure.
Procedure
Checking Pre-treatment Solution Level
Checking Treatment
Solution Level
1
Open the pre-treatment top cover.
Since mist tends to occur in the negative pre-treatment portion,
contact lenses should be removed when removing the top cover
and protective goggles should be worn to prevent mist from entering your eyes.
2
Check with the level gauge in the pre-treatment tank if the
treatment solution level is lower than the lower limit line. If
lower than the lower limit, replenish the solution by the following procedure.。
Pre-treatment tank
Lower limit line
Float switch
Replenishing Pre-treatment Solution
Checking Treatment
Solution Label
16TWL-650F Instruction Manual
3
Check the treatment liquid label to see if the pre-treatment solution for replenishing is correct.
How to Check Pre-treatment Solution Level and Replenish
Work preparation
4
Set OFF the breaker of the processor.
Be sure to turn off power before starting the work.
5
Remove the top cover of the pre-treatment portion.
Since mist tends to occur in the negative pre-treatment portion,
contact lenses must be removed when the top cover is removed,
and protective goggles must be worn to prevent mist from entering
your eyes.
Replenishing solution
6
While checking the level gauge, put in the pre-treatment solution until the solution level reaches the upper limit line.
Wear protective goggles to prevent splashing solution from entering your eyes, and wear rubber gloves to prevent it from contacting to your skin.
When the pre-treatment solution is replenished from a can, divide
the content into a proper container using a baby pump, etc. before
putting it in.
7
Return the rid of the pre-treatment portion to its original position.
8
Start operation.
After the solution is replenished, the solution temperature decreases and the OK lamp goes out, and it takes some time until it
lights again.
TWL-650F Instruction Manual
17
Maintenance
How to Check Developing/Aftertreatment/Washing Solution
Level and Replenish
Level checking and
replenishing
Since the treatment solution decreases as it is used, daily checking must be done,
and when the level approaches the lower limit, the solution must be replenished
according to the following procedure.
Procedure
Checking Solution Level
Checking treatment
solution level
1
Check with each level gauge on the right side face if the treatment solution level is lower than the red line. If lower than the
lower limit, replenish the solution in accordance with the following procedure.
Developing level gauge
(tap water)
After-treatment level gauge
(after-treatment solution)
Water-Washing
level gauge
(tap water)
Replenishing
required
(Upper limit)
green line
Red line
(lower limit)
18TWL-650F Instruction Manual
How to Check Developing/After-treatment/Washing Solution Level and Replenish
Replenishing Solution
Checking treatment
solution label
2
Check the treatment solution label to see if the after-treatment
solution for replenishing is correct. The developing portion
uses tap water regardless of the type of plates..
Work preparation
3
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
Solution replenishing
4
Remove the top cover of the developing/after-treatment
/washing portion.
5
Remove the developing/ after-treatment/washing brush
cover.
6
While checking the level gauge, put in water or after-treatment
solution until the level reaches the upper limit green line.
Wear protective goggles to prevent splashing solution from entering your eyes and rubber gloves to prevent it from contacting to
your skin.
When the after-treatment solution is replenished from a can,
divide it in a proper container using a baby pump, etc. before putting it in.
Be careful so that it will not enter the adjacent tank.
Checking
after replenishing
water/solution
7
Return the brush covers and the top covers to their original
positions.
8
Check again the developing water quantity/treatment solution
quantity with the level gauges.
9
Start the operation.
After the solution is replenished, the solution temperature decreases while the machine is stopped and the OK lamp goes out,
and it takes some time until it lights again.
TWL-650F Instruction Manual
19
Maintenance
How to Control
Shower Flow Rate
Controlling
shower flow rate
The shower flow rate gradually decreases due to clogging of the strainer and thefilter. Check the shower flow rate and adjust the opening of the shower flow valve
according to the following procedure, if it is low.
Procedure
Checking Shower Flow Rate
Work preparation
1
Turn ON the beaker of the processor.
2
After the OK lamp lights, set the operation switch to CHECK.
An operation other than transporting starts. During the CHECK
operation, the brush rotates, so the brush cover must not be removed.
Shower pipe
3
Brush or roller
short
Proper
Open the top cover and check that the shower solution quantity is sufficient. If it is insufficient, increase the shower flow by
the following procedure.
When the top cover is removed, wear protective goggles to prevent
splashing solution from entering your eyes. Especially in the negative type pre-treatment portion, mist tends to occur, and contact
lenses must be removed and your face must not be put near the top
of the pre-treatment tank.
Excessive
Adjusting Shower Flow Rate
Work preparation
4
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
5
Open the right side cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off.
6
Check the flow control valve corresponding to the shower to
be adjusted.
The valves are marked with the tags of pre-treatment solution, developing/washing water, and after-treatment solution control. Do
not mistake them with the solution recovery valves.
20TWL-650F Instruction Manual
How to Control Shower Flow Rate
Controlling flow rate
7
Adjust the opening of the shower flow control valve (green) for
the insufficient flow.
Valve Positions
Fully opened
P
6
Fully closed
Half opened
Counterclockwise turning is to open.
Checking
after adjusting
8
Return the right side cover/top cover to their original positions.
9
Turn ON the breaker of the processor.
If the pre-treatment solution temperature decreased during work,
the OK lamp is dark. Wait until it lights.
10 Automatic operation can be done by setting the operation
switch to AUTO.
Solution Flow Is Low
Even When Valve Is Fully Opened
Shower pipe holes are
clogged with foreign
matter
Check if the shower pipe holes are clogged. If so, remove the shower pipe andclean.
Filter is clogged
In the case of the developing/after-treatment /washing portion, check the number
of plates processed to see if the filter is to be replaced.
Recomend:after 2000 or more plates processing.
Strainer is clogged
with foreign matter
In the case of the pre-treatment/after-treatment portion, the strainer may be
clogged with cover film fragments. Clean the strainer.
Hoe to clean
P
22
TWL-650F Instruction Manual
21
Maintenance
How to Clean
Shower Pipe
Cleaning shower pipe
Check if the shower solution comes out uniformly. If the pipe holes are clogged,
clean the shower pipe according to the following procedure.
Procedure
Checking Shower Solution Quantity
Work preparation
1
Set to ON the breaker of the processor.
2
After the OK lamp lights, set the operation switch to CHECK.
An operation other than transporting starts.
During the CHECK operation, the brush rotates, so the brush cover
must not be removed.
3
Open the top cover, and check that the shower solution
comes out uniformly from the pipe holes. If the holes are
clogged, clean the shower pipe according to the following procedure.
When the top cover is removed, wear protective goggles to prevent
splashing solution from entering your eyes. Especially in the negative type pre-treatment portion, mist tends to occur, and contact
lenses must be removed and your face must not be put near the top
of the pre-treatment tank.
Cleaning Shower Pipe
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
22TWL-650F Instruction Manual
Remove the top cover.
How to Clean Shower Pipe
3
Remove the shower pipe.
Pin
3. Pull
2. Raise
1. Push
To remove it, raise the right side while pressing the shower pipe
against the left side face.
Cleaning pipe holes
4
Remove the dust clogging the shower pipe holes.
Clean the holes with a wire or toothpick, wash out the foreign matter in the shower pipe with water, and then drain well.
5
Return the shower pipe to its original position.
Set it in such a way that the pin of the pipe end is fit in the notch.
6
Return the top cover to its original position.
Checking after cleaning
7
Operate the automatic processor.
8
Check if the solution from the shower comes out uniformly and
if the direction of the solution coming out of the shower pipe is
correct.
After-treatment portion
Pre-treatment portion
Water washing portion
Developing portion
If the showering direction is wrong, the solution may be mixed in
the adjacent tank or solution leakage from the tank may be
caused.
TWL-650F Instruction Manual
23
Maintenance
How to Grease
Grease
gun
Greasing
Greasing is indispensable for maintaining the machine performance. If greasing is
neglected, seizure of the bearing and wear of the brush shaft will be caused. Greasing must be done at least once a month according to the following procedure.
Procedure
Greasing-Up of Bearings
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
Remove the right and left side covers.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off.
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Side cover
limit switch
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Greasing
24TWL-650F Instruction Manual
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
Water washing shower
drain valve
recovery valve
flow rate control valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
3
Using the grease gun, supply grease to the developing/aftertreatment/washing brush bearings, right and left.
How to Grease
Right side
Left side
Cam
Bearing
greasing
points
Greasing
port
(4 ports in total)
Bearing
Brush
shaft
Cam
The grease nipple is of standard type (conforming to JIS B-1575).
A regular grease gun sold on the market can be used.
JIS ; Japanese Industrial Standard
4
Grease up the cams and chain.
As the grease, general-purpose type such as industrial ordinary
grease and lithium type grease can be used.
Grease viscosity (consistency) shall be class 2 of JIS classification.
5
Return the right and left side covers to their original positions.
TWL-650F Instruction Manual
25
Maintenance
How to Clean
Pre-treatment Strainer
17
Cleaning pre-treatment
strainer
The pre-treatment strainer recovers cover film fragments and fiber pieces dropped
in the pre-treatment tank. It should be cleaned if solution flow becomes low even
when the shower valve is fully opened.
Procedure
Cleaning Pre-treatment Strainer
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
Open the right side cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off.
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Cleaning strainer
26TWL-650F Instruction Manual
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
drain valve
recovery valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
3
Remove the cap of the pre-treatment strainer.
How to Clean Pre-treatment Strainer
Connecting portion
Pre-treatment strainer
Packing
. Cap
Remove it using a 17mm spanner or monkey wrench.
Support the strainer of the piping connecting portion with the
monkey wrench so that unreasonable force will not be applied to
the PVC piping.
4
Remove the screen (wire gauze) fixed to the cap, remove
such dust as ravelings and cover film fragments attached to
the inside wall face, and wash with water.
5
Fit the screen (wire gauze) in the cap and then install the cap
to the strainer.
Screen
Cap
Packing
Checking
after cleaning
6
Lightly tighten with the wrench.
7
Return the right side cover to its original position.
8
Operate the automatic processor.
9
Check if a sufficient amount of solution is coming out of the
shower pipe. If an excessive amount comes out, adjust the
flow control valve.
Flow control
P
20
10 Check for any solution leakage onto the floor during opera-
tion.
Shower Solution Does Not Come Out Smoothly
Even After Cleaning
Pump suction port is
clogged with foreign
matter (cover film fragments, etc.)
It is necessary to overhaul and clean the pump.
Consult our dealer.
TWL-650F Instruction Manual
27
Maintenance
How to Replace Filter
of Developing Portion
Dedicated
Replacing
development filter
The development filter recovers silicon residue scraped off in the development.
Replace it according to the following procedure every 2000 plates processed as a
measurement.
Procedure
Replacing Filter
Work preparation
1
Check if a spare filter is available.
The filter is consumable. It should be purchased in advance from
the dealer of the processor.
2
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
3
Remove the right side cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
drain valve
recovery valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
4
Place a bucket under the developing water drain valve, open
the valve, and drain the developing water(about 10-15L).
The work can be done easier by connecting the hose to the drain
port if available nearby.
28TWL-650F Instruction Manual
How to Replace Filter of Developing Portion
5
Open the development filter/drain valve, and drain the developing water in the filter housing into a proper empty container.
About 500cc remains in the housing.
Replacing filter
Filter
housing
O ring
6
When the water no longer comes out of the drain valve, close
the valve.
7
Remove the filter housing by turning it to the left (clockwise as
seen from the top).
8
Remove the filter in the filter housing, and install a new filter.
9
Check that the O ring (packing) in the upper part of the filter
housing is fit in the correct position.
10 Set the filter housing to its original position by turning it to the
right.
Filter
11 Check that the drain valve is closed.
Drain valve
OPEN
CLOSE
12 Readjust the opening of the developing water shower flow
control valve to about half opened.
Just after the filter is replaced, the shower flow increases and
there is a possibility of the shower solution being scattered if the
valve remains fully opened, so it should be half opened.
13 Return the right side cover to its original position.
Checking
after replacing
14 Check that the water is filled to the green line of the level
gauge.
If insufficient, replenish the water. Care must be taken when replenishing because if the water is lacking in the pre-treatment
portion, the developing performance is extremely lowered.
15 Operate the automatic processor, and check if the solution
quantity from the shower pipe is proper.
If excessive, adjust with the shower flow control valve.
TWL-650F Instruction Manual
29
Maintenance
How to Clean
After-treatment Strainer
17
Cleaning pre-treatment
strainer
The After-treatment strainer recovers cover film fragments and fiber pieces
dropped in the pre-treatment tank. It should be cleaned if solution flow becomes
low even when the shower valve is fully opened.
Procedure
Cleaning After-treatment Strainer
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
Open the left side cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off.
Side cover
limit switch
Side cover
limit switch
Valves for cleaning
strainer(two places)
Cleaning strainer
3
After-treatment
strainer
Remove the cap of the after-treatment strainer.
If these two valves are not closed, the solution will leak in the
following process.
4
30TWL-650F Instruction Manual
Place a suitable container below the strainer and remove the
cap of the after-treatment strainer.
How to Clean After-treatment Strainer
Connecting portion
Pre-treatment strainer
Packing
. Cap
Remove it using a 17mm spanner or monkey wrench.
You can also remove it by hand.
5
Remove the screen (plastic made) fixed to the cap, remove
such dust as ravelings and cover film fragments attached to
the inside wall face, and wash with water.
6
Fit the screen (plastic made) in the cap and then install the
cap to the strainer.
Screen
Cap
Packing
Checking
after cleaning
7
Lightly tighten with the wrench,then open the two cleaning
valves.
8
Return the left side cover to its original position.
9
Operate the automatic processor.
10 Check if a sufficient amount of solution is coming out of the
shower pipe. If an excessive amount comes out, adjust the
flow control valve.
Flow control
P
20
11 Check for any solution leakage onto the floor during opera-
tion.
TWL-650F Instruction Manual
31
Maintenance
How to Replace Filter
of After-treatment Portion
Dedicated
Replacing
after-treatment filter
The after-treatment filter recovers silicon residue not removed in the development. Replace it according to the following procedure every 3000 plates processed as a measurement.
Procedure
Replacing After-treatment Filter
Work preparation
1
Check if a spare filter is available.
The filter is consumable. It should be purchased in advance from
the dealer of the processor.
2
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
3
Remove the right side cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off.
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
drain valve
recovery valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
4
Close the filter replacing valve.
For the valve position, see the drawing on the following page. If it
is not closed, the solution will not stop in the following process.
32TWL-650F Instruction Manual
How to Replace Filter of After-treatment Portion
5
Open the after-treatment filter drain valve and drain the aftertreatment solution in the filter housing into a proper empty
container.
About 500cc remains in the housing.
6
When the treatment solution no longer comes out of the drain
valve, close the valve.
7
Using a filter wrench, remove the filter housing by turning it to
the left (clockwise as seen from the top).
Wear rubber gloves.
Replacing filter
Filter
housing
8
Remove the filter in the filter housing, and install a new filter.
9
Check that the O ring (packing) in the upper part of the filter
housing is fit in the correct position.
10 Set the filter housing to its original position by turning it to the
right.
O ring
Filter
11 Check that the drain valve is closed.
12 Readjust the opening of the after-treatment solution shower
flow control valve to about half open.
Drain valve
OPEN
CLOSE
Just after the filter is replaced, the shower flow increases and
there is a possibility of the shower solution being scattered if the
valve remains fully opened, so the valve should be half opened
.
13 Return the right side cover to its original position.
Checking
after replacing
14 Check that the solution is filled to the green line of the level
gauge.
If insufficient, replenish the after-treatment solution.
15 Operate the automatic processor, and check if the solution
quantity from the shower pipe is proper.
If excessive, adjust with the shower flow control valve.
TWL-650F Instruction Manual
33
Maintenance
Dedicated
How to Replace Filter
of Washing Portion
Replacing
development filter
The washing filter recovers silicon residue not removed when washing the plates.
Replace it according to the following procedure every 3000 plates processed as a
measurement.
Procedure
Replacing Filter
Work preparation
1
Check if a spare filter is available.
The filter is consumable. It should be purchased in advance from
the dealer of the processor.
2
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
3
Remove the right side cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off.
Back view of the processor
Fresh water
supply valve
Washing water
drain valve
drain valve
Overflow
Fresh water supply port
Overflow port
4
Open the washing water drain valve and the overflow drain
valve,then drain the water from the washing tank.
5
Close both valves when the water is completely drained.
6
Open the after-treatment filter drain valve and drain the aftertreatment solution in the filter housing into a proper empty
container.
About 500cc remains in the housing.
34TWL-650F Instruction Manual
How to Replace Filter of Washing Portion
7
When the treatment solution no longer comes out of the drain
valve, close the valve.
8
Using a filter wrench, remove the filter housing by turning it to
the left (clockwise as seen from the top).
Wear rubber gloves.
Replacing filter
9
Remove the filter in the filter housing, and install a new filter.
10 Check that the O ring (packing) in the upper part of the filter
housing is fit in the correct position.
Filter
housing
11 Set the filter housing to its original position by turning it to the
right.
O ring
Filter
Drain valve
OPEN
CLOSE
Checking
after replacing
12 Check that the drain valve is closed.
13 Open the top cover of the washing portion.
14 Remove the washing brush cover and fill water to the green
line of the level gauge.
15 Return the top cover to its original position.
16 Operate the automatic processor, and check if the solution
quantity from the shower pipe is proper.
If excessive, adjust with the shower flow control valve.
TWL-650F Instruction Manual
35
Maintenance
4
8
How to Adjust
Roller Nip Pressure
Adjusting
roller pressure
The roller becomes smaller in outside diameter as it is used, causing trouble such
as slipping of transportation, meandering, and solution squeezing fault. If any
such symptom appears, adjust the pressure according to the following procedure.
Procedure
Adjusting Roller Nip Pressure
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.。
2
Remove the top cover.
When the top cover is removed, wear protective goggles to prevent
splashing solution from entering your eyes. Especially in the negative type pre-treatment portion, mist tends to occur, so contact
lenses must be removed and your face must not be put near the top
of the pre-treatment tank.
Adjusting roller
nip pressure
3
Using an 8mm spanner, loosen the lock nut of the roller nip
pressure adjusting bolt.
Adjusting bolt
Lock nut
Shaft holding block
It is loosened by turning it counterclockwise as seen from the top.
4
Before adjusting, loosen the roller nip pressure adjusting bolt.
This is done to even the nip pressure, right and left.
5
Then tighten the roller nip pressure adjusting bolt with your
two fingers.
Tighten it with uniform force, right and left.
6
36TWL-650F Instruction Manual
When the bolt end hits the shaft holding block and it cannot be
further tightened by two fingers, tighten it 1/4 turn clockwise
How to Adjust Roller Nip Pressure
using a 4mm hexagon wrench.
This makes the pressure almost proper.
The tightening amount should be at the same angle, right and left.
If the tightening amount is different between right and left, meandering will be caused. 。
Checking
after adjusting
7
After the adjusting is completed, fix (tighten) the lock nut.
8
Operate the automatic processor, and check the solution
squeezing and transporting.
When the solution squeezing and transporting is checked with the
top cover removed, do not extend your hand to the roller.
9
If the improvement is not satisfactory, tighten another 1/4 turn.
The screwing must not exceed 2 turns. The roller center will rise
and solution cutting fault will be caused. The transporting motor
will also be burdened by extra stress resulting in failure.
10 After the work is completed, return the top cover to its original
position.
Not Remedied even after Adjusting
Roller Fatigue
It is necessary to replace the roller every 2 years or 20,000 plates (roller is consumable).
Consult the dealer (it is charged).
TWL-650F Instruction Manual
37
Maintenance
How to Change
Treatment Solution
Changing
treatment solution
Basically it is enough to replenish for the quantity reduced without requiring
changing, but depending on the using situation, it may be preferable to change the
solution.
Procedure
Draining/Changing (Normally Not Required) of
Pre-treatment/After-treatment Solution
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
Open the right side cover and top cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off.
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Recovering deteriorated
treatment solution
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
drain valve
recovery valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
3
Place an empty container under the pre-treatment/after-treatment solution recovery valve, open the valve, and drain the
treatment solution in the tank.
Wear rubber gloves to protect your skin from the treatment solution.
4
38TWL-650F Instruction Manual
Close the pre-treatment/after-treatment solution recovery
valve.
How to Change Treatment Solution
For the method of disposing of unnecessary treatment solution,
see "Explanation of Handling Treatment Solution."
5
Put in each treatment solution to the green line of the level
gauge.
Proper amount
Insufficient
(Upper limit)
green line
Proper
amount
Red line
(lower limit)
The after-treatment solution is to be put in from above the brush
after the after-treatment brush cover is removed.
6
Return the right side cover and developing/after-treatment top
cover to their original positions.
If the side cover is not put back to its original position, the limit
switch works and the power cannot be turned on.
TWL-650F Instruction Manual
39
Maintenance
How to Change
Developing/Washing Water
Changing developing/
Washing water
If the automatic water supply piping is not installed, it is necessary to change the
developing/Washing water at the frequency of once a week or every 100 plates
processed. Change it according to the following procedure.
Procedure
Changing Developing Water
(without Automatic Water Supply)
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
Open the right side cover and developing/after-treatment top
cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off..
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Side cover
limit switch
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
Water washing shower
drain valve
recovery valve
flow rate control valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
3
Place a proper container under the drain valve, open the
valve, and drain the water in the tank.
A container with the capacity of 20 liters or more is needed.
40TWL-650F Instruction Manual
4
Remove the silicon residue on the inner wall surface of the developing tank and the roller with a sponge, etc. and wash with
water.
5
Close the drain valve.
How to Change Developing/Washing Water
Supplying fresh water
6
Remove the development brush cover, and put in fresh water
to the green line of the level gauge from above the brush..
Proper amount
Insufficient
(Upper limit)
green line
Proper
amount
Red line
(lower limit)
7
Return the side cover and developing/after-treatment top cover to their original positions.
If the side cover is put back to its original position, the limit switch
will work and the power cannot be turned on.
Changing Washing Water
1
Place a proper empty container below the overflow port if thedrain pipe is not connected.
Back view of the processor
Fresh water
supply valve
Washing water
drain valve
Overflow
drain valve
Fresh water supply port
Overflow port
2
Open the overflow drain valve.
3
Open the washing solution drain valve and drain the water.
4
Close the washing solution drain valve and the overflow drain
valve.
Keep the overflow drain valve open if the drain pipe is connected.
5
Open the top cover of the washing portion.
6
Remove the washing brush cover, and put in fresh waterto the
green line of the level gauge from the above brush.
7
Replace the top cover to its original position.
TWL-650F Instruction Manual
41
Maintenance
−
How to Measure and Adjust
Brush Pressure
Measuring/adjusting
brush pressure
The brush pressure is already adjusted at the time of delivery, but it becomes necessary to periodically check/adjust it because the brushing pressure will be reduced causing fatigue of the brush as it is used. Measure the brush pressure
according to the following procedure.
Procedure
Measuring Brush Pressure
Work preparation
1
Insert an unnecessary plate, aluminium face up, in the same
way as for normal operation.
2
If the operation switch is changed from AUTO to CHECK
when the rear end of the plate has passed the pre-treatment
portion, only the transporting roller stops.
If the plate is small, check that the plate is under the brush.
3
Let it stand in that state for about 3 minutes, and then change
the operation switch from CHECK to AUTO. The machine
stops once.
4
Press the limit switch of the inserting board for several seconds until the brush turns. The transporting starts.
5
When the plate has been carried out, the operation switch is
to be set to STOP.
If it remains AUTO, the machine is automatically stopped after
about 3 minutes.
Measuring
brush pressure
Proper width
Developing 10-12mm
After-treatment 6-8mm
Washing 8-10mm
6
Brushing trace remains on the plate brought out. Measure the
width of the brushing trace.
Plate passing direction
Brushing trace
Proper brushing width
Developing
brush
10-12mm
After-treatment
brush
6-8mm
Washing
brush
As the brush wears out, a further adjustment of a few mm above
theproper width is available..
42TWL-650F Instruction Manual
How to Measure and Adjust Brush Pressure
If the brushing width (brush pressure) is found to be weak by measuring the brush
pressure, adjust according to the following procedure.
Adjusting Brush Pressure
Work preparation
1
Turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
Remove the developing/after-treatment portion rid.
3
Remove the brush cover.
It can be easily removed by raising it.
Adjusting
brush pressure
4
4. Using a screwdriver, turn the brush pressure adjusting
bolts(4 bolts in total, right and left) 1/4 turn to the left (counterclockwise).
Brush
Adjusting bolt
Adjusting bolt
Increase
Decrease
Brush shaft
The brush pedestal rises and the brush pressure increases about
1mm in brushing width with 1/4 bolt turn.
All four brush pressure adjusting bolts should be turned at the
same angle to the left. Do not turn the bolt more than 1 turn. The
brush motor will be burdened by extra stress resulting in failure.
5
Return the brush cover to its original position.
Pay attention to the direction of the cover.
Checking
after adjusting
6
Return the top cover to its original position.
7
Operate the automatic processor, and measure the brush
pressure again.
8
After the brush pressure adjustment, check the development
of the plate.
TWL-650F Instruction Manual
43
How to Measure and Adjust Brush Pressure
Development Is Not Recovered
after Brush Pressure Adjustment
Brush fatigue
It is necessary to replace the brush every 2 years or 20,000 plates used. (The brush
is consumable.)
Consult the dealer .
44TWL-650F Instruction Manual
4
Troubleshooting of
Processor/Plate
If any trouble occurs with the machine or plate, please read the relevant item of this
chart. If the trouble is still not remedied or occurs again, consult the dealer.
TWL-650F Instruction Manual
45
Troubleshooting of Processor/Plate
Unusual Machine Condition
(Before Repair Service Is Requested)
Repairing machine
If the automatic processor condition is abnormal, check the following points in accordance with the symptom before making a request for repair to the dealer. If it
still cannot be fixed, make a request for repair service to the dealer.
Breaker Cannot Be Turned ON
Operation of side cover
limit switch
- Is the side cover removed?
Emergency stop button
locked
- Is the emergency stop button locked?
The side cover is provided with a limit switch.
Unlock it by turning it clockwise.
MAIN Lamp Does Not Light
with POWER ON
Breaker
- Is the breaker turned on?
Turn on the breaker.
Receptacle
- Is the plug inserted in the receptacle?
Insert the plug.
MAIN Is Lit, but OK Lamp Does Not Light
with POWER ON
Insufficient treatment
solution
- Is the treatment solution short?
Heater fuse
- Is the heater fuse blown?
Check the level gauge on the right side face.
Check the fuse inside the control box.
MAIN/OK Lamps Light, but Operation Does Not
Start after Plate Is Inserted
Operation switch
- Is the operation switch set to STOP?
Set the operation switch to AUTO.
Operation Starts but Plate Is Not Transported
Operation switch
46TWL-650F Instruction Manual
- Is the operation switch set to CHECK?
Unusual Machine Condition (Before Repair Service Is Requested)
Set the operation switch to AUTO.
No Solution from Shower
Insufficient Treatment
solution
- Is the treatment solution short?
Flow control valve
- Does the shower flow control valve remain closed when the filter
is replaced?
Check the level gauge on the right side face.
Check the flow control valve inside the right side cover.
Shower pipe holes
clogged
- Are the shower pipe holes clogged?
Clean them with a toothpick, etc.
P
23
Clogging of filter/
strainer
- Is the filter or strainer clogged?
Replace the filter or clean the strainer.
Operation Stops during Processing
Insufficient Treatment
solution
- Is the treatment solution short?
Check the level gauge on the right side face.
Plate Sticks in After-treatment/Washing Portion
Checking plate end
- Is the plate end bent when the plate is inserted?
It is raised by the after-treatment brush.
Plate Comes Out with Its End Bent
Checking plate end
- Is the plate end bent upward when the plate is inserted?
It is raised by the development brush.
TWL-650F Instruction Manual
47
Troubleshooting of Processor/Plate
Causes and Measures
for Plate Processing Faults
Plate troubles
When the plate is processing faultes is caused, not only the factors of the automatic
processor but also those of the exposure condition may be suspected. Check the
following points in accordance with the trouble phenomena.
Positive Working Type
Partial Developing/No Dots of Highlight
Light fog
- Is it exposed to light before/after printing?
Check if it is not exposed to the exposure light source or sunlight.
Contact time fault
- Is the vacuum contact poor?
Proper conditions are vacuum of 700mmHg and contact time of
30 seconds or more.
Exposure time too long
- Is the exposure time too long?
The degree of exposure of 7-9 (white solid) on the gray scale is
proper. Check the degree of exposure using the gray scale. If the
gray scale is not available, try to halve the exposure time.
Insufficient shower flow
P
20
Improper setting of
developing speed
- Is the shower flow of the automatic processor good?
Visually check paying special attention to the pre-treatment and
developing portions.
- Is the developing speed too fast?
The proper value is 40cm/min. Measure the transporting speed.
P
8
Insufficient brush
pressure
- Is the brushing width of the development brush proper?
The proper value is about 12mm. Measure the brushing width.
P
42
Deteriorated
pre-treatment solution
- Is a lot of water mixed in the pre-treatment solution?
Check if water is replenished by mistake or if water is fcoming into
via the plate from the developing tank to pre-treatment tank when
the plate is passing, because the shower of the development inlet
portion is too strong.
Stripe-Like Unevenness of Screen Tint
48TWL-650F Instruction Manual
Causes and Measures for Plate Processing Faults
in Plate Passing Direction
- Check the above.
Stripe-Like Dyeing Unevenness
in Plate Passing Direction
Insufficient solution
quantity of after-treatment shower
P
20
Insufficient exposure
time
- Is the solution quantity of the after-treatment shower proper?
Visually check the solution quantity from the shower. Simple dyeing unevenness will not affect to the printing.
Film Edge/Dust Not Removed
- Is the exposure time too short?
Check the degree of exposure with the gray scale.
No-Image Area Is Separated/Shadow Dots
Are Crushed
Insufficient exposure
time
- Is the exposure time too short?
Exposure temperature
too low
- Is the exposure temperature too low?
Check the degree of exposure with the gray scale. If the gray scale
is not available, try to double the exposure time.
The proper temperature is 20¡C or higher. Check the degree of exposure as well.
Negative Working Type
Partial Developing/No Highlight Dots
Insufficient exposure
time
- Is the exposure time too short?
Insufficient amount of
shower solution
- Is the shower solution amount of the automatic processor
proper?
P
20
Wrong setting of developing speed
The degree of exposure of 4-6 (solid) on the gray scale step is proper. Check the degree of exposure using the gray scale. If the gray
scale is not available, try to double the exposure time.
Visually check paying special attention to the pre-treatment and
developing portions.
- Is the developing speed too fast?
The proper value is 40cm/min. Measure the transporting speed.
P
8
TWL-650F Instruction Manual
49
Causes and Measures for Plate Processing Faults
Insufficient brush pressure
- Is the brushing width of the development brush proper?
The proper value is about 12mm. Measure the brushing width.
P
42
Deteriorated pre-treatment solution
- Is a lot of water mixed in the pre-treatment solution?
Check if water is replenished by mistake or if the water is flowing
reversely via the plate from the developing tank to the pre-treatment tank when the plate is passed, because the shower of the development inlet portion is too strong.
Stripe-Like Unevenness of Screen Tint
in Plate Passing Direction
- Check the above.
Stripe-Like Dyeing Unevenness
in Plate Passing Direction
Insufficient solution
quantity of after-treatment shower
P
20
Light fog
- Is the solution quantity of the after-treatment shower proper?
Visually check the solution quantity from the shower. Simple dyeing unevenness does not affect the printing.
No-Image Area Is Separated/Shadow Dots Are
Crushed
- Is it exposed to light before/after printing?
Check if it is exposed to the exposure light source or sunlight.
Insufficient contact time
- Is the vacuum contact poor?
The proper conditions are vacuum of 700mmHg and contact time
of 30 seconds or more.
Exposure time too long
- Is the exposure time too long?
Check the degree of exposure with the gray scale.
Deteriorated
pre-treatment solution
50TWL-650F Instruction Manual
- Is a lot of water mixed in the pre-treatment solution?
Check if water is replenished by mistake or if the water is flowing
reversely via the plate from the developing tank to the pre-treatment tank when the plate is passed, because the shower of the development inlet portion is too strong.
5
How to Change
Installation of Automatic
Processor/
Specifications
Although the automatic processor is installed by the dealer, this section
describes the procedures when the machine installation place is subsequently changed or when the negative/pos itive specifications of the
plate are changed.
TWL-650F Instruction Manual
51
How to Change Installation of Automatic Processor/Specifications
How to Install
Automatic Processor
Installing automatic
processor
Although the automatic processor is installed by the dealer, the following procedure is to be used when the installation place of the machine is subsequently
changed.
Installation Procedure
Selection of Preferable Installation Environment
1
Installation floor surface: solid, level floor
2
Ambient environment: place with little humidity and dust
3
Water supply/drain: place near the water supply/drainage but
no water freezing in winter.
4
Power supply equipment : 230V (20A) receptacle should be
available nearby (the power cord length is 5m(16ft) from the
control portion (under the plate inserting board of the machine)
5
Prevention of exposure to light: place not subject to direct sunlight and light of exposure machine (to prevent developing failure due to light fogging of the plate material)
6
Ambient spacing: working space must be secured (secure a
space to allow working by opening the right and left covers
and minimum 50cm(20in) around the machine).
Recommended installation space
3000
52TWL-650F Instruction Manual
730
1090
650
2500
2430
How to Install Automatic Processor
Installation of Automatic Processor
1
Remove the right/left and top covers in advance.
2
Move it to the installation place, and position it.After leveling
the processor by an adjusting bolt, fix it by a locking screw nut.
Leveling screw nut
Caster
Adjusting Bolt
Connection of the water supply/drain
1
Connect the fresh water supply port to the water supply pipe.
Each port is on the backside of the processor..
Back view of the processor
Fresh water
supply valve
Washing water
drain valve
Overflow
drain valve
Fresh water supply port
Overflow port
Water supply ... 1/4B hose nipple inside diameter 12mm hose
Drain ... Rigid PVC 40A socket required
2
Adjust the opening of the fresh water supply valve and fully
open the overflow drain valve.
Fully open for the drain from the overflow drain port. While measuring the quantity, adjust the opening of the water supply valve
so as to obtain about 1 liter of drain from the machine. (Check
while passing the plate.)
TWL-650F Instruction Manual
53
How to Install Automatic Processor
Putting in the solution
1
Check that the pre-treatment/after-treatment solution recoveryvalves, drain valve, and overflow drain valve are closed.
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Side cover
limit switch
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
Water washing shower
drain valve
recovery valve
flow rate control valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
2
Check that the pre-treatment/developing/after-treatment
shower flow control valves are half opened.
If they are fully opened, there is a possibility of the treatment solution splashing from each tank shower. Although each valve is attached with a name tag, care must be taken not to mistake the
control and recovery.
3
Put in the pre-treatment solution until the solution level reaches the upper limit line.
Pre-treatment tank
Lower limit line
Float switch
54TWL-650F Instruction Manual
How to Install Automatic Processor
4
Put the pre-treatment/after-treatment solution in the pre-treatment/ after-treatment tank and the tap water in the developing/washing tank.
Proper amount
Insufficient
(Upper limit)
green line
Proper
amount
Red line
(lower limit)
The pre-treatment solution is colorless and transparent, and
theafter-treatment solution is blue or bluish green.
Pay special attention when you handle After-treatment solusion,because dye in After-treatment solusion is hard to remove
from your skin..
5
After returning the covers to their original positions, insert the
power plug into the receptacle.
If the side covers are not returned to their original positions, the
cover limit switch will work and the breaker cannot be turned on.
Be sure to connect the earthing
----------The above has completed the installation.----------
For the actual operating method, see "How to Operate Automatic Processor."
TWL-650F Instruction Manual
55
How to Change Installation of Automatic Processor/Specifications
Changing Specification
of Automatic Processor
Changing specification
of processor (changing
treatment solution)
When the specification of the automatic processor is changed from negative type
to positive type, only the treatment solution is to be changed according to the following procedure.
Procedure
Changing from Negative Type to Positive Type
Draining negative type
pre-treatment/after-treatment solution
1
Remove the plug of the power cord from the receptacle, and
turn OFF the breaker of the processor.
Be sure to turn off power before starting the work.
2
Open the right side cover and top cover.
If the breaker was not turned OFF, the limit switch would work
and the breaker would be turned off
Pre-treatment
strainer
Operation
portion
Flow rate of pre-treatment shower control valve
Developing brush bearing
After-treatment brush bearing
Emergency Stop Botton
Inserting
board
Plate inserting
limit switch
Side cover
limit switch
Pre-treatment
solution
recovery valve
Developing
filter
After-treatment
filter
Developing water After-treatment
solution
drain valve
recovery valve
Flow rate of developing water
Flow rate of after-treatment
control valve
control valve
3
Place an empty can under the pre-treatment/after-treatment
solution recovery valve, open the valve, and drain the treatment solution in the tank.
Wear the rubber gloves to protect your skin from the treatment solution.
4
56TWL-650F Instruction Manual
Place a proper empty container under the after-treatment filter
drain valve, open the valve, and drain the solution in the filter
housing.
Changing Specification of Automatic Processor
Cleaning tank interior
5
Close the pre-treatment/after-treatment solution recovery
valve and after-treatment filter drain valve.
6
Put in the positive type pre-treatment solution to the lower limit
of the level gauge and after-treatment solution to the green
line of the level gauge.
Positive type pre-treatment solution: PP-1
Positive type after-treatment solution: PA-2
7
Return all the covers to their original positions.
8
Operate the processor for about 5 minutes in accordance with
"How to Operate Automatic Processor."。
P
How to Operate 10
After the OK lamp lights, manually press the limit switch。 .
9
Set the breaker to OFF.
Inputting positive type
treatment solution
10 Drain only the pre-treatment solution and put in fresh positive
Changing set temperature of pre-treatment
11 Double check that the power cord plug is removed from the re-
pre-treatment solution to the upper limit notch of the level
gauge in the tank.
ceptacle.
12 Open the cover of the control box, and change the setting of
the pre-treatment temperature (control panel TC).
Do not touch the wiring portion in the control panel. For the method of changing the setting, consult the manufacturer.
13 Return all the covers to their original positions.
Changing from Positive Type to Negative Type
Draining positive type
pre-treatment/after-treatment solution
1
Use the same procedure as in 1-5 above. For changing from
positive to negative, steps 6-8 for washing the tank interior are
not required.
Inputting negative type
treatment solution
2
Put in the negative type pre-treatment/after-treatment solution
to the green line of the upper limit of the respective level
gauge.
Negative type pre-treatment solution: NP-1
Negative type after-treatment solution: NA-1
3
Open the cover of the control box, and change the setting of
the pre-treatment temperature (control panel TC)
4
Return all the covers to their original positions.
Changing Setting of Temperature ofPre-treatment
TWL-650F Instruction Manual
57
Changing Specification of Automatic Processor
Solution
Preparation for working
1
Set to ON the power breaker of the processor, and then ON
the [AUTO] switch of the operation portion.
Changing set
temperature
2
Cancel the protect by setting the [PROTECT] to the lower side.
Temperature controller
Temperature indication
C
ON
AL
SP AL
Select
indication
C
SP AL
ON Output lamp
AL Alarm lamp
PROTECT
Indication
select key
(up)
(down)
Sey key
Protect switch
3
4
If the [Indication Select Key] is pressed, (SP) is indicated in the
select indication portion and the set temperature in the temperature indication portion.
Change the set temperature by pressing the [Set Key (up)] or
[Set Key (down)].
Changing alarm
temperature
1
2
3
After taking the steps 1 and 2, take the following steps.
If the [Indication Select Key] is pressed once more, (AL) is indicated in the select indication portion and the alarm set temperature in the temperature indication portion.
Change the set temperature by pressing the [Set Key (up)] or
[Set Key (down)].
The alarm temperature must not be set higher than 50ûC
4
If the [Indication Select Key] is pressed again after the set value
is changed, (SP) is indicated in the select indication portion
and the set temperature in the temperature indication portion.
If the temperature indication select key is pressed once again,
[H2], [L1], etc. may be indicated in the temperature indication portion, and these indicate the temperature correction values which
should not be changed.
58TWL-650F Instruction Manual
5
Press the [Indication Select Key] until the present temperature
is indicated in the temperature indication portion after the indication of the temperature select indication portion disappears.
6
After the setting is completed, set the [PROTECT] to the upper
side to protect the set value so that the set value will not be
changed.
6
Wiring Diagram/
Specifications
TWL-650F Instruction Manual
59
Wiring Diagram/Specifications
TWL-650F Wiring Diagram
Control box
interior work
Do not touch the control box interior with bare hands because there is a possibility
of electrical shock.
Sketch of Control Box Interior
ELB
C1
F
OF
TRIP
P
ED
ON
CP1
C2
R1
CP2
R3
R2
TB4
TC
R4
SPC
PC
NF
TB1
TB3
TB2
CN
123 456789------
22
EB
Functions of Parts and Symptoms at Failure
Function
CP1
CP2
R1
R2
R3
R4
TC
SPC
PC
60TWL-650F Instruction Manual
Symptom at failure
AC230V 50/60HZ
E
L1
N1
TB1
E
CN1
A3
A1
GREEN/YELLOW_AWG#8
TWL-650F Wiring Diagram
230V
0V
E
100V
TR
AC230/200V
2.5KVA
0V
B3
B1
CN1
UL2464 #18x2
CN18
CN19
A2
LS2 A3
LS3 A3
LS4 A3
TBL2
CN17
LS1 A3
ELB1(20A)
CN16
A2
Y0
A2
X0
A1
TB3
TBL1
CN16
CN17
CN18
CN19
CN20
CN21
TB4
Side cover limit switch
LS1Å`4
Temperature limit switch
PB1
A3
Emergency stop button
A3
Y01
R4
PB2
A2
A1
R4
X01
CN20
CN21
RED_AWG#16
PB1,PB2
UL2464 #18x2
L1 L2 L3
NF
L4 L5 L6
E
CP1(10A)
BLACK_AGW#14
X1
R1
TB3
BLACK_AGW#14
CN2
QTM2
STO#16x3
U1
M1
200W(5.2A)
V1
Y1
Developing brush motor
GREEN/YELLOW_AWG#16
E
TB3
CN3
QTM3
STO#16x3
P1
Developing/After-treatment pump
45W(0.92A)
GREEN/YELLOW_AWG#16
E
TB3
U1
U1C
CN4
C2 W1
QTM4
STO#16x4
M2
Electromagnetic valve
90W(1.8A)
GREEN/YELLOW_AWG#16
E
X02
Y02
X1
Y1
U1
2-AMP#187
W1
TWL-650F Instruction Manual
61
TWL-650F Wiring Diagram
X02
Y02
X1
Y1
W1
U1
TB3
UL2464 #18x2
QTM1
CN5
A1
Electromagnetic valve
SV
A2
GREEN/YELLOW_AWG#16
QTM64-2
A3
E
TB3
STO#16x4
TH2
QTM64-1
CN8
A2
Q5
A1
M3
M3
∼
B1
M3C
Transport motor
60W(1.2A)
B2
FAN
SC
QTM64-2
CN9
SSG
SSG
A2
A3
CN10 CW
UL2464 #18x2
E
UL2464 #18x2
CW
A3
VR
A2
CCW
UL2464 #18x2
R2
CN6
TB3
BLACK_AGW#16
U2
QTM5
STO#16x3
A1
W2
M4
∼
Washing brush motor
200W(5.2A)
A2
GREEN/YELLOW_AWG#16
A3
E
QTM6 STO#16x3
CN7
TB3
Q6
A1
P2
∼
Pre-treatment heater
45W(0.92A)
A2
GREEN/YELLOW_AWG#16
A3
X1
Y1
E
CP2(10A)
BLACK_AGW#14
R3
H11A
APK1.25Squ*3
H11 TB2
BLACK_AGW#14
APK1.25Squ*3
CAB_H1
H12A
H12
H1
Pre-treatment heater
800W(8A)
G/Y #16
E
X02
Y02
X1
Y1
TIC1
10
11
Solution temperature control unit
7
5
1
CAB_TE1
CN15
TE1
2
6
TE2
1
4
3
A1
TE1
X1
A2
Y1
62TWL-650F Instruction Manual
16
TWL-650F Wiring Diagram
Specifications of TWL-650F
Treating process
Roller transporting system: pre-treatment immersion,
rotating brush brushing development, after-treatment water wasdhing,dyeing
Pre-treatment (dedicated treatment solution) --development (tap water)
--after-treatment (dedicated treatment solution)--washing(tap water)
Maximum
width
Minimum
Plate size
length
Plate
thickness
Plate transporting speed
620 mm(24.4 inch)
300 mm(11.8 inch)
0.15--0.4mm(0.006-0.012 inch)
10--100cm/min(0.4-4.0 inch/min)
Pre-treatment tank 12 liters(3.2gallon),
after-treatment/developing tank 10 liters(2.6gallon)
AC230V single phase 1.2KW 20A
1/4B hose nipple
Rigid PVC 40A pipe
1090mm(42.9inch)
2430mm (95.7inch)(including delivery board)
920mm(36.2 inch)
350Kg(771.6 pound)
Pre-treatment solution (for Negative, for Positive and for CTP)
After-treatment solution (for Negative, for Positive and for CTP)
for TWL-650F
Tank capacity
Power supply
Work at
installation Water supply
Drain
Width
Machine
Depth
size
Height
Weight
Treatment
solution
Filter
Please note that the machine specifications and appearance are subject to change for
improvement without notice.
Schematic Drawing
1090
650
2430
310
1650
900
440
920
Consumabl
es
730
Type
TWL-650F Instruction Manual
63
Toray Industries,Inc
Graphic Systems Department
Export Section
1-8-1, Mihama, Urayasu, Chiba 279-0011
Phone: (047) 350-6049
2002.12