manual Polymount Plate Cleaner installation protocol Setting / maintenance compressed air + pump pg. 16 Maintenance table settings pg.

Transcription

1 manual Plymunt Plate Cleaner installatin prtcl Setting / maintenance cmpressed air + pump pg. 16 Maintenance table settings pg. 18

2 Dear Custmer, Thank yu fr purchasing a Plymunt Plate Cleaner. Plate cleaners frm Plymunt are prfessinally built t industrial standards and ffer an excellent price / perfrmance rati. Our n-ging innvatin and develpment wrk ensures that we always use the latest technlgical and safety standards. We make every effrt t prvide yu with prducts that yu will enjy using, will make yur wrk easier and mre cst effective. T ensure yur safety and t prevent damage t the machine, yu must read this manual thrughly befre using the machine. Please keep this manual safe fr future reference. Abut this manual This manual cntains all the necessary instructins fr the prper usage and maintenance f the machine and is supplied with every machine. The cntent is intended fr the user. Clsely fllwing the instructins in this manual will ensure the safety f the user and prvide fr the efficient peratin f the machine. The main tpics are rganised in separate chapters. The index quickly shws the way t each chapter. Safety It is very imprtant t Plymunt that the Plymunt Plate Cleaner is used in a safe manner. All persns wh will use the machine must read and understand all the usage and safety advice in this manual befre perating the machine. Safety starts with yu. Mst accidents happen because f carelessness r by nt fllwing the safety rules. Fllwing these basic rules and using cmmn sense will ensure that the machine is perated in a safe manner. If there is anything that yu are unsure f please cntact the Plymunt Helpdesk fr clarificatin r instructins. Imprtant The machine shuld nly be used when it is in gd wrking cnditin. Any changes r alteratins that have been made by nn-qualified peple may reduce the safety f this machine. Any changes r alteratins that are made t the machine, ther than by urselves, will invalidate ur guarantee. Failure t fllw all the safety instructins in this manual wuld als remve the manufacturer frm any liability fr injury r damage. Plymunt plate cleaner manual 2

3 INDEX Page Cntent 4 Specificatins & flrplan PPC S 6 Specificatins & flrplan PPC M2 (T) 8 Specificatins & flrplan PPC L2 (T) 10 Specificatins & flrplan PPC XL2 (T) 12 Specificatins & flrplanppc XXL2 (T) 14 Specificatins & flrplanppc XXL2 (T) Crrugated 16 Symbls 17 Safety instructins 19 Operatin 22 Maintenance - Changing brush 24 Maintenance - Munting the brush 25 Maintenance - Spnge rll 26 Setting / Maintenance Cmpressed air + pump 29 Maintenance - Tank 31 Maintenance - Table setting 32 Service 33 Trubleshting 34 Descriptin Plymunt plate cleaner manual 3

4 Specificatins PPC S Size Height Width Length Table height Weight Sticky plate size : 1260 mm : 1030 mm : 2400 mm : 980 mm : 310 kg : 600 x 900 mm Technical specificatins Vltage : EU / 400 Vlt Frequency : EU / 50 Hz Nminal intensity : EU / 16A Nminal pwer : 5,3 kwh Supply cable : 5 m / 3 ph / +N+PE / 5 wire 2,5 mm Dryer / heater : 3 Fans / 2 heater 4,0 kwh Temp : 0 60 ºC Air dryer : min 2,0 Bar max 4,0 Bar Tank capacity : 75 Litre Optinal exhaust : 230 Vlt Capacity (ptinal exhaust) : 320 m³ / hur Cnnectins Flush system Electric supply / EU Electric supply / US Air supply : 12 / 19 mm : 400 V / 3 h + N + PE / Length 5 m : requires a special transfrmer : ¼ inch Plymunt plate cleaner manual 4

5 flr plan PPC S Plymunt plate cleaner manual 5

6 Specificatins PCC M2 (T) Size Height Width Length Table height Weight Sticky plate size : 1345 mm : 1230 mm : 3860 mm : 980 mm : 450 kg : 800 x 1200 mm Technical specificatins Vltage : EU / 400 Vlt US / 110 V Frequency : EU / 50 Hz US / 60 Hz Nminal intensity : EU / 16A US / 20A Nminal pwer : 3,2 kwh Supply cable : 5 m / 3 ph / +N+PE / 5 wire 2,5 mm² Dryer / heater : 1 Fan / 1 heater 2,5 kwh Temp : 0 50 ºC Air dryer : min 4,0 Bar max 5,0 Bar Tank capacity : 125 Litre Optinal exhaust : 230 Vlt Capacity (ptinal exhaust) : 320 m³ / hur Cnnectins Flush system Electric supply / EU Electric supply / US Air supply : 12 / 19 mm : 400 V / 3 ph + N + PE / Length 5 m : 110 V / 2 ph +PE : ¼ inch Plymunt plate cleaner manual 6

7 flr plan PPC m2 (T) 100 cm 123 cm 97 cm 97 cm 14 cm 3,5 cm Pwer Air 40 cm 103 cm 30 cm 12 cm 103 cm 40 cm 100 cm 386 cm Adjustable legs Ø 6 cm Pwer: 5 x 2,5 mm² / 16A / 400V Air: min. 4 Bar Height f the Machine is: 132 cm Plymunt plate cleaner manual 7

8 Specificatins PCC L2 (T) Size Height Width Length Table height Weight Sticky plate size : 1345 mm : 1430 mm : 4700 mm : 980 mm : 510 kg : 1000 x 1600 mm Technical specificatins Vltage : EU / 400 Vlt US / 110 V Frequency : EU / 50 Hz US / 60 Hz Nminal intensity : EU / 16A US / 20A Nminal pwer : 3,2 kwh Supply cable : 5 m / 3 ph / +N+PE / 5 wire 2,5 mm² Dryer / heater : 1 Fan / 1 heater 2,5 kwh Temp : 0 50 ºC Air dryer : min 4,0 Bar max 5,0 Bar Tank capacity : 125 Litre Optinal exhaust : 230 Vlt Capacity (ptinal exhaust) : 320 m³ / hur Cnnectins Flush system Electric supply / EU Electric supply / US Air supply : 12 / 19 mm : 400 V / 3 ph + N + PE / Length 5 m : 110 V / 2 ph + PE : ¼ inch Plymunt plate cleaner manual 8

9 flr plan PCC L2 (T) 100 cm 143 cm 117 cm 117 cm 14 cm 3,5 cm Pwer Air 81 cm 105 cm 30 cm 12 cm 105 cm 81 cm 100 cm 472 cm Adjustable legs Ø 6 cm Pwer: 5 x 2,5 mm² / 16A / 400V Air: min. 4 Bar Height f the Machine is: 132 cm Plymunt plate cleaner manual 9

10 Specificatins PCC XL2 (T) Size Height Width Length Table height Weight Sticky plate size : 1345 mm : 1630 mm : 5500 mm : 980 mm : 600 kg : 1220 x 2000 mm Technical specificatins Vltage : EU / 400 Vlt US / 110 V Frequency : EU / 50 Hz US / 60 Hz Nminal intensity : EU / 16A US / 20A Nminal pwer : 3,2 kwh Supply cable : 5 m / 3 ph / +N+PE / 5 wire 2,5 mm² Dryer / heater : 1 Fan / 1 heater 2,5 kwh Temp : 0 50 ºC Air dryer : min 4,0 Bar max 5,0 Bar Tank capacity : 125 Litre Optinal exhaust : 230 Vlt Capacity (ptinal exhaust) : 320 m³ / hur Cnnectins Flush system Electric supply / EU Electric supply / US Air supply : 12 / 19 mm : 400 V / 3 ph + N + PE / Length 5 m : 110 V / 2 ph + PE : ¼ inch Plymunt plate cleaner manual 10

11 flr plan PCC XL2 (T) 100 cm 163 cm 136 cm 136 cm 14 cm 3,5 cm Pwer Air 115 cm 110 cm 30 cm 12 cm 110 cm 115 cm 100 cm 550 cm Adjustable legs Ø 6 cm Pwer: 5 x 2,5 mm² / 16A / 400V Air: min. 4 Bar Height f the Machine is: 132 cm Plymunt plate cleaner manual 11

12 Specificatins PCC XXL2 (T) Size Height Width Length Table height Weight Sticky plate size : 1320 mm : 2000 mm : 6300 mm : 980 mm : 800 kg : 2400 x 1630 mm Technical specificatins Vltage : EU / 400 Vlt US / 110 V Frequency : EU / 50 Hz US / 60 Hz Nminal intensity : EU / 16A US / 20A Nminal pwer : 3,2 kwh Supply cable : 5 m / 3 ph / +N+PE / 5 wire 2,5 mm² Dryer / heater : 1 Fans / 1 heater 4,0 kwh Temp : 0 50 ºC Air dryer : min 5,0 Bar max 6,0 Bar Tank capacity : 125 Litre Optinal exhaust : 230 Vlt Capacity (ptinal exhaust) : 320 m³ / hur Cnnectins Flush system Electric supply / EU Electric supply / US Air supply : 12 / 19 mm : 400 V / 3 ph + N + PE / Length 5 m : 110 V / 2 ph + PE : ¼ inch Plymunt plate cleaner manual 12

13 flr plan PCC XXL2 (T) 100 cm 177 cm 203 cm 177 cm 14 cm 3,5 cm Pwer Air 140 cm 125 cm 30 cm 12 cm 125 cm 140 cm 100 cm 630 cm Adjustable legs Ø 6 cm Pwer: 5 x 2,5 mm² / 16A / 400V Air: min. 4 Bar Height f the Machine is: 132,5 cm Plymunt plate cleaner manual 13

14 Specificatins PCC XXL2 (T) Crrugated Size Height Width Length Table height Weight Sticky plate size : 1320 mm : 2000 mm : 6300 mm : 980 mm : 800 kg : 2400 x 1630 mm Technical specificatins Vltage : EU / 400 Vlt US / 110 V Frequency : EU / 50 Hz US / 60 Hz Nminal intensity : EU / 16A US / 20A Nminal pwer : 3,2 kwh Supply cable : 5 m / 3 ph / +N+PE / 5 wire 2,5 mm² Dryer / heater : 1 Fans / 1 heater 4,0 kwh Temp : 0 50 ºC Air dryer : min 5,0 Bar max 6,0 Bar Tank capacity : 125 Litre Optinal exhaust : 230 Vlt Capacity (ptinal exhaust) : 320 m³ / hur Cnnectins Flush system Electric supply / EU Electric supply / US Air supply : 12 / 19 mm : 400 V / 3 ph + N + PE / Length 5 m : 110 V / 2 ph + PE : ¼ inch Plymunt plate cleaner manual 14

15 flr plan PCC XXL2 (T) Crrugated 100 cm 177 cm 203 cm 177 cm 14 cm 3,5 cm Pwer Luft 140 cm 125 cm 30 cm 12 cm 100 cm 125 cm 140 cm 626 cm Adjustable legs Ø 6 cm Pwer: 5 x 2,5 mm² / 16A / 400V Air: min. 5 Bar Height f the Machine is: 132,5 cm Plymunt plate cleaner manual 15

16 Symbls: Wear glves Risk f injury! Watch ut High Vltage Risk f Injury! Wear safety glasses Risk f injury! Watch ut Rtating parts Risk f injury! Turn ff main switch Risk f injury! Primary earth symbl Plymunt plate cleaner manual 16

17 Safety Instructins Imprtant: Read the instructins fr perating and maintaining the machine carefully befre turning n the machine. The machine may nly be used by persns wh have read and understd the manual. Cautin! Repairs, maintenance and adjustments shuld nly be perfrmed by qualified persnnel and nly after the machine is turned ff (discnnect frm Pwer supply). Always check the crrect installatin f the machine befre switching it n. While wrking with the machine keep yur hands away frm any mving parts! Keep the machine and wrking area clean and prvide adequate lighting. The design f the machine must nt be mdified and the machine must nt be used fr tasks ther than thse fr which the manufacturer has develped it. Never use the machine if yur cncentratin is reduced by illness, fatigue, alchl r medicatin. D nt turn n the machine after installatin r repair befre replacing all tls used and remving any lse parts. Make sure that yu are aware f all the warnings fr yur safety and ptential hazards. Ensure that these label s are all undamaged and clearly visible. Keep children r peple unfamiliar with the machine away frm the wrkplace and the machine. The machine shuld nly be used and maintained by persns familiar with the risks assciated with the machine. Switch the machine ff befre perfrming maintenance r changing any settings! Pull the mains plug frm the wall scket r discnnect the machine frm the mains! If yu pull the pwer cable frm the scket, never pull the cable, but pull the plug firmly. Prtect the pwer cable frm heat, il and sharp edges. Always check that the pwer switch is in the OFF psitin befre cnnecting the pwer cable t a utlet, t ensure that the unit is nt inadvertently switched n. Plymunt plate cleaner manual 17

18 Wear clse-fitting clthing, safety gggles, safety shes and earmuffs. Tie lng hair tgether. When wrking with the machine d nt wear watches, bracelets, chains r rings, because they can cause injury if caught in rtating parts! Repair any prblems immediately as they culd represent a safety hazard. Never leave the machine unattended r leave the machine until all cmpnents cmpletely cme t a standstill. Then pull the pwer crd frm the utlet, s that the machine can nt be accidentally switched n. Prtect the machine frm dampness. (Risk f electric shck!) D nt use electrical equipment and machines near flammable liquids and gases. (Risk f explsin) Befre switching the machine n, check if any parts are damaged. Replace any damaged parts immediately, t avid danger! Use nly riginal spare parts and accessries, t avid any risks f accidents. Even when all the safety guidelines are fllwed there still remains sme residual risks. These are: Risk f injury thrugh tuching mving parts Pssible fracturing f machine cmpnents Risk f injury thrugh flying materials r damaged printing plates Insufficient ventilatin arund the machine Risk f injury thrugh tuching live parts Risk f hearing damage after prlnged perids f wrk withut wearing hearing prtectin Imprtant: We wish t pint ut that as with all machines, the Plymunt Plate Cleaner shuld be used with cautin and maximum attentin t the ptential dangers. It is yur respnsibility t use the machine as instructed in this manual. Plymunt plate cleaner manual 18

19 Operatin Wear glves and prtectin glasses. 1. Fill the tank with a minimum f 75 Litres f Plywash Only use apprved Plywash prducts. 2. Cnnect the plate cleaner t the electrical system 3. Turn main switch n 4. Set speed n standard between Lw speed = lnger / slw wash - High speed = shrter / quick wash 5. Check that all emergency switches are de-activated 5b Check pump setting (page 21) 5c Check if Spnge rlls are munted crrectly (page 14-15) Plymunt plate cleaner manual 19

20 Operatin 6. Check that the cver is lcked n bth sides (therwise the security switch will be activated) 7. Munt yur dirty plates n the sticky plate 8. Press the START buttn t start the cleaning prcess. 9. When the sticky plate has gne thrugh the machine, the censr will stp the machine autmatically. 10. De-munt the clean plates Plymunt plate cleaner manual 20

21 Operatin 10. De-munt the clean plates Be gentle when de-munting the plates. DO NOT use sharp tls!!! 11. Munt anther set f dirty plates 12. Press the START buttn. The machine will nw wash in the ppsite directin. Plymunt plate cleaner manual 21

22 maintenance - changing brush Always turn ff the main pwer switch befre changing the brush. Mark all parts in step 1-6 t refit them crrectly! 1. Release the 4 retaining screws (rings) n the brush 2. Remve the 6 screws n the frame 3. Remve the prtectin plate Plymunt plate cleaner manual 22

23 maintenance - changing brush 4. Discnnect the pipe n the side f the machine 5. Remve the frame frm the machine 6. Remve the prtectin plate Und the drive rail frm the pipes 7. Remve the 4 mving shafts frm the machine Plymunt plate cleaner manual 23

24 munting the brush 7. T munt the brush back n, d the reverse f step Make sure yu have the sticky plate and a printing plate under the brush befre tightening the retaining screws. 9. The surface f the printing plate under the brush shuld be the flr 10. Nw lift the brush slightly and let it fall back under it s wn weight 11. The brush is nw set fr the thickness f the plate that yu use Always d this setting with the thinnest plate yu use in prductin! When cleaning a thicker plate the brush will lift autmatically. 12. Nw tighten the 4 retaining screws Plymunt plate cleaner manual 24

25 maintenance - spnge rll Never run the machine withut the spnge rllers munted. 1. Lsen the retaining screw 2. Lift the spnge rllers and put int the tanks Plywash T re-munt the spnge rlls d step 1 and 2 in reverse rder 4. When cleaning the spnge-rlls they shuld be left in the Plywash 1000 tank fr at least 1 hur (r preferably vernight). 5. Befre re-munting the spnge-rll make sure that yu squeeze all the Plywash 1000 frm the spnge rll int the tank. Plymunt plate cleaner manual 25

26 Setting/ Maintenance Cmpressed air + Pump Cmpressed air setting Set the cmpressed air min. 2.0 Bar / max. 4.0 Bar. A = incming air B = airflw adjusting screw (pull dwn t set) C = utging air D = air gauge T set the air pressure pull dwn the adjusting knb (B). Turn the screw anti-clckwise t increase the pressure. T lck the setting push the knb upwards. Plymunt plate cleaner manual 26

27 Setting/ Maintenance Cmpressed air + Pump Pump Be careful when handling the high capacity pump. A = B = C = D = Brush (pen t the mark = apprx 25%, check flw) Pre-flush (pen t the mark = apprx 25%, check flw) Circulatin/ Drain tank (pen t the mark = 25%) Main (pen 100%) Make sure that the electric cable frm pump is cnnected. T the empty tank clse tap A + B + C. Place hse frm tap C in tank r bucket. Open tap C and start the pump. Plymunt plate cleaner manual 27

28 Setting/ Maintenance Cmpressed air + Pump Pump extra functin This is an extra functin t run the pump withut mving the sticky plate and washing brush. 1. Push bth START and STOP buttn at the same time (when the pwer is n) Hld fr 5 secnds Nw nly the pump will run. Plymunt plate cleaner manual 28

29 Maintenance - tank When the red lamp is flashing the level f Plywash is t lw. Never run the machine with less than 75 Litres f Plywash. When the detergent (Plywash) is t dirty the machine will nt give an ptimal perfrmance. 1. T clean the tank start by turning ff the machine 2. Clse taps 3. Place the hse frm tap ver a tank r bucket 4. Turn n, pen tap and empty the tank 5. Wipe the tank clean 6. Empty the cascade tank and wipe it clean 7. Clean the filter Plymunt plate cleaner manual 29

30 Maintenance - tank 8. Place the cascade tank back int the tank 9. Place the filter back int the cascade tank 10. Re-fill the tank with new Plywash Always start by filling the cascade tank! 11. Hse and lid must be in the crrect psitin befre starting the plate cleaner again. Plymunt plate cleaner manual 30

31 Maintenance - table settings It is imprtant that the tables are set crrectly 1. The 2 tables shuld be set t 980 mm. 2. Simply adjust the level cntrl n each leg. Plymunt plate cleaner manual 31

32 service Daily service 1. Refresh the spnge rll 2. Make sure that the sticky plate is clean and tacky 3. Check the filter t ensure it is clean and nt blcked Mnthly service 1. Check Plywash in tank, replace if it is t dirty 2. Clean the cascade tank 3. Check all cnnectins frm the pump 4. Change t see if brush is damaged 5. Check the rack n the sticky plate and remve any ink residue frm the rack. 6. Check the pins n the sticky plate, tighten them if they re lse. Yearly service 1. This will be dne by yur supplier Plymunt plate cleaner manual 32

33 trubleshting Prblem: Check: See page: Sticky plate nt mving Pwer Plate nt in crrect psitin Check Detergent nt pumping Level in the tank If tap is pen Fuse Printing plates are nt clean Detergent t dirty (change) Brush height nt set Speed set t fast Plates are wet after cleaning Refresh spnge rll Adjust Air-pressure n air-knive Detergent n table Table setting incrrect Refresh spnge rll Spnge rll is munted crrectly Red lamp flashing Plywash level t lw helpdesk Plymunt Helpdesk Telephne: Plymunt plate cleaner manual 33

34 descriptin The transprtatin system pulls the sticky plate int the wash sectin. The sticky plate first passes thrugh a flushing sectin where Plywash detergent is sprayed nt the printing plates. The detergent then begins t disslve the ink n the printing plate. The next sectin cmprises a very sft, fine haired brush which cleans the plate. Then a spnge rll starts t dry the plates and the in-line drying sectin finishes the prcess with ht air. The sticky plate will emerge frm the machine with perfectly clean, undamaged and dry printing plates. The Plymunt Plate Cleaner is ecnmical, efficient and very envirnmentally friendly. Plymunt plate cleaner manual 34