CTP 2000

This manual is for Service Technicians only and the directions given
must not be followed by unauthorized personnel. Always read
the Safety Instruction Manual part No 21741 before starting up the
equipment and keep it with the machine for reference at all times.
Edition AA This book has part no. 51208
T 1973
GENERAL INFORMATION
This manual is valid for equipment from Serial No. 106938
IMPORTANT!
Approvals:
Approvals will appear from the labels attached to the processor name plate or the frame part of the
processor.
Intended use of the equipment:
Development of photographic materials as specified in TECHNICAL SPECIFICATIONS in Section 1 of this
manual.
Installation:
Never install the processor in explosive environments.
It is the responsibility of the owner and operator/s of this processor, that the installation is made in
accordance with local regulations, and by engineers authorized to carry out plumbing and electrical
installations.
Installation, service and repair must be performed only by service technicians who are trained in servicing
the equipment.
The installation procedure is described in the separate INSTALLATION MANUAL.
The manufacturer cannot be held responsible for any damage caused by incorrect installation of this
processor.
Technical data:
Observe technical data from the processor name plate located on the rear panel of the processor
0.2 0149
CTP 2000
THIS MANUAL
Intended use of this manual:
This manual is for Service Technicians only and the directions given must not be followed by unauthorized
personnel.
Always read the Safety Instruction Manual part No 21741 before starting up the equipment and keep it with
the machine for reference at all times.
Reservations:
This manual was written and illustrated using the best possible information available at the time of
publication.
Any differences between this manual and the equipment reflect improvements introduced after the
publication of the manual.
Changes, technical inaccuracies and typographic errors will be corrected in subsequent editions.
As a part of our policy of continuous improvement, we reserve the right to alter design and specifications
without further notice.
WARNINGS, CAUTIONS AND NOTES!
Throughout the manual warnings, cautions, and notes are written in bold on a grey background like the
example below:
CAUTION! Always replace a fuse with one of the same size and rating as the old one.
Explanation:
NOTE!
The operator should observe and/or act according to the information in order to obtain the best possible
function of the equipment.
CAUTION!
The operator must observe and/or act according to the information in order to avoid any mechanical or
electrical damage to the equipment.
WARNING!
The operator must observe and/or act according to the information in order to avoid any personnel injury.
0149 0.3
CTP 2000
SET OF MANUALS
The processor is delivered with a set of manuals consisting of the following:
Processor Service Manual
Language: English
Processor User Manual
Language: Local *
Safety Manual
Language: Various
CE Declaration Of Conformity
Language: Various
0.4 0149
CTP 2000
TABLE OF CONTENTS
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0149 0.5
CTP 2000
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
IMPORTANT! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
WARNINGS, CAUTIONS AND NOTES! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
Explanation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
SET OF MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4
Processor Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4
Processor User Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4
Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4
CE Declaration Of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5
1. TECHNICAL SPECIFICATIONS 1.1
GENERAL ENVIRONMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
THE PROCESSOR DOES NOT CONTAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
PLASTIC PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
BATTERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
END OF LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
PACKAGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
NOISE EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
CHEMICAL EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
MACHINE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
PLATE DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
TOTAL TANK CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
DRIER POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
NOISE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
ELECTRICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VOLTAGE TOLERANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
POWER CONSUMPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TABLE OF CONTENTS
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CTP 2000
MECHANICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
DRY-TO-DRY TIME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
HOSE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
WATER SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
WATER CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
WATER PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
See illustrations opposite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
2. INSTALLATION 2.1
PREPARATIONS BEFORE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
ENVIRONMENTAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
WATER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
DRAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
CLEANING FACILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
POWER CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MECHANICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Water Connections (if a water recirculation unit is fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Water Recirculation Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
3. FUNCTIONS AND FEATURES 3.1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
DEVELOPER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
REPLENISHMENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
WASH SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
WATER RECIRCULATION UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
GUM SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
GUM-RINSE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
DRYER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
TRANSPORT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
EXIT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
TABLE OF CONTENTS
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CTP 2000
4. OPERATOR'S CONTROLS AND INDICATORS 4.1
THE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
1 POWER ON INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
2 PROCESSOR INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
3 REPLENISHMENT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4 RE-ENTRY/RE-WASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
5 DEVELOPER SECTION FILL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
6 DRIER HEATER CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
7 LIQUID CRYSTAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
8/9/10 DEVELOPER TEMPERATURE C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
11 DEVELOPER CONDUCTIVITY (mS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
12 PLATE COUNTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
13 MACHINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
15 KEY OPERATED SERVICE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
18 AUTO OR CONTINUOUS DRIVE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
20 ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
DIRECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
5. OPERATING PROCEDURES 5.1
PREPARATION FOR PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
MACHINE SETTINGS AND ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SETTING NIP PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SETTING DEVELOPER REPLENISHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
SETTING PROCESS TIMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
SETTING CYCLE TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
SPRAY BAR FLOW CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
GUM ROLLER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
GUM ROLLER ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
DRIVE ROLLER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
SCRUB ROLLER ADJUSTMENT (WASH ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
PUMP PRIMING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Follow these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
TABLE OF CONTENTS
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6. CLEANING, MAINTENANCE, AND ADJUSTMENTS 6.1
OPERATORS GUIDE TO CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
PRIOR TO DEVELOPER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
CHANGING THE FILTER ELEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
CHANGING
THE SCRUB COVER MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
7. TROUBLE SHOOTING 7.1
ATTENTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
8. SPAREPARTS 8.1
9. ADDITIONAL SERVICE INFORMATION 9.1
PLATE SENSOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
TEMPERATURE AND DEVELOPER CONDUCTIVITY CALIBRATION . . . . . . . . . . . . 9.2
ENTERING THE CALIBRATION MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TEMPERATURE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
CONDUCTIVITY CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
1 -UNCOMPENSATED CALIBRATION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
1a -LOOP METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
1b -DEVELOPER IN BATH METHOD (UNCOMPENSATED) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
2 -COMPENSATED CALBRATION MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
ELECTRICAL DIAGRAMS 9.5
1. TECHNICAL SPECIFICATIONS
GENERAL ENVIRONMENTAL INFORMATION
THE PROCESSOR DOES NOT CONTAIN
Ozone depleting substances according to
Montreal protocol.
Asbestos.
PCB or PCT.
Mercury.
Cadmium.
Lead as additive to plastic parts.
PLASTIC PARTS
Plastic parts >50g are marked according to ISO
11469.
BATTERIES
No batteries in this equipment.
END OF LIFE
Estimated product life: 10 years
Spare parts and service period:
7 years after last sales.
PACKAGING
Plastic packaging materials are marked according
to ISO 11469.
NOISE EMISSION
Acoustical noise according to ISO 11201:1996
Sound pressure level
Operational mode: 65 dB
Stand-by mode: 55 dB
CHEMICAL EMISSIONS
Ozone: 0 mg/m3
Dust: 0 mg/m3
Styrene: 0 mg/m3
0149 1.1
CTP 2000
MACHINE SPECIFICATION
This manual covers processors 85, 125, and 150
FUNCTION
PREHEAT DEVELOPER WASH GUM DRY RE-ENTRY
85 N/A Yes Yes Yes Yes Yes
125 N/A Yes Yes Yes Yes Yes
150 N/A Yes Yes Yes Yes Yes
SPEED
(PLATE SPEED/BRUSH SPEED)
85 Variable up to 1.5m (60") per minute
125 Variable up to 2.3m (92") per minute
150 Variable up to 2.3m (92") per minute
PLATE DIMENSIONS
MINIMUM LENGTH MAXIMUM WIDTH MAXIMUM THICKNESS
SHORT PLATE* STANDARD
85 370mm (14 1/2") 470mm (18 1/2") 850mm (33 1/2")
All recognised Lithoplate
thicknesses
125 491mm (19 1/2") 650mm (25 1/2") 1250mm (49 1/2")
All recognised Lithoplate
thicknesses
150 491mm (19 1/2") 650mm (25 1/2") 1500mm (59 1/2")
All recognised Lithoplate
thicknesses
*) SHORT PLATE REFERS TO MACHINES WITH THIS OPTION.
1.2 0149
CTP 2000
TOTAL TANK CAPACITIES
DEVELOPER GUM WATER
85 30Ltr (8 U.S.Gals.) 3.5Ltr (1 U.S.Gal) N/A
125 80Ltr (21 U.S.Gals.) 6Ltr (1.5 U.S.Gals) N/A
150 98Ltr (26 U.S.Gals.) 7.5Ltr (2 U.S.Gals) N/A
DRIER POWER
TOP
NORMAL BOOST
85 2Kw N/A
125 3Kw N/A
150 3Kw N/A
NOISE LEVEL
All versions less than 70dB.A
ELECTRICAL SPECIFICATIONS
POWER SUPPLY
85 1x230V 50-60Hz Single Phase 14A
125 1x230V 50-60Hz Single Phase 19A
150 3x400V+N 50-60Hz 3 Phase 3x14A
VOLTAGE TOLERANCES
230 V, +10%, -14%
POWER CONSUMPTION
85 3100W
125 4200W
150 8800W
0149 1.3
CTP 2000
MECHANICAL SPECIFICATIONS
DRY-TO-DRY TIME
TEMPERATURES
HOSE CONNECTIONS
Mains water in: 3/4" NHT
Drain out: 1" BSP
WATER SUPPLY
WATER CONSUMPTION
WATER PRESSURE
1.4 0149
CTP 2000
0149 1.5
CTP 2000
1.6 0149
CTP 2000
E
F
D
B C
H
G
A
E
D
B C
H
G
A
DIMENSIONS
See illustrations opposite
85 125 150
dim mm in mm in mm in
A 1040 41 1110 43.7 1110 43.7
B 1070 42 1530 60.2 1530 60.2
C 1100 43 1500 59 2000 78.7
D 900 36 900 36 900 36
E 1410 56 1880 74 2180 85.5
F 470 18.5 470 18.5
G 860 33.9 860 33.9 860 33.9
H 2170 85.4 3030 119.3 3530 139
WEIGHTS
in Kg NET GROSS
85 320 470
125 550 760
150 610 865
0149 1.7
CTP 2000
1.8 0149
CTP 2000
2. INSTALLATION
PREPARATIONS BEFORE INSTALLATION
GENERAL
To avoid waste of your production time, as well as
the time it will take for the engineer to install the
machine, some preparations ought to be made
before delivery of the processor.
ENVIRONMENTAL REQUIREMENTS
Provide a heating and ventilating system capable of
maintaining room temperature between 15 and
25C (59 and 77F) and relative humidity on max.
80%.
SPACE REQUIREMENTS
Decide where the processor shall be placed and
make sure that the free space around the machine
makes servicing possible. The recommended
minimum free space around the machine is
specified in illustration below.
WATER SUPPLY
NOTE! Water supply must be equipped with a
DIN 1988-approved return valve.
A water tap should be installed next to the
installation site of the machine.
Max. distance to the water tap should be 2-3 m
(6-10 ft.). The tap must be able to accept a
reinforced hose 12 mm (1/2") inner diameter. This
hose is not included with the machine.
Another possibility is to provide the machine with
tempered water through a thermostatically
controlled mixing valve or to connect the processor
to a water recirculation unit (see chapter 3).
DRAINS
The drain inlet must have a funnel shape. This
allows for proper drain line routing.
The recommended distance from the machine to
the drain should be 0.5-2 m (2-6 ft.).
CLEANING FACILITIES
It would be convenient to have easy access to a
water tap and a sink where rollers, guides, and
brushes can be washed and where chemicals can
be mixed. The minimum recommended size of the
sink is 100 x 40 cm (40 x 16").
A further requirement is two plastic containers of 20
litres (5.3 US gal.) each, one for replenishment
developer and one for waste chemicals.
POWER CONNECTIONS
If not already there, a main power outlet should be
installed in the room, where the machine will be
situated. Max. distance to the machine 2 m (6 ft.).
For requirements please see technical
specifications.
0149 2.1
CTP 2000
UNPACKING
MECHANICAL INSTALLATION
Position the processor,and level using a spirit level
placed along the tank side and also
across the roller,adjust as required by means of the
jacking feet.This levelling is very
important as the correct operational liquid levels in
the tanks will be affected.
Water Connections
(if a water recirculation unit is fitted)
Water Inlet:-Water at mains pressure should be
connected to the water inlet at the rear of
the processor via a conveniently sited isolating
valve.Copper or high pressure hose should
be used.
Note: Obtaining water by teeing off from an
existing supply should be avoided as the
resultant drop in pressure when both outlets are
turned on may result in insufficient water
being supplied to the processor.
Waste Outlet:-A large bore waste pipe,(minimum
recommended bore is 1 1/2"or 38mm)
should be connected to the outlet of the processor
at the rear.If connecting into an existing
drainage system,a bottle trap or U bend is
recommended.
Note:Under no circumstances must the highest
point of the drainage system be located higher
than the waste outlet at the rear of the
processor.
Water Recirculation Unit Connection
Site the unit at the rear of the processor close to
the mains water inlet and waste outlet.
Connect the outlet from the unit to the
inlet,(3/4"fitting),on the processor by a short length
of tube.
The inlet on the unit (larger connection)should be
similarly connected to the waste outlet of
the processor by a short length of flexible tube
(minimum recommended bore is 38mm)
Note:The processor developer heating system
will not operate until the developer tank has
been filled and the safety float switch activated.
2.2 0149
CTP 2000
ELECTRICAL INSTALLATION
UK-The processor must be connected via a
switched fused isolator,or a fused plug in a
switched socket,depending upon the power
requirements.The isolator or plug must be
mounted adjacent to the machine and within easy
reach.Pay particular attention to the
routing of any cables around the working area of
the machine in order to avoid possible trip
hazards and contact with chemicals.
Countries other than the UK-Consult a qualified
electrician.
0149 2.3
CTP 2000
2.4 0149
CTP 2000
3. FUNCTIONS AND FEATURES
GENERAL
The processor contains four major sections (Fig
3/1): DEVELOPER (A), WASH (B), GUM (C), and
DRYER (D). Each section performs a basic function
to change the exposed plate into a fully developed
and dry plate, ready for handling.
The plate material is fed into the machine from the
feed-table (E). At this stage the machine will
normally be in STAND-BY mode, but activating the
input sensor(s) makes the machine start up in
PROCES mode (see description of the different
operating modes later in this chapter).
When the plate is fed into the processor, the
transport roller system takes over and leads it
safely and smoothly through each of the four
sections.
Shortly after the plate material has left the machine
and has landed on the exit table (F), the machine
returns to STAND-BY mode.
0149 3.1
CTP 2000
The following pages show the schematic views of
the different sections of the processor, illustrating
the flow of developer, water and gum through the
machine.
DEVELOPER SECTION
In the developer section (Fig. 3/2) the exposed plate
is developed and the remaining unexposed
emulsion is removed from the plate by the built-in
brush roller(s). Since the emulsion on positive plates
is dissolved more easily with todays kinds of
chemicals, the use of a single brush roller is
sufficient, whereas the development of negative
plates still requires a more efficient cleaning. For
this purpose some models are equipped with an
extra brush roller in the developer section.
A circulation pump recirculates the developer
through a spray tube and a filter unit keeps the
solution clean.
The developer bath is equipped with a heater and a
thermostat to keep the temperature in range, and a
level detector circuit to prevent processor operation
with insufficient chemistry. An overflow drain
opening prevents the level from becoming too high.
NOTE! If the overflow drain opening is blocked,
the liquid might overflow the tank wall and ruin
the electrical system.
REPLENISHMENT SYSTEM
An oscillation pump connected to an external
replenishment container automatically adds
developer to the developer section to compensate
for chemicals used during plate processing. It also
supplies additional developer to compensate for
lost activity caused by oxidation.
The replenishment pump can be operated manually
on the control board to the left of the feed table
(see Chapter 5).
Film sensor(s) at the entrance of the processor
start(s) the replenishment control circuit when a
plate is entered.
3.2 0149
CTP 2000
WASH SECTION
In the wash section (Fig. 3/3) the developer
chemicals is washed off the plate. The water is
distributed through two spray-tubes, an upper and
a lower. The flow of the water is controlled by a
solenoid valve, which opens just before the plate
enters the wash section. This reduces the
consumption of fresh water.
WATER RECIRCULATION UNIT
Not available for all models.
See APPENDIX B - SPECIAL ACCESSORIES.
GUM SECTION
In the gum section a thin layer of gum is applied to
the developed and washed plate to protect it from
dirt, fingerprints etc. Later, when the plate is fixed
in the printing machine, the layer will be rinsed off.
If the plate has been corrected or if it has to be
used again on a later occasion you should rewash
and regum the plate.
The gum is in a container, easily accessible through
the right side panel. An oscillating pump pumps the
gum from the container into a distributing tube and
a restrictor valve enables adjustment of the gum
flow.
The tank, pump, and gum container are connected
in a closed system, so the gum runs back from the
tank into the container and keeps recycling.
Like in the wash section, the gum oscillation pump
starts delayed, after the input sensor is activated.
0149 3.3
CTP 2000
GUM-RINSE PROGRAM
The processor features an automatic gum-rinse
program which cleans the gum distributing tube
and the rollers of the gum section.
The rinse program must be performed at least once
a day.
A button for starting this program is on the control
panel (see chapter 5).
The rinse program works by means of two solenoid
valves, one for opening to fresh water and one for
opening to drain.
The fresh water runs through the gum distribution
tube down on the rollers and then to the drain.
When finished, the processor automatically shuts
down.
NOTE! If gum-rinse program is not executed
according to description above you will get
problems with water entering the gum-system.
DRYER SECTION
In the dryer section the plate is dryed, and so
further handling of the plate is possible immediately
after it exits the processor.
A centrifugal fan with a built-in heater blows hot air
through a manifold into two pipes and dries the
plate on both sides. The system recirculates a
volume of hot air, and at the same time it takes in
some fresh air from outside of the processor.
3.4 0149
CTP 2000
DEVELOPER
FILTER
DEVELOPER
RECIRCULATION
PUMP
DRAIN
PRIMING VALVE
WATER IN
PRIMING
TANK
GUM
RECIRC.
PUMP
GUM
REPLENISHER
BOTTLE
SOLENOID VALVE
RE-ENTRY
DEVELOPER
REPLENISH
PUMP
EMERGENCY
OVERFLOW
DRAIN MANIFOLD
DEVELOPER
DRAIN
COLLECTION
BOTTLE
(IF REQUIRED)
DEVELOPER
BOTTLE
DEVELOPER
REPLENISHER
BOTTLE
FILL
PUMP
WASH GUM DRY
TRANSPORT SYSTEM
The transport system (Fig. 3/5) consists of a drive
motor with a worm gear drive system. The drive
system turns a series of rollers which direct the
plate through the processor.
The rubber rollers (2) at the entrance always run dry
to ensure a homogeneous development. A plate
guide (13) in the developer section ensures that the
plate is transported correctly through the section
and under the brush roller(s) (4 & 5).
The first pair of rollers (6) in the wash section
squeezes any residual chemicals off the plate. The
plate is then washed on both sides by means of the
spray tubes (7 & 17), and is again squeezed by the
second pair of rollers (18).
The gum section contains three rollers with the
smallest roller (8) situated close to the upper rubber
roller. The gum mass from the gum tube (9) forms a
small bath between these two rollers, and a thin
coat of gum is applied to the plate while the extra
gum is forced backwards.
EXIT TABLE
When processed, the plate ends on the exit table
(Fig. 3/6). The telescope supports (A) make the
downgrade of the table adjustable. By moving the
end-stop (B) in or out it is possible to adjust the
output length of the table.
0149 3.5
CTP 2000
3.6 0149
CTP 2000
4. OPERATOR'S CONTROLS AND INDICATORS
THE CONTROL PANEL
1 POWER ON INDICATOR
This will illuminate when power is supplied to the
machine and is in standby mode.
2 PROCESSOR INDICATOR
This will illuminate whenever the processor scrub
roller and the developer recirculation system are
running or when the plate is being processed.
3 REPLENISHMENT INDICATOR
This will illuminate whenever the replenishment
pump is in operation, normally for a short period
immediately after placing a plate over the infeed
table sensor. (See MACHINE SETTINGS AND
ADJUSTMENTS).
4 RE-ENTRY/RE-WASH
If a plate is required to be re-washed and gummed
after deletions, it should be entered into the
re-entry slot between the front and back lids and
button, item 4, pressed. The plate will then be
processed through the wash, gum and dry sections
of the processor with only these sections in
operation. At no time must a plate be fed into this
slot whilst another plate is being processed.
5 DEVELOPER SECTION FILL SWITCH
This must be pressed and held down in order to
run the fill pump during transfer of developer from a
container into the developer section of the
processor. Pumping will stop when the switch is
released.
Note: The fill switch only operates whilst the
machine is in off mode.
0149 4.1
CTP 2000
1 2 3 4 5 6 7 8
9
10 11 12 13 14 15 16 17 18 19 20
6 DRIER HEATER CONTROL
Fitted on 150 size machines only. Push button to
boost drier heat output.
7 LIQUID CRYSTAL DISPLAY
Indicates either developer temperature, conductivity
or plate count.
8/9/10 DEVELOPER TEMPERATURE C
When the temperature button (10)is pressed, the
temperature LED lights to indicate temperature
display mode, and the temperature is indicated to a
resolution of 0.1 C. The display is of the form XX.X
C,with leading zero suppression. The set
temperature may be adjusted by pressing and
holding the temperature button (10) for 5 seconds.
The temperature LED then flashes, indicating that
the display is now reading set temperature. Set
temperature is changed by pressing the up button
(8) to increase, and the down button (9) to
decrease. The set temperature can be quickly
adjusted to 25 C by pressing the down button (9)
and the up button (8) together. Normal temperature
display is resumed by momentarily pressing the
temperature button (10).
11 DEVELOPER CONDUCTIVITY (mS)
If the conductivity option probe is fitted, then
pressing the conductivity button (11) will cause the
the conductivity LED to light, and the display will
indicate developer conductivity in mS. Display is of
the form XXX.X mS, with leading zero suppression.
The conductivity reading is temperature
compensated, and the developer temperature
reading modifies the conductivity value using a
lookup table within the controller. Compensation is
valid for developer temperatures between 15 C and
35 C. If the developer temperature is <15 C, then
the display will show t Lo . If the temperature is
>35 C the display will show . The
uncompensated conductivity value can be
displayed by pressing and holding the conductivity
button (11) for 5 seconds. The conductivity LED will
flash, and the uncompensated conductivity value
will be displayed. To return to compensated
conductivity, momentarily press the conductivity
button (12).
If the conductivity option is not present, the display
will indicate .
4.2 0149
CTP 2000
1 2 3 4 5 6 7 8
9
10 11 12 13 14 15 16 17 18 19 20
12 PLATE COUNTER
If the count button (12) is pressed, then the count
LED will light to indicate batch plate counting
display. An event on either plate counter input will
cause the display to increment by one count. The
count can be zeroed by pressing the count button
(12) for 5 seconds. There is also a totalising counter
which can be displayed by pressing the count
button (12) and the down button (9) simultaneously.
This count remains when the batch count is reset.
This totalising counter is resettable by pressing the
count button (12) and the down button (9) for 5
seconds. HOURS RUN:-Pressing the count button
(12) and the up button (8) simultaneously displays
the elapsed time that the PCB has been powered
up divided by 10, i.e.a display of 24 means 240
hours run. It is intended that this function is used
by service personnel only.
13 MACHINE SPEED CONTROL
Turn clockwise to increase speed.
15 KEY OPERATED SERVICE SELECTOR
Turn anti-clockwise to symbol 16, remove the key
for normal operation, OR turn clockwise to symbol
14 for operation with all safety interlocks
overridden. For use only by service engineers or
other designated key holders.
18 AUTO OR CONTINUOUS DRIVE
SELECTOR
Turn anti-clockwise to symbol 19 to operate the
drive/gum pump only when a plate is being
processed, OR turn clockwise to symbol 17 to
operate the drive/gum pump continuously.
20 ON/OFF
On Iand off Obuttons with green indicator.
0149 4.3
CTP 2000
1 2 3 4 5 6 7 8
9
10 11 12 13 14 15 16 17 18 19 20
DIRECTION SWITCH
Neutral position
Turns processor drive rollers off.
Forward position
With the toggle in this position, the drive rollers will
rotate to advance the plate through the processor.
Reverse position
With the toggle in this position, the drive rollers will
rotate to reverse the plate out of the processor.
4.4 0149
CTP 2000
REAR (PROCESSOR) FRONT
IN
IN
IN OUT
OUT
OUT
5. OPERATING PROCEDURES
PREPARATION FOR PROCESSING
1.
Switch on the power supply.
2.
Switch on the isolator on the right hand side of the
machine.
3.
The mains and developer temperature indicators
will illuminate and the liquid crystal display will
indicate the temperature within the developer
section.
4.
Press the ON (I)button.
5.
The machine ONindicator will illuminate (as will
the PLC screen, if fitted).
6.
Depress an emergency stop button and check that
the machine ready indicator extinguishes, if it does,
reset the button by turning it anti-clockwise and
allowing it to spring out to it's stand-by position,
the machine ready indicator should remain
extinguished. Press the ON button and the machine
ready indicator will illuminate. Repeat for each of
the emergency stop buttons in turn. In the event of
any deviation in the machine ready indicator
condition an electrician will be required to rectify
the control circuit before the machine can be used.
7.
Lift and replace the rear top lid. Again, the machine
ready indicator should extinguish. Repeat with the
front lid and intermediate lids in turn. Again,in the
event of any deviation in the machine ready
indicator condition an electrician will be required to
rectify the control circuit before the machine can be
used. Lift and remove all lids clear of the machine.
8.
Place a 3/4 full container of gum below the
machine, insert the gum replenishment probe and
return hose into it.
9.
Fill the gum section, with diluted gum, by placing a
funnel between the gum roller and gum blade, fill
until the gum starts to return into the gum
replenishment/return container.
10.
For CE machines place an empty container below
the machine and insert the developer return hose
into it.
11.
Place a full container of working strength developer
below the machine and insert the developer fill
hose into it and then open the valve.
12.
Ensure the water supply is on and the drain is
connected.
13.
Turn the auto/continuous drive selector switch to
auto.
0149 5.1
CTP 2000
14.
Turn the processor/service key selector switch to
service.
15.
Remove the developer section lid then fill the
developer section by pressing the pump switch,
monitor the liquid level in the machine tank and
stop filling, by releasing the switch, as soon as, a,
(for CE )- the liquid starts to return into the
developer return container or b, (for UL) the liquid
reaches the overflow level. Alternatively manually fill
direct into the tank from containers.
16.
When filling is complete, close the valve and
remove the container from the fill hose.
NOTE:-The processor developer heating system
will not operate until the developer tank has
been filled and the safety float switch activated.
17.
Press the ON button.
18.
The machine ready indicator will illuminate.
19.
Place a full container of developer replenisher
adjacent to the machine and insert the developer
replenishment probe into it. Visibly check the
developer, water and gum spray bars for liquid
flow, if not satisfactory refer to the Machine
Settings and Adjustment section.
20.
Using a piece of plate/card, cover the infeed plate
sensor for a couple of seconds. This sensor is
located immediately inside the input slot at the front
of the processor.
21.
The process and replenishment indicators will
illuminate and the processing system will start.
22.
(See Operator Instructions for settings)
23.
Visibly check the operation and rotation of the
brush roller, this should be rotating clockwise when
viewed from the left hand side, if not, refer to the
Machine Settings and Adjustment section.
24.
The processor is equipped with a pre-heating
section and a developer tank heater therefore, allow
the machine to stand until the indicated
temperatures reach the set temperatures. The brush
roller drive may stop during this time due to the
process timer, passing a plate/card over the input
sensor will restart the brush drive if required. Again
refer to the Machine Settings and Adjustment
section if incorrect.
SAFETY NOTE:-Parts of the pre-heating system,
exposed by removal of the lids, will be very hot.
25.
Set the drive speed as required.
26.
Feed a spare plate into the input slot at the front of
the machine.
27.
Watch the plate as it passes through the various
sections to ensure smooth transport, be prepared
to stop the machine quickly using the emergency
stop if any plate jam occurs. Observe the plate
surface to confirm consistent/even wetting with
developer, also check that sufficient gum is flowing
onto the gum blade to give full coverage on the
roller, if changes are required refer to the machine
settings and adjustment section.
28.
Repeat steps 26 and 27 with the drive speed
increased one number at a time until the drive
speed is as required for plate development.
5.2 0149
CTP 2000
29.
If all the preceding checks prove correct, then the
processor can be switched off at the supply
plug/isolator, the developer and top lids replaced
and the process service key selector switch turned
to process.
0149 5.3
CTP 2000
MACHINE SETTINGS AND ADJUSTMENTS
SETTING NIP PRESSURES
If the pressure between each pair of rollers is
excessive, there will be undue load on the drive
motor and the rollers will bow, this will result in the
middle of the plates becoming wet, and possible
drive motor failure. If the pressure is too slack, the
plates will slip on their way through the processor,
and the plates will be wet all over. Both situations
will allow chemical carry over between the sections
resulting in short chemical life and wet plates.
To adjust proceed as follows:-
1.
Ensure the machine is switched off.
2.
Remove top lids.
3.
Disengage the roller drive coupling.
4.
Remove the roller assembly and lay it flat on the
top edges of the tank.
5.
For the drive/gum rollers the initial setting of a
uniform gap of 0.5mm (0.020ins.) between the
rollers is essential to set the correct pressure. This
gap should be checked with a feeler gauge, which
should touch both rollers without rotating them.
(See 7. for scrub roller adjustment).
6.
To set the pressure for the drive rollers tighten each
adjusting screw 1 1/4 turns (450 degrees).
To set the pressure for the gum rollers tighten each
adjusting screw 1 1/2 turns (540 degrees).
7.
For scrub roller adjustment follow steps 1 to 4 for
wash and steps 1and 2 for dev. (the dev scrub
must be done in the tank), and then proceed as
follows:-
Feed a narrow (75mm/100mm) strip of plate
between the rollers, the rollers must be stopped
from rotating, pull the strip through and note the
resistance. Adjust the setting screws as necessary
to give a uniform light resistance along the
complete length of the rollers.
8.
The overall height of the drive/gum rollers is
determined by the slot depth in the tank side walls
and is therefore not adjustable.
The overall height of the scrub rollers is factory set,
however if adjustment is required, jacking screws
for this purpose are located in the base of the
bearing blocks.
9.
Replace the roller assemblies in the tank.
Re-engage the roller drive couplings.
10.
Check the gum rollers for alignment. The rollers are
paired in manufacture, and misalignment indicates
that the bearing bushes are worn. Incorrect
alignment will allow excessive gum to run around
the roller ends making the edges of the plate wet
and therefore difficult to dry.
11.
Once the rollers are replaced, and no further
adjustments necessary, repeat the Preparation for
Processing section of this manual to check the
correct transport of the plate through the processor
before use.
5.4 0149
CTP 2000
SETTING DEVELOPER REPLENISHMENT
The developer replenishment rate is set via timer
KT1, (situated on the main electrical chassis),
proceed as follows:-
1.
Ensure the machine is switched off.
2.
Ascertain the volume of developer required per unit
area of the plate to be processed, and then
calculate the total volume needed for the plate.
3.
Divide this total volume by the flow rate of the
replenishment pump, 15cc (0.75fl oz) per second.
The resulting figure is the time in seconds to be set
on the timer KT1.
SETTING PROCESS TIMER
The process timer, KT2 is initially factory set for 2
minutes in the lower range of 1 to 10 minutes but
may be further adjusted by first selecting the range
and then the final figure.
SETTING CYCLE TIMER
The cycle timer, KT3 is initially factory set for 1 hour
in the lower range of 1 to 10 hours but may be
further adjusted by first selecting the range and
then the final figure.
SPRAY BAR FLOW CONTROL
Flow rate is controlled by manually operated valves
in the feed pipes to the spray bars. The rate of flow
being dependent on user preference and pressure
of supply.
GUM ROLLER LEVEL
1.
The bottom roller should be 12 mm into the fluid,
as this will apply the proper coating of finisher to
the plate.
2.
If the processor is not level, finisher is unevenly
applied.
GUM ROLLER ALIGNMENT
1.
If rollers are not aligned, excess finisher runs along
the roller making the plate edges too wet to dry.
2.
When rollers are properly aligned this provides a
clean nip and avoids having the finisher run back
along the roller.
0149 5.5
CTP 2000
1
2
m
m
DRIVE ROLLER ADJUSTMENT
NOTE! In some cases fixed one-piece bearing
blocks are utilised, thus eliminating the need for
adjustment.
SCRUB ROLLER ADJUSTMENT (WASH ONLY)
5.6 0149
CTP 2000
0.5 mm feeler gauge
(important to check at both ends)
Pressure adjustment screw
Gears shown are not used
in all appplications
Light resistance is important
check both ends of rollers
Jacking screws
Pressure adjustment screws
PUMP PRIMING INSTRUCTIONS
This machine must not be used until pump has
been primed as per following instructions.
It is imperative that this operation is carried out
after changing the finisher solution, or, if the
processor has been unused for an extended period.
Follow these instructions
1.
Turn off power supply.
2.
Close gum drain tap.
3.
Open valve A and B see illustration.
4.
Ensure silicon pickup pipe is immersed in gum
solution bottle.
5.
Pour approximately 800ml of gum solution into the
gum tank, then wait 60secs.
6.
Close valve A see illustration.
7.
Ensure reservoir is approximately 1/2 full or more, if
so pump is primed.
8.
Fill gum tank to required level.
9.
Reinstate power supply.
Machine is now ready for use.
0149 5.7
CTP 2000
1/2" Ball valve
(Priming valve)
3/4" Ball valve
WARNING!
This pump will be damaged
if allowed to run dry
INITIAL START-UP
1.
Select auto or continuous drive.
2.
Set the drive speed control as required.
3.
Set the drier heat control as required.
4.
Set the developer temperature and replenishment
rates to the required settings.
5.
Press ON button.
6.
Allow sufficient time for pre-heat and developer to
reach operating temperatures.
7.
Feed an exposed plate into the machine.
8.
Once the plate has passed through, check for full
processing of the plate. If the plate is not
processed, consult your plate technician.
9.
The machine can now be used for processing
production plates.
5.8 0149
CTP 2000
6. CLEANING, MAINTENANCE, AND ADJUSTMENTS
OPERATORS GUIDE TO CLEANING
DAILY
1.
Wipe the processor over with a damp cloth to
remove any traces of developer or dust, pay
particular attention to the input table area of the
machine.
PRIOR TO DEVELOPER CHANGE
1.
Switch off electrical supply.
2.
Remove top lids.
3.
Drain off all chemicals into suitable containers for
disposal.
4.
Close all drain valves and clean the inside of the
tanks with warm soapy water and a soft cloth.
Dis-engage drive couplings, rotate the rollers by
hand to clean off any build-up of residue from
them, re-engage couplings on completion.
5.
Drain the filter, unscrew the housing from the head
unit.
6.
Wash the filter housing and Oring in warm soapy
water. Check the condition of the Oring, and
replace if necessary.
7.
Re-fit the housing and Oring, ensure correct
fitment of Oring to obviate the risk of leaks.
8.
Fill the developer and gum tanks to a depth of
approximately 50mm (2").
9.
Supply power to the processor, turn the service key
switch to service position, press the mains on
button and cover the sensor at the plate input, this
will start the rollers, scrubs and pumps to flush the
internal plumbing.
10.
Switch off the power, then drain both tanks and
filter, refill with clean water and repeat steps 8. and
9.
11.
Switch off the power and open the drain valves to
drain the water from both tanks.
12.
Drain the filter again, and fit a new filter element,
re-assemble ensuring correct fitment of O ring.
13.
If the processor is to be used in the immediate
future, then refill with fresh chemicals, refer to
Preparation for Processing section of this manual,
otherwise thoroughly dry the processor for storage.
14.
Refit the top lids.
0149 6.1
CTP 2000
CHANGING THE FILTER ELEMENT
1.
Switch off the machine.
2.
Place an empty container under the filter housing,
close the two valves (A) at the top of the housing.
3.
Drain the filter housing by opening the valve (E) at
the base of the housing. Unscrew the filter housing
(B) anticlockwise.
4.
Remove the old filter element (C) and dispose of
carefully in accordance with local regulations.
5.
Install the new filter element.
6.
Check the O ring (D) is in good condition, replace if
required.
7.
Reassemble the filter (do not over-tighten, hand
tight only). Close the drain valve (E) in the housing,
open the two valves (A) at the top.
8.
Switch the machine on, process a plate and check
for leaks.
6.2 0149
CTP 2000
A A
B
C
D
E
E
CHANGING
THE SCRUB COVER MATERIAL
1.
Switch the machine off at the mains.
2.
Remove the lids and the gear covers, if fitted.
3.
Dis-engage the roller drive coupling.
4.
Lift the scrub roller assembly from the tank.
5.
Place on an absorbent cloth and wipe the excess
chemical from the assembly.
6.
Remove the end bearing blocks.
7.
Remove the old scrub cover by carefully cutting the
ties and the cover such that the roller surface is not
damaged. Stretch the new cover onto the roller,
secure with ties and trim excess material from both
ends.
8.
Re-assemble the scrub assembly.
9.
Refer to the adjustments section to obtain the
correct scrub set-up.
10.
Replace the scrub assembly into the tank. (Note
that the numbers on the roller assemblies must
match those on the tank).
11.
Re-engage the roller drive coupling.
12.
Replace the lids and gear covers.
13.
Switch on the mains supply.
14.
Refer to Preparation for Processing to check plate
transport before use.
0149 6.3
CTP 2000
6.4 0149
CTP 2000
7. TROUBLE SHOOTING
ATTENTION:
All corrective maintenance must be carried out only by suitably skilled or properly instructed/supervised
personnel. The fault finding section is a table format which lists some possible problems, causes and
remedies for processor malfunctions.
Use the Fault Finding table to locate and solve any specific processor malfunctions. To correct a processor
problem, do the following:
Find the sympton which best describes your problem.
Match the sympton with a probable cause and solution.
Correct the problems by trying each solution.
NOTE: Fault finding cannot be performed in a thorough manner unless the processor is operated
under recommended specifications.
0149 7.1
CTP 2000
7.2 0149
CTP 2000
inthismanual
asdescribedelsewhere
Adjust detectionheight
Sensor set toolow
Relayfaulty
Sensor unit faulty
Brushdrive, pumpwater
spraysandheatersdo
not come intooperation
whenplate isinserted
circuit diagram
Re-set emergency
stopswitch
Close covers
connection
Loose electrical
Emergencystop
switchactivated
M.C.B. tripped
inprocessor
off or tripped
circuit breaker switched
Mainsisolator switch/
Replace relay
Re-set circuit breaker. If
additional problemsare
present, see electrical
circuit breaker
Replace fuse/re-set
Fuse blownor circuit
supplydistributionbox
breaker trippedinpower
Electrical supply
lampoff
lampon
Electrical supply
start whenPower
Processor will not
isswitchedON
Switchonisolator
Replace sensor
Checkwiring
Topcoversopen
PROBLEM CONDITION POSSIBLECAUSE SOLUTION
0149 7.3
CTP 2000
PROBLEM POSSIBLECAUSE SOLUTION
hardenedgum.
uptoallowdispersionof
minutesafter initial start
allowedtorunfor 10
Ensure machine drive is
NOTE:
activated.
sensor or re-entryis
tooperate onlywhenthe
Thissectionisdesigned
NOTE:
Openregulating
valve
turnedoff
toprocessor
Water supply
or fullyclosed
processor partially
Regulatingvalve on
Replace valve (if
electrical supplyis
present at valve coil
Cleanwithsuitable
pointedtool
Turnonwater
Replace fuse
Blockedspraybars
Solenoidvalve
failingtooperate
Water solenoid
fuse blown
inoperative
Water section
supply
gumming
Inconsistant
Damagedor
scratchedplate
Replace roller(s)
Drainandreplace
withfreshgum
Addmore water or
gumasrequired
Realigntocontact
entire widthof top
squeegee roller
Replace rollers
Cleanroller with
warmwater
Fill replenisher
bottle
Free wheel(s)
scrubroller(s)
or replace
Clean, recover
Replenisher
bottle empty
Hardenedgum
depositsonroller
squeegee rollers
Damaged
Gumviscositytoo
highor low
misaligned
Spreader blade/roller
ondrive roller(s)
Damagedsurface
Contaminatedgum
scrubroller(s)
Grit particle(s)
trappedinthe
drive wheel(s)
Seizedfinal
7.4 0149
CTP 2000
PROBLEM CONDITION POSSIBLE CAUSE SOLUTION
Replace plates
contaminatedor
incorrect developer
Exhausted,
Cleanor
replace covers
Replace bristle rollers
Replace covers
Checkpump, timer,
etc. andadjust or
replace asrequired
element
Replace filter
Valve onfilter
developer change
left closedafter
Due to:
FaultyPlates.
ScrubRoller Fault.
Due to:
fault. Due to:
Developer System
Chemical.
Due to:
poor plate
Inconsistant or
development
Replace withfresh
drumof developer
Replace motor and/or
fuse asrequired
faultypreparation
excessivelyoldor
Fogged, badlystored,
Faultyscrub
motor/fuse blown
Badlywornbristle
scrubrollers
Cleanwithsuitable
pointedtool
Replace fuse
Replace covers
Openvalve
unrestrictedflow
drumtogive pipe(s)
Positiondeveloper
Highpigmentation
builduponcovers
Wornor split
covers
covers
Badlywrinkled
Developer pump
fuse blown
element
Cloggedfilter
(if fitted)
Blockedspraybars
systemfault
Replenishment
assembly
Kinkedpipe(s) on
replenishment probe
8. SPAREPARTS
0149 8.1
CTP 2000
8.2 0149
CTP 2000
1 10 4 6
5 8
7
ONLY ON GUM ROLLER
1 3 2 4 6
9 5 8
7
ONLY ON GUM ROLLER
85 SIZE
MACHINES
100, 125 & 150
SIZE MACHINES
3
DRIVE ROLLER ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21050076 21050075 21050075 21050075 Lovejoy Coupling
2 21850303 21150303 21150303 21150303 Bearing Block - Top
3 21070045 21071361 21070070 21070070 Cheese Hd. Bolt
4 21103131 21103132 21103132 21103132 Bush
5 21050273 21050272 21050272 21050272 Shim
6 21370302 21430302 21250302 21150302 Roller Top, Rubber
21130301 21310301 21340301 Roller Top, Silicone**
7 21050066 21050064 21050172 21050172 Delrin Gear
8* 21370303 21430303 21250301 21150301 Rubber Roller - Bottom
9 21850304 21150304 21150304 21150304 Bearing Block - Bottom
10 21153254 Bearing Block - One Piece
**Gum and Dev. exit rollers
* Gum Section Only.
0149 8.3
CTP 2000
8.4 0149
CTP 2000
2
3
9
8 14
1 10
13 12
4
5
6
11
7
10
SCRUB ROLLER ASSEMBLY - DEV
ITEM 85 100 125 150 DESCRIPTION
1 21050056 21050056 21050059 21050059 Short Gearbox Bush
2 21850402 21440402 21150402 21150402 Long Gearbox Shaft
3 21850403 21850403 21150403 21150403 Short Gearbox Shaft
4 21050118 21050118 21050072 21050972 Gear
5 21050118 21050118 21050123 21050123 Gear
6 21050118 21050118 21050072 21050072 Gear
7 21850404 21850404 21150404 21150404 Slave Block
8 21370304 21440304 21250401 21150401 Scrub Roller
9 21050273 21050273 21050272 21050272 Shim
10 21050057 21050057 21050060 21050060 Long Gearbox Bush
11 21850410 21850410 21150611 21150611 Gearbox
12 21050076 21050076 21050075 21050075 Coupling
13 21370218 21440218 21450218 21450218 Gearbox Retainer
14 21050071 21050071 21050117 21050117 Scrub Roller Cover
x1m x1.25m x1.5m x1.75m
0149 8.5
CTP 2000
8.6 0149
CTP 2000
1 3 5
6
2
10
9 7
4 8
SCRUB/SLICK ROLLER ASSEMBLY (BRISTLE)
ITEM 85 100 125 150 DESCRIPTION
1 21050076 21050075 21050075 21050075 Lovejoy Coupling
2 21850303 21150303 21306222 21306222 Bearing Block - Top
3 21070047 21070362 21070362 21070362 Cheese HD Bolt
4 21050219 21050247 21050247 21050247 Bush
5 21050273 21050272 21050272 21050272 Shim
6 21130306 21240301 21310322 21580322 Roller (Bristle)
7 21070150 21073363 21073363 21073363 Grub Screw
8 21370312 21340310 21270404 21260404 Roller (Slick)
9 21304025 21150304 21306023 21306023 Bearing Block - Bottom
10 21050481 21050783 21050783 21050783 Spring
0149 8.7
CTP 2000
8.8 0149
CTP 2000
1 1 2
3
DRIER HEATER ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21041040 21041041 21041040 21041041 Heater
2 21153140 21144119 21154114 21155108 Heater Carrier
3 21042319 21042319 21042319 21042319 Heater Thermostat
0149 8.9
CTP 2000
8.10 0149
CTP 2000
3 5 1 2
6
5 4
FINAL DRIVE (DRIVEN) ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21050942 21050942 21050942 21050942 Spacer Tube
2 21050126 21050126 21050126 21050126 Plastic Wheel
3 21130136 21440802 21250802 21150802 Idler Shaft
4 21050089 21050362 21050095 21050095 Sprocket
5 21050125 21050125 21050125 21050125 Rubber Wheel
6 21130326 21440801 21250801 21150801 Final Drive Bar
0149 8.11
CTP 2000
8.12 0149
CTP 2000
2 4
4
3
3
1
1 2
FINAL DRIVE (IDLER) ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21050942 21050942 21050942 21050942 Spacer Tube
2 21130136 21440802 21250802 21150802 Idler Shaft
3 21050126 21050126 21050126 21050126 Plastic Wheel
4 21050125 21050125 21050125 21050125 Rubber Wheel
0149 8.13
CTP 2000
8.14 0149
CTP 2000
2 1 1 3* 4 5
2 1 1
Optional Guide Wheels
* - For Gum Spray Bar See Later
SPRAY BAR ASSEMBLY (QUICK RELEASE)
ITEM 85 100 125 150 DESCRIPTION
1 21040073 21040073 21040073 21040073 Cable Gland
2 21304119 21304119 21304119 21304119 Connector Spray Bar
3 21237214 21240232 21238109 21244120 Spray Bar (50mm Spacing)
4 21240227 21240227 21240227 21240227 Spray Bar Cap
5 21130220 21130220 21130220 21130220 Guide Wheel
0149 8.15
CTP 2000
8.16 0149
CTP 2000
1
StandardSprayBarAssembly
2
SPRAY BAR ASSEMBLY (STANDARD)
ITEM 85 100 125 150 DESCRIPTION
1 21040073 21040073 21040073 21040073 Cable Gland
2 21370214 21440214 21450214 21460214 Spray Bar
0149 8.17
CTP 2000
8.18 0149
CTP 2000
9
3
7
8
4
6
5
2
1
10
MOTOR/PUMP ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21042352 21042352 21042352 21042353 Pump Dev. (M4)
2 21042351 21042351 21042351 21042351 Scrub Motor (M2)
3 21004121 21004121 21004121 21004121 Gum Recirc/Replen. Assy (M6)
4 21050201 21050201 21050201 21050201 Sprocket 36T
5 21060081 21060081 21060081 21060081 Filter housing
6 21042354 21042354 21042354 21042354 Replen. Pump Dev (M8)
7 21042350 21042350 21042350 21042350 Drive Motor (M1)
8 21050088 21050088 21050088 21050088 Sprocket 19T
9 21042355 21042355 21042355 21042355 Pump Fill (M19)
10 21042361 21042361 21042361 21042361 Pump Chiller (M30)
0149 8.19
CTP 2000
8.20 0149
CTP 2000
8 2 3 2 6 9
14 5 2 15 1
7
2 3 4 2 6
10 11
5
12 13
5
10 11
5
ASSEMBLY 'A' ASSEMBLY 'B' ASSEMBLY 'E' ASSEMBLY 'F'
ASSEMBLY 'G' ASSEMBLY 'H' ASSEMBLY 'C' ASSEMBLY 'D'
E
H
A
F
D
A
A
A
F
A
F
C C
G
B G
G
C
16 16
DRIVE PLATE ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21050094 21050094 21050094 21050094 Drive Roller Shaft Assy.
2 21050120 21050120 21050120 21050120 Flange Bearing
3 21050076 21050075 21050075 21050075 Coupling
4 21050069 21050069 21050069 21050069 Scrub Drive Sprocket Assy.
5 21050083 21050083 21050083 21050083 Packing Washer
6 21050089 21050089 21050089 21050089 Sprocket 19T x 3/4" Bore
7 21153119 21144106 21154107 21154107 Drive Plate
8 21050091 21050091 21050091 21050091 Scrub Roller Shaft Assy.
9 21050093 21050093 21050093 21050093 Roller Drive Shaft Assy.
10 21050090 21050090 21050090 21050090 Oilite Sprocket
11 21050046 21050046 21050046 21050046 Eccentric Idler Spigot
12 21050115 21050115 21050115 21050115 Oilite Duplex Sprocket
13 21050276 21050276 21050276 21050276 Eccentric Idler Spigot
14 21050090 21050362 21050095 21050095 Sprocket
15 21130326 21440801 21250801 21150801 Final Drive Shaft
16 21104012 21104170 21104013 2110401 Drive Chain Kit 3
0149 8.21
CTP 2000
8.22 0149
CTP 2000
1
2
3
4
5
6
7
8
9
PRIMING PUMP COMPONENTS
ITEM 85 100 125 150 DESCRIPTION
1 21102867 21102867 21102867 21102867 Priming Reservoir
2 21060217 21060217 21060217 21060217 3/4" BSP Nipple
3 21060112 21060112 21060112 21060112 3/4" BSP Female Tee
4 21060074A 21060074A 21060074A 21060074A 3/4" Safi Tap
5 21060286 21060286 21060286 21060286 Swept Elbow 3/8" x 12mm
6 21060035 21060035 21060035 21060035 Hose Adaptor 1/2" x 3/4"
7 21060113 21060113 21060113 21060113 Connector 1/2" Female
8 21060324 21060324 21060324 21060324 Reducer 1/2" x 1/4"
9 21041072 21041072 21041072 21041072 Pump AC-2C
0149 8.23
CTP 2000
8.24 0149
CTP 2000
1
1 2
4
4
5
7
8
1 3
5
6
9
10
PLUMBING COMPONENTS
ITEM 85 100 125 150 DESCRIPTION
1 21060040 21060040 21060040 21060040 3/4" BSP x 3/4 Hose Adaptor
2 21060170 21060170 21060170 21060170 3/4" BSP M/F Elbow
3 21060178 21060178 21060178 21060178 3/4" BSP Plug
4 21060191 21060191 21060191 21060191 1/2" BSP Plug
5 21060035 21060035 21060035 21060035 1/2 BSP x 3/4" Hose Adaptor
6 21060028 21060028 21060028 21060028 1/2" F/F Elbow
7 21060120 21060120 21060120 21060120 1 1/2" BSP F/F Coupler
8 21060116 21060116 21060116 21060116 1 1/2" BSP F/F Elbow
9 21060049 21060049 21060049 21060049 Waste Pipe 4 1/2"
10 21543200 21543200 21545200 21545200 Waste Pipe
0149 8.25
CTP 2000
8.26 0149
CTP 2000
4
2
1
4
3
1
4
FILTER ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21060081 21060081 21060081 21060081 Body
2 21060067 21060067 21060067 21060067 O Ring
3 21060060 21060060 21060060 21060060 Filter
4 21060074 21060074 21060074 21060074 Tap
0149 8.27
CTP 2000
8.28 0149
CTP 2000
1 4 3
2
GUM APPLICATOR ROLLER
ITEM 85 100 125 150 DESCRIPTION
1 21103503 21103629 21103630 21103631 Gum Spreader Roller
2 21982567 21982567 21982567 21982567 Roller Wedge Block
3 21103581 21103583 21103584 21103585 Gum Spray Tube
4 21103620 21103620 21103620 21103620 Gum Deflector
0149 8.29
CTP 2000
8.30 0149
CTP 2000
1 2
DEV. EXIT LAY-ON ROLLER
ITEM 85 100 125 150 DESCRIPTION
1 21103508 21103634 21585301 21586301 Lay-on Roller
2 21982567 21982567 21982567 21982567 Roller Wedge Block
0149 8.31
CTP 2000
8.32 0149
CTP 2000
4
5
1
2
3
DELIVERY TABLE ASSEMBLY
ITEM 85 100 125 150 DESCRIPTION
1 21153123 21144125 21154123 21155114 Delivery Table Support
2 21305205 21156202 21145210 21146204 Delivery Table Top
3 21153120 21144126 21154122 21155113 Delivery Table
4 21153121 21144127 21154124 21155115 Delivery Table Leg
5 21050129 21050129 21050129 21050129 Feet
0149 8.33
CTP 2000
8.34 0149
CTP 2000
FILL
FRONT
PowerSupply
220V 10Amp.
To PowerSupply
inProcessor
2
3
9
1
4
6 7
8
CHILLER KIT
ITEM PART No. DESCRIPTION
1 21103156 Chiller Unit
2 21042060 Pump (M30)
3 21059045 Bracket
4 21063002 Header Tank
5 21060148 Hose Adaptor
6 21060007 Clip, 1/2"
7 21060001 Hose, 1/2"
8 21060223 Hose Adaptor 1/2" 90 Deg
9 21040073 Gland
0149 8.35
CTP 2000
8.36 0149
CTP 2000
6
5
4
3
2
1
13
12
11
10
9
8
7
SWITCH PANEL
ITEM PART No. DESCRIPTION
1. Stop (QS1)
21041013 Non Latching Switch
21041014 Switch Base
21040384 Red lens
2 21040388 LED Green (VH2)
3 Start (QS4)
21041013 Non Latching Switch
21041014 Switch Base
21040386 Green Lens
4 21042054 Automanual (QS5)
21041106 Switch
21041100 Mounting Collar
21041105 Control Block (x2)
5 Service (QS1)
21041103 Switch
21041100 Mounting Collar
21041105 Control Block
6 21042338 Potentiometer 5K (R2)
21042339 Control Knob & Brake
7 21040020 LED Red UL (VH1)
21040388 LED green CE
8 21040388 LED Green (VH4)
9 21040387 LED Amber UL (VH3)
21040388 LED Green CE
10 Re-Entry (QS6)
21040013 Non Latching Switch
21040014 Switch Base
21040310 White lens
11 21041033 Rocker Switch (QS2)
0149 8.37
CTP 2000
8.38 0149
CTP 2000
6
5
4
3
2
1
13
12
11
10
9
8
7
SWITCH PANEL
ITEM PART No. DESCRIPTION
12 Heater Boost (150 Models Only) (QS7)
21041017 Latching Switch
21041014 Contact Block
21040385 Amber Lens
13 21042286 LCD Temperature Readout
0149 8.39
CTP 2000
8.40 0149
CTP 2000
85/100/125 UL CHASSIS REFERENCE
ITEM CIRCUIT REF PART No. DESCRIPTION
1 21041044 Terminal Earth
2 21041043 Terminal 2.5mm
3 21040997 Terminal 4mm
4 21040323 Capacitor Fixing Clip
5 C1 21040322 Capacitor
6. U1 21041028 Rectifier
7 T1 21043126 Transformer 100VA
8 L1 21043123 Choke
9 QF1 21040941 M.C.B. 25A Double (125 Model)
11 ST9 21043127 Drive MotorTCCB, 0.7A
12 21042320 Drive Board
13 K1,K2,K4,KT1,KT2,KT3 21041126 Relay Base, 14 Pin
14 KQ1,KQ2 21041228 Siemens Contactor
15 KT1 21041206 Timer, Multi Range
16 K1,K2,K4 21041163 Relay, 14 Pin
17 KQ1 21041227 Aux. Contactor (2 x NO, 2 x NC)
KQ2 21041226 Aux. Contactor (4 x NO)
18 21041026 Fuse Holder
19 T2 21043124 Transformer 6VA
20 Q1 21040520 Isolator
26 21043148 10A Fuse Holder
28 21040938 MCB 20 Amp, Double (85 & 100 Models)
36 21040873 Fuse Link Bar-Entrelec
37 C3 21042132 Capacitor
101 ST8 21043128 Motor Overload Relay
102 F27, F28 21043130 Bussman Fuse Holder, 10A Double
104 21042293 Socket, 3 Way
105 21042294 Socket, 4 Way
107 21042301 Socket, 15 Way
108 21042365 Brass Stand Off (M3 x 16mm)
110 21042312 Plug, 12 Way
0149 8.41
CTP 2000
8.42 0149
CTP 2000
85/100/125 UL CHASSIS REFERENCE
ITEM CIRCUIT REF PART No. DESCRIPTION
111 21042318 Plug, 18 Way
114 21042315 Plug, 15 Way
116 21042304 Plug, 4 Way
117 21042303 Plug, 3 Way
119 21042302 Socket, 18 Way
120 21042300 Socket, 12 Way
130 21042299 Socket, 9 Way
131 21042309 Plug, 9 Way
151 2104315 7Isolation Transformer, 0.7A
152 21042337 General Line Filter
157 21042327 Triac Board Incl. Mounting Bracket
0149 8.43
CTP 2000
8.44 0149
CTP 2000
S
O
C
K
E
T
S
P
L
U
G
S
150 UL CHASSIS REFERENCE
ITEM CIRCUIT REF PART No. DESCRIPTION
1 21041044 Terminal Earth
2 21041043 Terminal 2.5mm
3 21040997 Terminal 4mm
4 21040323 Capacitor Fixing Clip
5 C1 21040322 Capacitor
6 U1 21041028 Rectifier
7 T1 21043126 Transformer 100VA
8 L1 21043123 Choke
9 QF1 21040943 M.C.B. 25A Triple
11 ST9 21043127 Drive MotorTCCB, 0.7A
12 21042320 Drive Board
13 K1,K2,K4,KT1,KT2,KT3 21041126 Relay Base, 14 Pin
15 KT1 21041206 Timer, Multi Range
16 K1,K2,K4 21041163 Relay, 14 Pin
18 21041026 Fuse Holder
19 T2 21043124 Transformer 6VA
20 Q1 21040520 Isolator
24 KQ1 21042367 Aux. Contactor N/C
25 KQ2 21042368 Aux. Contactor N/O
26 21043148 10A Fuse Holder
27 KQ1, KQ2, KQ3 21042366 Contactor (LS 5K) AEG
36 21040873 Fuse Link Bar-Entrelec
37 C3 21042132 Capacitor
101 ST8 21043128 Motor Overload Relay
102 F27, F28 21043130 Bussman Fuse Holder, 10A Double
104 21042293 Socket, 3 Way
105 21042294 Socket, 4 Way
107 21042301 Socket, 15 Way
108 21042365 Brass Stand Off (M3 x 16mm)
110 21042312 Plug, 12 Way
113 21043131 Bussman Fuseholder Triple
0149 8.45
CTP 2000
8.46 0149
CTP 2000
S
O
C
K
E
T
S
P
L
U
G
S
150 UL CHASSIS REFERENCE
ITEM CIRCUIT REF PART No. DESCRIPTION
114 21042315 Plug, 15 Way
116 21042304 Plug, 4 Way
117 21042303 Plug, 3 Way
119 21042302 Socket, 18 Way
120 21042300 Socket, 12 Way
130 21042299 Socket, 9 Way
131 21042309 Plug, 9 Way
151 21043157 Isolation Transformer, 0.7A
152 21042337 General Line Filter
157 21042327 Triac Board Incl. Mounting Bracket
0149 8.47
CTP 2000
ELECTRICAL ITEMS NOT ILLUSTRATED
PART No. COMPONENT DESCRIPTION
21042138 Varistor with Crimps
21040314 Slotted Din Rail
21040316 Terminal End Stop
21040459 Fuse Holder End Stop
21040999 Jumper Bar 4mm 10 Way
21041092 Safety Switch & Actuator
21041099 Emergency Stop Switch
21041100 Mounting Collar
21041101 Contact Block
21041113 Reversing Switch
21040655 Earth (Ground) Clamp
21040402 Capacitor 470 Mfd
21040379 Diode IN 4004
21040378 Circuit Board Mounting Pillar
21042015 Aux. Socket Body
21042016 Aux. Socket Body Insert
21042023 Aux. Socket Body Contact Socket 1mm
21042069 Aux. Socket Body Cap
21040004 Aux. Socket Body A.B.S Box
2104072801 Sensor (FE7A - DA6V - HE)
21040880 Fuse 20mm x 5mm 0.5 Amp Anti Surge (T) 250V
21041029 Fuse 20mm x 5mm 1 Amp Quick Blow (F) 250V
21041037 Fuse 20mm x 5mm 2 Amp Quick Blow (F) 250V
21041038 Fuse 20mm x 5mm 3 Amp Quick Blow (F) 250V
21041039 Fuse 20mm x 5mm 5 Amp Quick Blow (F) 250V
21043133 Fuse 20mm x 5mm 100mA Quick Blow (F) 250V
21043329 Fuse 20mm x 5mm 250mA Anti Surge (T) 250V
21040451A Fuse 20mm x 5mm 10A Quick Blow (F) 250V
21043129 Fuse 10mm x 38mm 10A Time Delay (Class G) 250V
2104012401 Float Switch
2104202501 Cartridge Heater
8.48 0149
CTP 2000
ELECTRICAL ITEMS NOT ILLUSTRATED
PART No. COMPONENT DESCRIPTION
21370217 Temperature Probe Tube
21042287 Temperature Probe
21042288 Conductivity Probe
0149 8.49
CTP 2000
8.50 0149
CTP 2000
9. ADDITIONAL SERVICE INFORMATION
PLATE SENSOR ADJUSTMENT
NOTE! Extreme care must be exercised when
implementing the following procedures.
1.
Ensure the processor is switched off.
2.
Remove the input table cover (if fitted) and locate
the sensor.
3.
Detach the sensor, with its mounting bracket, from
the tank end and lift clear until the adjustment
screw is accessible.
CAUTION! - Beware of stretching the sensor
cable.
4.
Zero the sensor by turning the adjustment screw
fully anti-clockwise.
5.
Switch on the processor.
NOTE! That when the sensor is triggered the
machine will come into operation.
6.
Adjustment of the sensor is achieved by turning the
adjustment screw clockwise until the LED activates
when a suitable plate is presented to the sensor
window at a distance of approximately 100mm (4"),
the sensor is then set.
7.
Switch off the processor.
8.
Replace the sensor and input table cover.
9.
The processor can now be switched on to continue
processing.
0149 9.1
CTP 2000
Mounting bracket
Plate
1
0
0
m
m
(
4
"
)
Sensor window
Led
Sensor
Adjustment screw
TEMPERATURE AND DEVELOPER
CONDUCTIVITY CALIBRATION
It is possible to adjust the conductivity and
temperature display to suit an individual
requirement once the panel has been installed in
the processor machine
ENTERING THE CALIBRATION MODE
The calibration mode is entered by pressing and
holding the conductivity button whilst the machine
is turned on.
Once this has been done the readout is in
calibration mode, and will remain so until power is
removed, when any changes made will be stored in
memory. Once in calibration mode, the controller
does not control the developer heater.
TEMPERATURE CALIBRATION
In order to calibrate the temperature reading of the
readout, first ensure the developer bath has
reached the correct temperature for calibration, and
that the calibration thermometer has stabilised.
Next enter the calibration mode as described
above.
Once in calibration mode, the temperature reading
can be adjusted to suit the calibration thermometer
by selecting temperature display, and pressing the
up and down buttons accordingly until the required
calibration temperature reading is displayed. Be
careful not to disturb the conductivity calibration by
pressing up or down buttons if the conductivity
reading is displayed.
The temperature calibration is an offset adjusting
process.
Once the calibration is done, and if conductivity
calibration is not required, then save the calibration
by powering the machine down for a few seconds.
Once power is reapplied, the readout should enter
normal operation mode, and display the correctly
calibrated reading.
CONDUCTIVITY CALIBRATION
There are two methods possible for calibrating the
conductivity reading, and the user may choose
either method according to preference, since either
method will achieve a valid calibration:
Conductivity calibration is a gain setting process.
1 -UNCOMPENSATED CALIBRATION
MODE
This method allows a calibration loop to be used,
and can be useful if there is no developer in the
machine. Alternatively, this method can be used to
match the reading to a calibration conductivity
meter which has temperature compensation
switched out.
1a -LOOP METHOD
First enter calibration mode, and press the
conductivity button. The conductivity LED will light.
Press and hold the conductivity button for five
seconds, and the conductivity LED will start
flashing, indicating that uncompensated
conductivity is being displayed. Release the button
and ensure that the LED continues flashing.
Attach the loop through the conductivity probe, and
verify that the conductivity reading is near the value
printed on the label that is attached to the
conductivity probe.
The up and down buttons may now be pressed to
adjust the displayed value of conductivity to match
the exact calibration value required.
Power the machine down to save the calibration
value.
9.2 0149
CTP 2000
1b -DEVELOPER IN BATH METHOD
(UNCOMPENSATED)
First run the machine normally until the developer
has reached a stable temperature that suits
calibration, and place the calibration conductivity
probe in the developer bath.
Enter calibration mode, and press the conductivity
button. The conductivity LED will light. Press and
hold the conductivity button for five seconds, and
the conductivity LED will start flashing, indicating
that uncompensated conductivity is being
displayed. Release the button and ensure that the
LED continues flashing.
The up and down buttons may now be pressed to
adjust the displayed value of conductivity to match
the exact calibration value required.
Power the machine down to save the calibration
value.
2 -COMPENSATED CALBRATION MODE
This method can only be used if there is developer
in the machine, and requires the use of a calibration
conductivity meter dipped in the developer bath.
First run the machine normally until the developer
has reached a stable temperature that suits
calibration, and place the calibration conductivity
probe in the developer bath. Ensure that the
calibration conductivity meter has the correct
compensation value selected, and compensation
enabled. Enter calibration mode, and press the
conductivity button. The conductivity LED will light,
the readout is now displaying compensated
conductivity. The up and down buttons may now
be pressed to adjust the displayed value of
conductivity to match the exact calibration value
required as read from the calibration meter.
Power the machine down to save the calibration
value.
0149 9.3
CTP 2000
Probe
Loop
Probe is screwed
into the Dev. section
tank wall inside the tank
Connector
100 Ohm
Resistor
9.4 0149
CTP 2000
ELECTRICAL DIAGRAMS
0149 9.5
CTP 2000
9.6 0149
CTP 2000