CONCEPT 200 C

V 1.1

TECHNICA L MANUAL
CONCEPT 200 C TABLE OF CONTENTS

MACHINE DESCRIPTION:
Manufacturers address: ...........................................................................3
Range of application: ................................................................................3
Maximum capacity of the unit: ..................................................................3
Principle description:.................................................................................3
Safety Warnings: ......................................................................................4

PRE INSTALLATION:
Technical datas :.......................................................................................5
Crate dimension:.......................................................................................5
Floor space requirement:..........................................................................5
Connections Location : .............................................................................6
Accessories needed for the connections: .................................................6

INSTALLATION:
Unpacking:................................................................................................7
Parts delivered with the machine : ............................................................8
Connections:.............................................................................................9

TECHNICAL MANUAL:
Restricted access screen:.......................................................................11
Solvent replenishment: ...........................................................................14
Plates counter :.......................................................................................15
Machine setup : ......................................................................................16
Solvent diagram:.....................................................................................22
Electrical scheme:...................................................................................23
CE Certificate:.........................................................................................35

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CONCEPT 200 C MACHINE DESCRIPTION

Manufacturers address:

DEGRAF Srl
"Il Girasole" - Palazzo Donatello 8/03b
20084 Lacchiarella (MI)
Italy

Range of application:
This unit is a part of a full range dedicated for the treatment of flexographic printing plates.
This range includes Exposure, Processor, Dryer and light finisher.
The CONCEPT 200 C is a unit designed for the exposure, the washout, the drying as well as
the post exposure and light finishing of solvent washable printing plates.

Maximum capacity of the unit:

CONCEPT 200 C
Number of plates: 1 in washout section
1 in exposure section
4 in dryer section
1 in light finisher section
Minimum plate size: 4 x 4 inches
100x100mm
Maximum plate size: 26 x 32 inches
660 x 810 mm

Warning: This unit is designed to work with solvent and has been tested with conventional
product. Always ask your dealer before trying to change the type of solvent. This may result
in major damages and safety issues. This machine has not been designed as an explosion
proof unit.

Principle description:

This unit is designed to expose, wash, clean, dry, post expose and light finish printing
plates.
The machine is divided in major sections
o Control panel: allow the operator to select the correct parameters to process
the plates.
o Washout section: designed to provide high quality and even washout of the
plates as well as high performance cleaning.
o Exposure section : 18 lamps of 60W to ensure even exposure
o Dryer section: 4 drawers. 2x 800W heating resistors.
o Post exposure /light finishing section: 12 UVA lamps (60W) and 11 UVC lamps
(75 W).
The operator interface is made touch screen which ensures a very easy interface.

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CONCEPT 200 C MACHINE DESCRIPTION

Safety Warnings:

To use this unit safely, it is essential that operators and maintenance people follow the
safety instructions and safety precautions and warnings specified in the manuals.

The unit is equipped with emergency switches which allow the operators to stop the
machine in case of an emergency.

These emergency switches cut off the power supply of the entire machine.

Make sure that the risk or the problem has been eliminated before restoring the power on
the unit.

To release the emergency switches, turn clockwise. The unit has to be re-started
following the Initial Operation- procedure.

Safety Interlocks
For the safety of operators, interlocks exist for the following:
Opening the top covers during operation,
Opening the Exposure covers during operation,
Opening the Light Finisher drawers during operation,
Opening the Dryer drawers during operation,
Removing the rear panels of the unit.

If any of the interlocks are not installed or closed, the unit or a specific section of the unit
will not operate.

If an interlock is activated during operation, the unit or a specific section of the unit stops
immediately. Do not open the side or rear panels during plate preparation.

NOTE : The Exposure section is fitted with a safety interlock to prevent the user to be
exposed to UV-A light radiation.

NOTE : The Dryer section is fitted with safety interlocks to prevent the user to be exposed
to solvent fumes.

NOTE : The Light Finishing drawer is fitted with a safety interlock to prevent the user to be
exposed to the UV-C and UV-A light radiation.

WARNING
UV-C light radiation is dangerous for human skin and particularly the eyes. Even a short
exposure time may cause burnings in the lower skin layers and damages the eyes retina.
Due to the SAFETY systems installed, it should never be required to check the UV-C
tubes by view the UV-C light directly when operating, maintaining or servicing the unit.
However, in case of need it is mandatory to wear a welding helmet with at least shade 6.

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CONCEPT 200 C PRE INSTALLATION

Technical datas :

Dimensions (w x l x h) : 1 550 x 2 110 x 1 300 mm

Net Weight : 880 Kg
Compressed air supply: 6 bars minimum
Exhaust : Washout : 400 m3/h minimum
Dryer : 100 m3/h minimum
Post exposure/light finisher: 400m3/h minimum
Power supply : 400V 3Ph / N / PE 50/60Hz 8,2 KW 12 A
230V 3Ph / PE 50/60Hz 8,2 KW 20 A

Crate dimension:

Please ensure the handling of the crate

will be compatible with the building
configuration: doors dimensions, load
capacity of the floor

W: 1 750 mm.
L: 2 200 mm
H: 1 610 mm.
Weight (crate included): 1130 Kg

Floor space requirement:

Please ensure there will be sufficient space around the machine for safe use as well
as easy access for maintenance. 1 meter free space is needed in front of the machine
to give an easy access. On the sides and the back of the unit 500 mm are requested
to allow the access.

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CONCEPT 200 C PRE INSTALLATION

Connections Location :

All the connection points are located on the back of the unit.

PROCESSOR EXHAUST
DIRTY SOLVENT
LEVEL SENSOR LIGHT FINISHER EXHAUST

FRESH SOLVENT COMPRESSED AIR

LEVEL SENSOR
EXPOSURE EXHAUST
POWER SUPPLY
DRYER EXHAUST

SOLVENT IN

SOLVENT OUT

Accessories needed for the connections:

Compressed air supply: 6 mm diameter hose

Exhaust : 100 mm. hose (Processor, Light finisher)
60mm hose (Dryer)
Power supply : 5 x 4mm2 cable for the 400V configuration
4 x 4mm2 cable for the 230V configuration
Solvent : 20 mm diameter solvent resistant hose

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CONCEPT 200 C INSTALLATION

Upon receipt of your machine please check with the carrier the status of the crate. Notify him
of any damage you see on the crate.

Before starting to unpack the unit, make sure you have all required tools ready to hand.

Unpacking:
Warning: For safety reasons, please wear appropriate protective clothing (gloves, glasses,
and safety shoes) while unpacking.

Start by removing the top section of the crate.

Remove the sides one by one.
The machine is now resting on the base of the crate.
Remove all blocking pieces of wood.
Use the appropriate forklift to lift the unit and get it to its installation location. Take care
that the forks are long enough to lift the machine without causing damage.
Ensure there is sufficient space around the machine (see Pre-installation section).
Remove all protection from the unit (do not use sharp tools to prevent damages).
No special anchorage is needed for this unit. The unit will rest only on its feet.
Align the machine precisely by means of a water gauge. The alignment is made by
using the adjustable feet.

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CONCEPT 200 C INSTALLATION

Parts delivered with the machine :

Items : Qty :
Hose 100 mm. 6 m.
Locking collars (100mm) 4
Hose 60 mm. 3 m.
Locking collars (60mm) 2
Panel key 1
High level used solvent sensor. 1
Plug and cable for used solvent sensor. 1
Low level fresh solvent sensor. 1
Plug and cable for fresh solvent sensor. 1
Dirty solvent barrel adapter. 1
Fresh solvent barrel adapter. 1
Solvent hoses (20mm diameter) with fittings. 2 x 3 m.
Set of fuses 1
Tube for compressed air 3 m.
Front cover handle 1
Lamps Already
installed in the
unit.

Verify that all parts are with the machine.

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CONCEPT 200 C INSTALLATION

Connections:
All the needed connections have to be made in accordance with the rules of the
installation country.

Electrical connection :
Connection such as electrical power supply has to be made by certified people.
It is recommended to use a ground fault circuit breaker as well as a lockout type power
switch for the electrical connection.
Before switching on the machine, ensure that the voltage measured on the main
switch of the machine match the identification plate fixed on the back of the unit.

Exhaust blower connection:

Connect all the exhaust, except the exposure exhaust which may blow into the room,
to the appropriate location (directly to the outside or to the building exhaust
installation). Ensure the airflow is correct.

Compressed air connection:

Connect the compressed air line to the unit.

Solvent connection:
Connect the solvent lines to the correct points.
Connect the solvent level sensors (high level used solvent and low level fresh solvent)
in the correct plugs.

Filling the heater/cooler tank:

Remove the panel located on the left side of the unit.
Remove the cover of the heater/cooler tank.
Prepare 4 litters of a solution based on 70% of de-mineralized water (or distilled
water), 30% of ethylene glycol and some drops of algaecide (anti-foam action).
Fill the tank to the maximum.
After running the unit for a couple of minutes, it may be needed to check again the
level of the heater/cooler tank and to add solution to reach the correct level.

Note: This operation has to be made with the machine switched OFF

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 CONCEPT 200 C

TECHNICAL SECTION

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CONCEPT 200 C TECHNICAL MANUAL

Restricted access screen:

To access to the restricted access screens, passwords are required from the configuration
screen:

1969 1006 1309

8888
Access to Access to Access to 9999
manual function plates counters machine setup
screen. screen. screen.

Enable (9999) or
disable (8888) the
solid content
measurement
device.

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CONCEPT 200 C TECHNICAL MANUAL

Manual functions :

Warning: all available functions in this section should be accessed by trained and
skilled people only. Bad manipulation in this section may result in poor plate quality,
damage of the machine or safety risks.

Manual functions screens :

To start the desired function, simply press on its graphic symbol on the screen. An action
on the touch screen starts the function, a second action stops it.

Note concerning the pump :

It is not possible to start the pump if the associated solenoid valves have not been opened
previously. This is to prevent any damage on the pump itself (no circulation of solvent). If the
solenoid valves are closed with the pump running, the pump will stop automatically.

It is possible to run the transfer chain forward or

backward by pressing on the direction desired.

To change the transfer chain speed, press on the

speed display and enter the new value. The new
value is used only in the manual function and does not
affect the speed parameters stored for plate
production.

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CONCEPT 200 C TECHNICAL MANUAL

Solid content measurement device :

Warning: all available functions in this section should be accessed by trained and skilled
people only. Bad manipulation in this section may result in poor plate quality, damage of the
machine or safety risks.

To enable or disable the solid content measurement device, simply enter the dedicated
password. Depending of the configuration desired.

8888 9999

Disable the function of the solid Enable the function of the solid
content measurement. content measurement.

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CONCEPT 200 C TECHNICAL MANUAL

Solvent replenishment:

2 different methods of solvent replenishment are available on the machine depending on the
configuration of the solid content measurement device.

If the solid content measurement device is enabled:

The replenishment is made automatically depending of the result of the measurement. It is

possible to define the quantity of fresh solvent to put in the machine in case the solid% is too
high as well as the time in between two measurements.
In case the solid% is too high, washout solvent is removed from the washout tank first and
then is replaced by fresh solvent.

If the solid content measurement device is disabled:

The replenishment is based on the calculation made by the computer. It depends on the plate
size memorised, the relief of the plate entered on the display and the setup of the
replenishment value. It is possible to define the value of the replenishment, the quantity of
fresh solvent to put in the machine and the time in between to supply of fresh solvent.
In case the quantity of fresh solvent needed is higher than a specific threshold, washout
solvent is removed from the washout tank first and then is replaced by fresh solvent.

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CONCEPT 200 C TECHNICAL MANUAL

Plates counter :

1006

Access to plates counters

screen

On this screen two different kind of information are available:

The plates counter :

The plates processed counter is the numbers of plates which have been
made in the unit. This counter can not be reseted to zero without a specific
programmable tool for the PLC.

The hours counters:

The hours counter for lamps in exposure and light finisher indicate the
working hours of the lamps. When the working hours exceed 800 hours an
alarm will be shown on the display indicating the lamps have to be
exchanged. After the replacement the working hour counter has to be
reseted to zero by keeping pressed the dedicated button for 5seconds.

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CONCEPT 200 C TECHNICAL MANUAL

Machine setup :

Warning: all available functions in this section should be accessed by trained and
skilled people only. Bad manipulation in this section may result in poor plate quality,
damage of the machine or safety risks.

1309

Access to machine setup

screen.

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CONCEPT 200 C TECHNICAL MANUAL

Speed Scaling :

The parameters configure the speed of the

transfer chain. It is possible by adjusting these
parameters to modify the speed of the chain in
order to have the speed corresponding to the
display.
Parameters A & C must remain
respectively at 13 & 255.
Parameter B corresponds to the minimum
speed.
Parameter D corresponds to maximum speed.

Process :
WO speed: speed during the washout process.
Cleaning speed: speed used during the cleaning of the plate.
Wiping speed: speed used during the wiping of the plate.
Delay to start WO: time to put WO solvent on the brushes before to move the plate in the
washout section (to have the brushes wet).
Delay to change direction: time in between two transfer movement (forward and
backward)
Delay between WO-Cleaning: time between the end of the Washout and the beginning
of the cleaning
Rinsing brushes after WO: time to rinse the brushes with fresh solvent after the washout
and before to start the cleaning
Rinsing brushes after CL: time to rinse the brushes with fresh solvent after the cleaning
and before to start the wiping.

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CONCEPT 200 C TECHNICAL MANUAL

Scaling :
The measurement of the solid content in the solvent is based on the viscosity of the solvent.
The measure is made by emptying a calibrated pot and measuring the time needed to have it
empty. A simple calculation gives then an idea of the percentage of solid content in the
solvent.

Used only when solid content measurement

enabled.
The parameters configure the solid content
measurement device.

A is the % value corresponding to the value

B readed by the sensor (low % value).
C is the % value corresponding to the value
D readed by the sensor (high % value).
Note : D must be higher than B.
Note : C must be higher than A .

Last measure: gives the last measurement of the solid content measurement (in s.)
TEST: by pressing this touch, start a measurement cycle and return the time needed to
empty the solid content device.
%Max filling time: maximum time to fill the solid content device.
Qty of solvent: define the quantity of fresh solvent to put in the machine when the solid
content is higher than the threshold.
% offset: define the point where the replenishment will start : setpoint + offset.
% analyser cleaning: time to clean the solid content device with fresh solvent at the end
of the washout cycle.

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CONCEPT 200 C TECHNICAL MANUAL

WO solvent circulation:
The parameters define the time the circulation
solenoid valve and the circulation pump are ON
and OFF. This is used to get an even
temperature in the tank when the machine is in
stand by and to keep the washout brushes wet.
The circulation is valid only when the temperature
of solvent is too high or too low compare to the
setpoint.

Plate cleaning fresh solvent pulses

The parameters define the time the fresh solvent
is supplied on the brushes during the cleaning of the plate.

Plate wiping fresh solvent pulses

The parameters define the time the fresh solvent is supplied on the brushes during the wiping
of the plate.

Cleaning cycle after plate:

The parameters define the different times of the cleaning steps made just after the end of the
wiping of a plate. This cleaning cycle is to ensure the brushes are cleaned prior to make the
next plate.

EL1 & EL7: time of fresh solvent supply on

the wiping brush.
M2: rotation time of the brushes.

Cleaning cycle at SW ON:

The parameters define the different times of the
cleaning steps when the machine is switched
ON.
EL1 & EL7 : time of fresh solvent supply on
the wiping brush.
Delay: rotation time of the brushes.
EL3 & EL4: washout solevtn supply on the
washout brushes to have them wet.

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CONCEPT 200 C TECHNICAL MANUAL

Replenishment:
Define the quantity of solvent needed per square
meter of plate per mm of relief. Used by the PLC to
calculate the fresh solvent needed per plate.
Valid only when the solid content measurement
device is disabled.

Solvent:
Fresh solvent pump calib: define the time
needed for the solvent pump to pump 1 liter of
solvent.
Draining on WO tank high level: define the
draining time when the washout solvent reaches the high level sensor. This is to prevent
the pump to continuously switch ON and OFF.
Draining after WO: define the draining tiem just after the washout process in order to
lower the solvent level befor to use fresh solvent to clean the plate.

Solvent temperature:
The parameters define the different temperature tresholds:
To start the cooling of the solvent.
To define the solvent temperature alarm.
To define the maximum temperature of the water.
TO define the temperature to start the heating of the water.
To define the water temperature alarm.

Exposure section:
Lamp T: define temperature to start the
cooling of the lamps.
Stop cooling: setpoint-: define the
temperature to stop the cooling of the lamps

Dryer section:
Start regulation: define temperature to start
the regulation of the temperature.
Stop regulation: define the temperature to
stop the regulation of the temperature.
T correction: define the T correction to have the temperature in the dryer matching the
temperature on the display.
Regulation ON: time the heating resistor are ON during the regulation phase.
Regulation OFF: time the heating resistors are OFF during the regulation phase.

Light finisher:
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CONCEPT 200 C TECHNICAL MANUAL

Delay between UVA-UVC: define the time

between UVA and UVC when the automatic
mode has been selected for the light finisher.
Exhaust time : time to continue the exhaust
at the end of the light finishing cycle.

Buzzer time:
Buzzer time at the end of any of the process
cycle.

Lamp alarm after:

Setpoint of the working hours of the lamp to activate the alarm.

Factory settings:
When both touches are pressed in the same time, all the different parameters of the machine
configuration and machine setup come back to the factory settings.

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Solvent diagram:

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Electrical scheme:

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 EEC Declaration of Conformity

Manufacturer's Name: DEGRAF S.p.A.

Address: Il Girasole - Palazzo Donatello 8/07

20084 Lacchiarella (MI), Italy
Tel.: +39 02 900 90 180 Fax: +39 02 900 90 149

The manufacturer declares that the equipment here below mentioned has been
designed and manufactured according to the EEC safety and health standards.

Product Name: CONCEPT 200C

Serial Number:

Year of Production:

EEC Directive: 98/037 EEC for machines II A

73/023 EEC for low voltage
89/336 EEC for electromagnetic conformity

Standards Applied: EN 292/1

EN 292/2
EN 60204/1

Noise Emission: < 70 dB (A)

Signature:

Riccardo de Caria
(Managing Director)

DEGRAF S.p.A. - "Il Girasole" - Palazzo Donatello 8/03b - I/20084 Lacchiarella (Milan), ITALY - Tel. +39 02 900 90 164/203 - Fax +39 02 900 90 196 - info@degraf-group.com - www.degraf-group.com
Codice Fiscale e Partita IVA: IT 03344270156 - Iscr. CCIAA Milano 961447 - Capitale Sociale e 500.000 i.v.