2 Instruction Manual

AUTOLITH TP
Instruction manual 2
November 2000 Page 1
Instruction Manual
1 Major safety and handling instructions ................................................................ 3
1.1 What is in this chapter ..................................................................................... 3

1.2 General safety measures ................................................................................ 4
1.3 Safety instructions concerning plate input....................................................... 5
1.4 Safety instructions concerning plate output..................................................... 5
1.5 Performing an emergency stop ....................................................................... 6
1.6 Handling instructions concerning chemicals ................................................... 8
2 General description.............................................................................................. 10
2.1 What is in this chapter ................................................................................... 10
2.2 About Agfa AUTOLITH TP ............................................................................ 11
2.3 Parts of the AUTOLITH TP............................................................................ 12
2.4 Processing printing plates using the AUTOLITH TP ..................................... 13
3 Prescriptions and precautions ............................................................................ 17

3.2 Before you start processing........................................................................... 18
3.3 General prescriptions and precautions.......................................................... 19
3.4 Prescriptions and precautions concerning full waste bottles......................... 20
3.5 Prescriptions and precautions concerning rollers.......................................... 21
4 Chiller unit............................................................................................................. 23
4.2 General description ....................................................................................... 24
4.3 Operation ....................................................................................................... 24
5 Operating the AUTOLITH TP................................................................................ 26

5.2 The control panel ........................................................................................... 27
5.3 The menu system hierarchy .......................................................................... 30
5.4 De-activating the Processor .......................................................................... 32
5.5 Starting up the AUTOLITH TP....................................................................... 33
5.6 How to switch the Processor off .................................................................... 35
5.7 Setting up the Processor parameters............................................................ 36
5.8 The AGENDA menu ...................................................................................... 40
5.9 Setting the plate formats................................................................................ 44
5.10 Viewing/resetting the plate counters............................................................. 45
5.11 Viewing and setting the developer/wash exhaustion settings ...................... 46
5.12 Viewing and setting the developer parameters ............................................ 48
5.13 Viewing and setting the wash save .............................................................. 52
5.14 Operating the Processor............................................................................... 53
5.15 Rewashing Printing Plates............................................................................ 54
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AUTOLITH TP
2 Instruction manual
Page 2 November 2000
6 Maintenance.......................................................................................................... 56
6.2 Golden Rules for Autolith TP ......................................................................... 57
6.3 Before Starting Maintenance ......................................................................... 58
6.4 Valves and Drains ......................................................................................... 60
6.5 Replacing the Developer or Finisher Bottle................................................... 61
6.6 Replacing the Waste / Developer Overflow Bottle ........................................ 62
6.7 Cleaning Frequency....................................................................................... 63
6.8 Draining tanks before cleaning ...................................................................... 65
6.9 Developer Tank Plate Guide ......................................................................... 67
6.10 Cleaning Rollers and Tank Components...................................................... 68
6.11 Cleaning Tanks............................................................................................. 69
6.12 Cleaning the Circulation Circuits .................................................................. 71
6.13 Preparing for Inactive Periods or Holidays ................................................... 73
6.14 Chiller unit preventative maintenance .......................................................... 75
6.15 Troubleshooting ............................................................................................ 76
6.16 Checklist after maintenance ......................................................................... 76
7 Assembly of section components ...................................................................... 78

7.2 Removing rollers............................................................................................ 79
7.3 Re-installing rollers ........................................................................................ 80
7.4 Assembling the developer section components ............................................ 82
7.5 Assembling the Water Section Components................................................. 84
7.6 How to assemble the Guide Plate Wash....................................................... 86
7.7 Assembling the Finisher Section Components.............................................. 89
8 Troubleshooting ................................................................................................... 92
8.2 Messages on the Display .............................................................................. 93
8.3 Status messages ........................................................................................... 94
8.4 Operator warning messages ......................................................................... 98
8.5 Operator Queries ......................................................................................... 101
8.6 Error Messages ........................................................................................... 106
8.7 Fatal Errors .................................................................................................. 108
8.8 Clearing Jammed Plates ............................................................................. 108
8.9 Power problems........................................................................................... 109
8.10 Start-Up Problems ...................................................................................... 109
8.11 Other Problems........................................................................................... 109
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AUTOLITH TP
April 20012000
November Page 3
1 Major safety and handling instructions
1.1 What is in this chapter
Introduction This chapter lists general safety prescriptions to be taken into

account before you start processing or maintenance
Take a few minutes to read this chapter carefully. Thus, personal

injury or (permanent) damage to the Processor or printing plates
can be prevented.
Overview This chapter covers the following topics:
Topic See
What is in this chapter page 2
General Safety Measures page 4
Safety Instructions concerning Plate Input page 5
Safety Instructions concerning Plate Output page 5
Performing an Emergency Stop page 6
Handling Instructions Concerning Chemicals Page 8
Please refer to Maintenance on page 56 and Troubleshooting on

page 92.
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November
1.2 General safety measures
Read the following safety measures carefully before you start

operating the AUTOLITH TP or carrying out the maintenance
instructions described in this Instruction Manual.
Machine usage Only use and maintain the AUTOLITH TP for the purpose described
in this manual.
Repairs and Repairs and troubleshooting other than described in this Instruction
troubleshooting Manual can only be carried out by Agfa service technicians.
Unless explicitly stated in this Instruction Manual, never open or

remove any covers or other parts of the Processor secured by
means of screws, for example. Only Agfa service technicians are
allowed to do so.
Power
Turn off the main switch before you carry out any intervention.
Make sure the Processor is in 'Inactive' mode before you turn off
the main switch.
High voltage Make sure power is switched off before opening areas marked with
the symbol illustrated below:
Only Agfa service technicians are allowed to open areas marked

with the high voltage label.
Incorporated safety Never bypass or turn off the incorporated safety and security
devices devices.
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AUTOLITH TP
November
April 20012000 Page 5
1.3 Safety instructions concerning plate input
Rewash cover
Release the printing plate immediately after it enters the rewash
section.
Damaged printing plates Never re-insert damaged printing plates into the Processor.
Printing plate edges Plate edges and corners may be fine and sharp and might cause
cuts and wounds
Use of safety gloves is recommended with all printing plates. Also

handle plates with care to avoid injuries to others.
1.4 Safety instructions concerning plate output
Final drive rollers
Keep fingers away from Final Drive Assembly.
Do not remove plates until they have fully exited the machine.
Delivery table (optional)
Beware not to get your fingers held between the exiting printing
plate and the delivery table
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November 2000
1.5 Performing an emergency stop
What is it used for You may need to stop the Processor immediately because:
• a printing plate is jamming or fed in out of alignment
• there is risk of personal injury.
How to perform an There are two Emergency Stop Buttons on the AUTOLITH TP. One is
Emergency Stop located on the front left hand side, and the other on the rear right hand
side.
Follow the procedure below to perform an Emergency Stop:
Step Action
1 Press the Emergency Stop Button. The following
screen is displayed:
SAFETY CIRCUIT OPENED
2 To reset, rotate the red push knob clockwise to unlock.

The following screen is displayed:
Then ... WAIT
After the Processor has reached all its operational

values, the following screen is displayed:
Then ...
READY
Please refer to ‘De- Activating the Processor' on page

32.
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AUTOLITH TP
An emergency stop by Follow the procedure below to perform an emergency stop by

opening the rear lid opening the rear lid:
Step Action
1 Open the rear lid. After a few seconds, the
following screen is displayed:
SAFETY CIRCUIT OPENED
2 To reset, close lid.

3
If ... The Processor did not enter ‘Jammed’ mode
Then ... The following screen is displayed:
WAIT
Then ... After the Processor has reached all its operational
values, the following screen is displayed:
READY
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AUTOLITH TP
1.6 Handling instructions concerning chemicals
Chemicals and MSDS Take into account the following safety measures and recommendations
before handling chemicals:
Consult the appropriate Material Safety Data Sheet (MSDS) before
handling chemicals.
Do not use other chemicals than the ones recommended by Agfa.
How to obtain MSIDS Upon request, your local Agfa representative will send you Material
Safety Data Sheets. Read them very carefully and store them with this
Manual.
MSDS contents What you will find in Material Safety Data Sheets:
• First-Aid measures
• Fire-fighting measures
• Accidental release measures
• Handling and storage
• Exposure control and personal protection
• Physical and chemical properties
• Information on stability and reactivity
• Toxicological information
• Ecological information
• Disposal information
• Regulatory information.
Avoiding personal injuries Take into account the safety measures listed below to avoid injuries
while or after handling chemicals:
• Do not drain chemicals into public sewage systems without checking
local regulations.
• Always follow the instructions on the label of the bottles.
• Always wear glasses or safety goggles to protect your eyes against
the splashing of chemicals.
• Always wear glasses and gloves when handling chemicals or while
working in the chemical section of the Processor.
• If your eyes come into contact with chemicals, rinse them with clean
and cold running water abundantly. If your eyes are irritated,
immediately consult an eye specialist.
• If your skin comes into contact with chemicals, wash it abundantly
with clean and cold running water.
Avoid inhaling chemical vapours. Make sure the room is well ventilated
(10 x room volume/h).
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AUTOLITH TP
April 20012000
November Page 9
Edition The table below lists all pages in Major Safety & Handling Instructions
with their edition:
Page Edition Page Edition

2 November 2000 7 November 2000
3 April 2001 8 November 2000
4 April 2001 9 April 2001
5 April 2001
6 April 2001
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Page 10 April 2001

November 2000
2 General description
Introduction This chapter provides you with general information on the

AUTOLITH TP

can be prevented.
Overview
This chapter covers the following topics:
Topic See
What is in this chapter page 10
About AUTOLITH TP page 11
Parts of the AUTOLITH TP page 12
Processing printing plates using the AUTOLITH
page 13
TP
Please refer to Section 1 - Technical Specifications
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AUTOLITH TP
2.2 About Agfa AUTOLITH TP
AUTOLITH TP The Agfa AUTOLITH TP is a high-speed Processor for digital

plate production. It combines the ease of handling and the stability
of aluminum printing plates with the speed and quality of the
Thermostar technology.
If properly used and maintained, the Processor will prove to be an
efficient printing plate production tool for many years.
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AUTOLITH TP
2.3 Parts of the AUTOLITH TP
Illustration The illustration below indicates the parts of the AUTOLITH TP:
Item Description
1 Re-entry cover
2 Re-entry cover Handle
3 Base
4 Right Cover
5 Left Cover
6 Control Panel
7 Front Panel
8 Doors
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AUTOLITH TP
2.4 Processing printing plates using the AUTOLITH TP
Schematic representation The basic functioning of the AUTOLITH TP is represented in the

illustration below. It gives a schematic overview of the different
stages in the process. The numbers of the illustration refer to the
stage numbers in the process description.
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Page 14 April 2000

November 2001
Process description The table below explains the different stages in the process and the
corresponding sections:
Stage Corresponding Section Description
1 In-feed Section The plate enters the Processor, either automatically

from an image setter or manually by an operator. As
it enters the Processor it passes over a photo-
electric sensor that detects the plate and starts the
Processor.
The in-feed rollers increase speed and transport the
plate through the various sections. As it progresses
through, sections are activated and deactivated in
sequence.
The plate is kept within sensor range by the first
guide roller and enters the developer section as it
passes under the powered divert roller.
2 Developer Section The plate is guided down into the developer where it
passes under a rotating scrub roller.
The developer is constantly pumped from the tank,
through two filters and returns to the tank via a
submerged port, and spraybar with flow adjustment
capability.
The developer temperature is monitored via a probe
controlling either a heater or chiller, as required.
Developer replenisher is added to the tank based on
m² of plate processed.
Any excess developer then overflows into the rear
section of the tank and to waste.
Both waste and replenisher bottles have level
sensors.
There is also an auto-fill feature as standard.
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April 20012000
November Page 15
Stage Corresponding Section Description
3 Wash section – Water Save After the plate has been developed it is then washed
(Standard configuration) with water on both sides.
It passes through a set of nip rollers and then under a
rotating scrub roller.
The wash water is held in the tank and is pumped
onto the rollers and plate surfaces via three spray
bars.
The tank is filled automatically, controlled by a level
sensor.
Fresh water is added to the tank, at a pre-set
amount, to reduce overall water consumption.
This water is then allowed to overflow to drain.
Wash Section – Mains wash

As an alternative to using recycled water, it is
(Alternative configuration)
possible to reconfigure the Processor to run on mains
wash. This change to the water section allows
mains water to be fed directly to the spraybars, and
then via the water waste pipe to drain.
The necessary mechanical parts are included in the
Installation Kit.
If this conversion is carried out, the mains wash
function will need to be activated via the configuration
screen on Androdiags.
4 Gum/Finisher Section A pump draws finisher from a bottle situated under

the Processor and delivers it through a flow control
valve and nozzle into the space between a meniscus
roller and the top nip roller. The top nip roller applies
the finisher to the plate.
A level sensor in the bottle prevents the pump from
operating if the level is too low.
5 Drier Section A centrifugal fan and electric heater element supply
hot air to upper and lower manifold tubes which direct
the air to dry both sides of the plate.
6 Exit Section At the rear of the drier section there are two exit
sensors. These are used to detect the plate exiting
the Processor. From this the area of the plate is
calculated and replenisher is added accordingly.
These sensors also act as plate jam detectors.
The processed plate is then output from the
Processor via the final drive assembly.
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November 2000
7 Plate Re-entry The re-entry facility allows plates to be re-washed

and re-gummed after any deletions that may have
been carried out.
Re-entry is started automatically when a plate is
passed under the sensor.
Edition The table below lists all pages in General Description with their edition :

10 April 2001 15 April 2001
11 November 2000 16 April 2001
12 November 2000
13 November 2000
14 April 2001
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April 20012000
November Page 17
3 Prescriptions and precautions
This chapter lists the prescriptions and precautions to be taken

Introduction into account before you start processing or carrying out any
maintenance
can be prevented.
Topic See
What is in this chapter Page 17
Before you start processing Page 18
General prescriptions and precautions Page 19
Prescriptions & precautions concerning full Page 20
waste bottles
Prescription & precautions concerning rollers Page 21

page 92.
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November 2000
3.2 Before you start processing
Before you start using the Processor, read the following prescriptions
carefully.
Follow instructions Always follow the instructions given by Agfa.

Take into account all the instructions and safety measures given in this
manual and in other Agfa publications in order to avoid problems related to
safety, quality and health.
Agfa AUTOLITH TP Use Agfa AUTOLITH TP consumables only.
consumables only
The use of Agfa chemicals and products ensures a permanent high quality
when processing printing plates with the AUTOLITH TP.
Handling chemicals Handle all chemicals with care.
Consult the Material Safety Data Sheets (MSDS) before handling chemicals
and always follow the safety instructions on the labels of the chemical tanks.
Please refer to ‘Handling Instructions concerning Chemicals’ on page 8 for

more information concerning MSDS.
Waste chemical Collect the waste chemistry for treatment.

collection
Please refer to the corresponding Material Safety Data Sheet.
You can obtain addresses of authorised waste collecting companies from
your local Agfa representative.
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April 20012000
November Page 19
3.3 General prescriptions and precautions
Read the following prescriptions and precautions carefully before

processing or carrying out maintenance work.
Maintenance During and after maintenance, keep the following prescriptions in mind:
• Make sure that no tools or debris remain in the Processor after
maintenance
• Drain tanks separately. Please refer to ‘Draining Tanks before
Cleaning’ on page 65.
• After maintenance, make sure that all manual drain valves and filter
drain valves underneath the Processor are closed
• Carry out a ‘holiday filling’ to avoid odour problems if you will not use
the Processor for a long time (holidays, etc). Please refer to
‘Preparing for Inactive Periods or Holidays’ on page 73.
Assembly If you have disassembled parts of the Processor for cleaning, carefully
assemble all parts and rollers. Before the Processor enters an Active
state, make sure that:
• The developer plate guide in the developer tank has been installed
correctly.
• The developer cover is fitted correctly before you close the front lid.
Please refer to ‘Prescriptions and Precautions Concerning Rollers’ on
page 21.
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November 2000
3.4 Prescriptions and precautions concerning full waste bottles
The following prescriptions and precautions allow you to prevent

problems with the waste bottle
Power On Before you start emptying bottles make sure the AUTOLITH TP is
switched On.
Waste bottle full If the waste bottle gets full during operation, the following window
will appear on the control panel:
REPLACE WASTE / TOP-UP
The Processor will stop operating when the waste bottle is full.
While cleaning
You should plan to stay with the Processor while cleaning tanks.
After the message appears on the display, you still have enough
time to close the drain valve of the section you are draining.
If you are prompted to replace the waste bottle, proceed as
follows:
Step Action
1 Close all drain valves.
Refer to ‘Valves and Drains’ on page 60 for

details.
2 Replace the full waste bottle with an empty one.
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April 20012000
November Page 21
3.5 Prescriptions and precautions concerning rollers
The following prescriptions and precautions allow you to prevent damage to

the rollers or the Processor.
Handling rollers Be careful not to damage the rollers when you take them out of the
Processor:
• Make sure that the rubber surface of a roller does not rest on the edge of
a sink or a tray.
• Make sure that there is no contact between the gears and the rubber
surfaces when you place rollers on top of each other.
Keep in-feed rollers dry The in-feed rollers should never come into contact with developer or any
other liquid. Moistened in-feed rollers might cause image quality problems for
subsequent plates.
Therefore:
• Never pull back a printing plate once it has been picked by the in-feed
rollers.
• In case of a plate jam in the developer section, stop the Processor, and
always release the rollers to remove the plate.
• In case of moistened in-feed rollers or diverter roller assembly, always
clean them with water and dry them using a clean cloth.
Please refer to Assembling the Developer Section Components on page 82.
Bottom rollers Before the Processor enters an Active state, make sure that all bottom rollers
have been installed correctly.
If a bottom roller has been provided with a gear, make sure that this gear
engages correctly when installing the corresponding top roller.
Top rollers Before the Processors enters an Active state, make sure that all top rollers
have been installed correctly and pushed towards the left hand side as far as
possible.
Make sure the tension levers on each side of the rollers are correctly set.
Lock securely and make sure that all gears engage correctly (where
appropriate).
The levers are locked when they are pointing inwards towards the centre of
the Processor.
Also refer to ‘Removing Rollers’ on page 79 and ‘Re-installing Rollers’ on
page 80.
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November 2000
Edition The table below lists all pages in Prescriptions and Precautions with their
edition:
17 April 2001 21 April 2001
18 April 2001 22 April 2001
19 April 2001
20 April 2001
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AUTOLITH TP
4 Chiller unit
Introduction This chapter provides information on the chiller unit.
Topic See
General description Page 24
Operation Page 24

page 92.
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4.2 General description
Scope In order for the plate to be accurately developed, the developer

temperature must be tightly controlled via the developer heater and
the chiller unit.
General Description The chiller unit is fitted with a tank which contains water that has
been chilled using an integral refrigeration unit. On demand by the
Processor, the chilled water is pumped from the chilled water tank
through a cooling tube, situated in the bottom of the Processor
developer tank. This removes excess heat from the developer and
subsequently reduces the developer temperature.
Electrical Safety
Switch off, disconnect power and lock off all electrical supplies
before carrying out any servicing of the chiller unit.
Work on electrical components must only be performed by qualified

personnel.
Environment The refrigeration components are charged with a gas which is

considered safe for the environment. However, it is recommended
that at the end of the chiller unit’s useful life or during repair of the
refrigeration components, the gas is reclaimed and not released into
the atmosphere.
4.3 Operation
General Please note that if the Autolith TP Processor is turned Off and
isolated, then all electrical power is also off to the chiller unit.
Although the water tank is well insulated, high ambient temperatures
will eventually raise the chiller Unit’s water temperature. This point
must be considered when turning the Processor Off.
Daily Start Up Check the water level in the chilled water tank and top up as
necessary.
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AUTOLITH TP
Edition The table below lists all pages in Chiller Unit with their edition :

23 November 2000
24 November 2000
25 November 2000
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AUTOLITH TP
5 Operating the AUTOLITH TP
Introduction This chapter provides information on starting, stopping and setting

up the AUTOLITH TP.
Topic See
The control panel Page 27
The Menu System Hierarchy Page 30
De-Activating the Processor Page 32
Starting –Up the AUTOLITH TP Page 33
How to switch the Processor Off Page 35
How to set up the Processor parameters Page 36
Setting the Agenda Page 40
Setting the Plate Formats Page 44
Viewing / Re-setting the Plate Counters Page 45
Viewing the Developer Exhaustion Settings Page 46
Viewing /Setting the Developer Parameters Page 48
Viewing the Developer Replenishment Rates Page 49
Operating the Processor Page 53
Rewashing Printing Plates Page 54
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AUTOLITH TP
5.2 The control panel
Description The AUTOLITH TP has a control panel with a 20 Character by 2 line

Liquid crystal display. Most of the control functions are accessed
using the display in conjunction with 4 control keys. There are also 2
dedicated keys for specific functions:
• Backlight On/Off
• Activate / Deactivate Machine
Using the control panel The following section describes how to use the keys and display of
the control panel:
5.2.1 Layout
Cancel Accept
Backlight ON/OFF Display screen key key
Left Programmable Right

Activate key Programmable key
Deactivate Alarm Timer ON
Key Indicator Indicator
(green LED) (red LED) (green LED)
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AUTOLITH TP
5.2.2 Control panel functions
Control Panel feature Function Explanation

Backlight This is a dedicated key for the LCD Backlight.
ON/OFF
Press to toggle Backlight between ON and OFF.
Timer ON/OFF The Green LED indicates when the timer function
(Agenda) is active. The LED is extinguished if the
Backlight is turned off.
Refer to 'Setting the Agenda' on page 1 on
how to use the AGENDA facility.
Alarm indicator An Alarm is active when the red LED is lit. The
Processor requires attention. The LED is
extinguished if the Backlight is turned off.
Refer to the Troubleshooting section on
page 92 for information on alarms
Cancel key This key is used to cancel a menu choice
presented on the display.
Accept (OK) key This key is used to Accept a menu choice

presented on the display.
ON/OFF key This key is used to activate or deactivate the

Processor. Press to toggle between Active and
Inactive.
WARNING: POWER IS STILL APPLIED
TO THE PROCESSOR WHEN IN THE
INACTIVE STATE
Left and right These keys are placed immediately below the LCD
programmable and are used to navigate the menu system.
keys
They perform different functions depending on
what message is displayed. The action assigned to
that key will be displayed above it.
LCD (Liquid The LCD presents the operator with messages,
Crystal Display) information and choices. By using the accept,
DISPLAY cancel and left/right programmable keys, the
operator can interact with the control system.
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AUTOLITH TP
5.2.3 How to adjust the display brightness and contrast
Why The operator may need to adjust the display backlight brightness and contrast
to suit the ambient lighting conditions. The following is also an exercise in how
to navigate the control system hierarchy using the programmable keys.
Procedure To make these adjustments proceed as follows:
Step 1 Turn the power on to the Processor at the mains switch, after a
short delay the display will show the machine title i.e.
AUTO_{TP and the software version:
AUTO_TP B1.03h
Setup
At this point you are able to adjust the display brightness and
contrast, to do this press the SETUP key once. If you do not
require to adjust the display then wait for a short while until the
display changes to the INACTIVE screen.
Step 2 If you have selected to adjust the display the screen will change
as below:
Backlight : 150
<< >>
Press þ once to adjust the backlight brightness.

Step 3
Backlight : 150
+ -
1. Use the programmable - or + keys to adjust the backlight

brightness. The minimum setting is 0 and the maximum
setting is 255. Set the brightness to suit the ambient
conditions.
2. Press þ once to lock the value set.

Step 4
Contrast: 150
<< >>
Press the >> key once display the contrast setting and adjust if
required (follow same procedure as steps 2 & 3 above) or press
þ once to return to the basic screen.
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AUTOLITH TP
5.3 The menu system hierarchy
What is it The AUTOLITH TP has a control system which interacts with the
Processor and the operator. The operator communicates to the control
system through the control panel. The control system presents the
operator with a series of choices The choice and context is called the
MENU system. The menu system is arranged in different levels to form
a Hierarchy. This Hierarchy is shown as a diagram on the following
page.
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April 20012000
November Page 31
Agenda Formats Plate Counters Plate area Developer Wash Maintenance Manual
Operation
Dwell Time: Water save % Drain Dev

Set agenda F1 – F10: Perm Count: Tot Area Dev
Tank
Flushing:
Set Temp:
Timer ON/OFF Length: Current Count: Max m2 dev: Drain Wash

Tank
Act Temp:
Clock Width: Total Days Dev:
Clean Fin
Tank:
Conductiv ms/cm:
Max Days:
Conduct %:
Tot Area Wash :
Conduct limit: %
Max m² Wash :
Repl rate: Sby repl:
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AUTOLITH TP
5.4 De-activating the Processor
Difference The AUTOLITH TP normally need not to be shut down entirely.

However, during periods of inactivity, the Processor must be
deactivated. This is explained below.
Activation vs deactivation You can activate or deactivate the AUTOLITH TP Manually or
Automatically:
Manual • Only switch off the AUTOLITH TP when it will be Inactive
during a long period of time. There is no need to switch the
Processor Off over the weekend. It is recommended that the
main supply switch of the Processor is left on at all times,
management of the power consumption of the Processor can
be regulated by programming the active and inactive periods.
• When shutting down for short periods (i.e. overnight) and you
are not using the pre-programmed AGENDA functions, press
the ON / OFF key on the Control Panel. The display will show
INACTIVE and the power warning LED will extinguish. You
switch from ‘Inactive’ mode to ‘Ready’ mode when required
by pressing the button on the control panel.
Automatic The Processor can be pre-programmed by the operator to switch
automatically between Inactive and Active and vice versa at
specific times. This is done using the AGENDA menu on the
Control Panel.
Please refer to Setting the Agenda – page 40.
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AUTOLITH TP
5.5 Starting up the AUTOLITH TP
The following procedure describes how to start up the Processor.
Turn main isolator to the ON Position • Chiller compressor will start if internal water temp is
0
above 6 C
• Display will be blank ,no backlight
• Back light ON
AUTO TP V1.02 • Software version displayed
Setup • Back light brightness and contrast can be adjusted in
this mode by pressing the right hand key below the
setup message (refer to page 30)
• The alarm indicator will be lit and the display will beep
The CHANGED DEVELOPER message will be displayed. If
the developer has been changed during power off, press
Changed Developer? YES. If not, press NO.
• The Processor will stay in this condition until either key is
Yes No pressed.
• Pressing YES resets:
1. Plate counter (not permanent counter)
2. Total area dev counter
3. Developer exhaustion alarm figure based on time
(days)
• Pressing NO maintains all the exhaustion information
• Alarm indicator will go out
Absolutely Sure?
• Note: If YES has been selected and the power has been
Yes No turned off WITHOUT any plates being processed then,
when power is restored the INACTIVE screen will be
displayed immediately without the CHANGED
DEVELOPER? screen being displayed.
• The CHANGED WASH WATER message will be displayed.

If the wash water has been changed during power off,
Changed Wash Water? press YES. If not, press NO.
• The Processor will stay in this condition until either key is
Yes No pressed.
• Pressing YES resets the total area wash counter.
• Pressing NO maintains all the exhaustion information
• Alarm indicator will go out
Absolutely Sure?
Yes No
Continued on next page…..
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Page 34 April 2001

November 2000
The INACTIVE screen. At this point it is possible to view

INACTIVE the MENU screens (refer to Menu Hierarchy page 57).
MENU
The Processor can now be started by pressing the

Activate/De-activate key.
Any errors detected will now be reported on the display
(refer to the Troubleshooting Section of this manual on
page 110).
When the Activate/De-activate Key has been pressed The

display will show the WAIT screen. While this screen is
displayed the Processor will:
WAIT
• Adjust the temperature of the developer
MENU solution as required to bring it to its
operational value
• Monitor the levels of the Processors tanks
and bottles.
WHEN THE DEVELOPER SOLUTION TEMPERATURE

AND LIQUID LEVELS ARE IN SPECIFICATION THE
PLATE PROCESSOR WILL DISPLAY THE READY
READY
SCREEN.
MENU
THE PLATE PROCESSOR IS NOW READY TO ACCEPT
PLATES FOR PROCESSING
Any errors detected will now be reported on the display
(refer to the Troubleshooting Section of this manual on
page 110).
abc
AUTOLITH TP
5.6 How to switch the Processor off
Only switch off the AUTOLITH TP when it will be Inactive

during a longer period of time. There is no need to switch the
Processor Off over the weekend. It is recommended that the main
supply switch of the Processor is left on at all times, management
of the power consumption of the Processor can be regulated by
programming the active and inactive periods.
When shutting down for short periods (i.e. overnight) and you are
not using the pre-programmed AGENDA functions, press the
ON/OFF key on the Control Panel. The display will show
INACTIVE and the power warning LED will extinguish.
Also refer to ‘Preparing for Inactive Periods or Holidays’ on page
73.
Shutdown Follow the procedure below to shut down the Processor:

Step Action
1
Press the key to enter ‘Inactive’ mode.
2 Switch Off the Main isolator.
abc
AUTOLITH TP
5.7 Setting up the Processor parameters
Overview This section tells you how to set up the various operating parameters
required to develop plates.
Accessing the Setup Selecting the MENU option in any screen will give you access to the
Screens following:
Agenda
In this function the operator can:
• automatically start and stop the plate Processor at pre set times .
• set the plate Processor’s clock
• Activate/deactivate the automatic start/stop function above
Formats
In this function the operator can define the dimensions of the Plates to be
developed. The operator enters in a table, a record of length and width for
each different size of plate which will be passed through the Plate
Processor. From this information the plate Processor will:
• Determine how much developer Replenishment solution to add based
on the area of Plate developed
• Display an error message if the plate area is not recognised from the
table of plate dimensions entered by the operator.
• Calculates the developer exhaustion point based on m²
abc
AUTOLITH TP
Plate Counters
• View the permanent Plate counter.
• View the current Plate counter.
Note: The permanent plate counter can never be reset and is a record of
the total number of plates passed through the machine. The current plate
counter is reset when ever YES is selected at the Developer Changed?
operator message.
Plate Area
• View the total area of plate developed, since the last developer solution
change.
• View and set the maximum of area of plate to be developed before the
developer solution has to be changed.
• View the number of days the developer solution had been in use.
• View and set the maximum of number of days the developer solution
can be used before the developer solution has to be changed.
• View the total area of plate washed, since the last wash water change.
• View and set the maximum of area of plate to be washed before the
wash water has to be changed.
abc
AUTOLITH TP
Page 38 April 2001

November 2000
Developer
• View Plate Dwell Time. The dwell time is defined as the time taken from
the point when the leading edge of the plate enters the developer
solution to the point where the leading edge leaves the solution. The
dwell time range is from 15 to 40 secs, and is factory pre set at 22 secs.
• View and set the Developer Solution Temperature .The developer
0 0 o
temperature range is from 18 C to 30 C, and is factory pre set at 25 C
• View the conductivity reading and set the conductivity limit of the
developer solution to tell when it is exhausted.
• View the Replenishment rate. The replenishment is added to the
2
developer solution per m of plate developed. Replenishment is in the
2
range of 0 to 500ml/m in 1 ml increments and is factory preset at
2
150 ml/m
• View the standby replenishment rate The standby replenishment is
added to the developer solution during wake cycles. Standby
2
Replenishment is in the range of 0 to 500 ml/m in 1 ml increments and
2
is factory pre set at 50 ml/m
Wash
This function allows the operator to restrict the water use in the wash
section of the Processor. The display shows a save percentage value 0%=
no water saved (ie water use is NOT restricted - full water replenishment)
100% = water is fully saved (ie water is fully restricted NO water
replenishment). The water save % value is factory set to 50%.
Contact your service representative if you suspect water contamination
problems.
Maintenance
Drain Dev
This function allows the operator to drain and autofill the developer section,
while power is applied to the Processor. Please refer to Maintenance
section page 56.
Drain Wash
This function allows the operator to drain and autofill the Wash section,
while power is applied to the Processor.
Please refer to Maintenance section page 56
Clean Finish
This function allows the operator to drain and flush the Finisher section,
while power is applied to the Processor.
Please refer to Maintenance section page 56
abc
AUTOLITH TP
Manual
operation
This function allows the operator to drive a plate through the Processor if
the mains power has been interrupted, an Emergency Stop Button has
been pressed or the Lids have been lifted while a Plate is in the Processor.
This function must not be used if a plate jam has been detected or the plate
is damaged.
abc
AUTOLITH TP
5.8 The AGENDA menu
Overview The Processor can be switched between Active or Inactive at

predetermined times. This is achieved by setting the agenda. The timer
function On/Off enables/disables the Agenda function.
Accessing the Agenda The Agenda menu appears after MENU is selected.
Menu
5.8.1 Setting the agenda times

Agenda
Agenda • When activated this function will automatically start and stop the Plate
Processor at pre set times.
<< >> • In this function the machine clock can be set
• The Agenda function is activated/de-activated by the Timer ON / Off
control menu
• The Agenda control can be overidden at any time by simply pressing
the On/Off Button to activate the Processor
Set agenda
Set agenda
Press þ at the agenda menu to enter this function.
<< >> This function allows the operator to set the periods when the Processor will
automatically switch on and off
Display Day ON/OFF times
Sun. ON 9:
Press þ at the Set agenda menu to enter this function.
This function allows the operator to display the periods when the Processor
<< >> will automatically switch ON / OFF
Select Day ON time

Press the << >> function keys to scroll through the Day and ON/OFF times
Mon. ON 9:
This function allows the operator to set the Day when the Processor will
<< >> automatically switch ON
Select hours ON time

Press þ at the display ON time menu to enter this function. This
Hour ON: 9: function allows the operator to set the hour when the Processor will
automatically switch ON
- +
Continued on next page
abc
AUTOLITH TP
Setting the agenda times (continued)
Min ON: 30 Set Minutes ON Time
- + Press þ at the display Hour ON menu to enter this

function.
This function allows the operator to set the minutes when the
Processor will automatically switch ON
Mon. ON 9:30
Set OFF Time
<< >>
Press ý at the display Day / Hour ON menu to return to the
set Agenda menu. The operator can now proceed as shown
above to set the OFF time for the day selected.
abc
AUTOLITH TP
5.8.2 Enabling/disabling the agenda timer function
Agenda To Activate / De activate the Agenda timer select the Timer function
menu as shown by the key sequences shown opposite. The timer
<< >> function is toggled
ON (Agenda active) or OFF (Agenda not active) by pressing either +
or – Function keys.
Set agenda
<< >>
Timer ON
<< >>
Timer OFF:
- +
abc
AUTOLITH TP
5.8.3 Setting the clock
Agenda To set the Plate Processor Clock, select the Clock function menu as
shown by the key sequences shown opposite. In the Clock function
<< >> the operator can select the Day ,Hour, Minute by scrolling with the <<
>> function keys.
When the required field has been displayed it can then bet set using
the + or – Function keys.
Set agenda
<< >>
Timer ON
<< >>
Clock : Monday 12:00

<< >>
Day : Monday
- +
Hour: 12.00
- +
Min : 01
- +
abc
AUTOLITH TP
5.9 Setting the plate formats

2
Overview The Processor will recognise the plate size (in m ) from the FORMAT
Width and length values entered.
When programmed with the correct plate dimensions this function
calculates the area of the plate so the correct amount of developer
replenishment solution can be added.
The Exit sensor is used to measure the length of the plate and the
2
compares it with the formatted list to calculate the area in m .
This function can hold information on 10 different plate sizes.
An error message will be displayed if a plate of an unknown size is
processed
Accessing the Format The FORMAT menu is accessed by selecting MENU from any screen
Menu and then pressing the >> key until the word FORMAT is shown on the
screen.
Dimension range The length of a plate can be between 0 and 2000 mm.
The width of a plate can be between 0 and 1500 mm.
Agenda
<< >>
Formats
<< >>
F1 : 500 x 600mm Press to accept

Len : 500 mm(e.g.)
<< >> - +
Press – or + to set
F2 : 0 x 0mm Wid : 600 mm(e.g.) Press to accept
<< >> - +
Press – or + to set
H
F3 to F10
abc
AUTOLITH TP
April 20012000
November Page 45
5.10 Viewing/resetting the plate counters
Overview The Processor will increment the permanent counter and current counter
for each plate passed through the Processor.
• The permanent counter cannot be reset by the operator and therefore
records the total number of plates developed by the Processor.
• The current counter records the number of plates processed since the
last ‘Power Off’ or ‘Change of Developer’.
The current plate count is reset by switching the main power supply off
and then back on. When the Changed Developer? screen is displayed,
selecting YES will zero the Plate counter. This will also reset the Total
2
Plate Area in m and the Total Days counter in the PLATE AREA menu.
Accessing the plate The PLATE COUNTERS menu is accessed by selecting MENU from any
counters Menu screen and then pressing the >> Key twice
Agenda
<< >>
Plate Counters
<< >>
Perm Count: 104 Current Count: 11

<< >> << >>
Cannot be Reset Resets to zero at Developer change IF H

the Yes option is selected when the
Developer Changed? screen is displayed
abc
AUTOLITH TP
Page 46 April2000
November 2001
5.11 Viewing and setting the developer/wash exhaustion settings

2
Overview The Processor will increment a record for each m of plate passed through
the developer bath and the wash section.
2
The maximum plate area Max m Dev will determine when the ‘Change
Developer’ message occurs. The ‘Change Developer’ message will also
occur after a Max days time period.
Accessing the Developer The Developer exhaustion menu is accessed by selecting MENU from any
Exhaustion settings screen and then pressing the >> Key until PLATE AREA is displayed
The Plate area menu contains the following information:
•
2
the total area of plate developed in m (taken from the data entered in
the Formats menu)
•
2
the alarm point for maximum plate area developed, Max m Dev (0 -
2
5000 m )
• the total time the developer has been in use since the last change (in
days).
• the alarm point for time in use, in Max Days (1 to 99 days)
•
2
the total area of plate washed in m (taken from the data entered in the
Formats menu)
•
2
the alarm point for maximum plate area washed, Max m Wash (10 -
2
5000 m )
abc
AUTOLITH TP
April 20012000
November Page 47
Plate Area
<< >>
Tot Plate : 0.0m2 • Running total of plate processed ( in m2)

• Reset at Developer Changed : (Yes)
<< >>
• Maximum plate area allowed to be

Max m2 Dev : 300 m2 Max m2 Dev = 300 m2 developed since last developer change.
• Range = 0 - 5000
+
<< >> -
• Press þ to set new value and
return to sub-menu.
• Dev Exhausted alarm will be displayed
when Max m2 Dev is reached
Total Days Dev : 1 day • Running total of days developer has

been in use.
<< >> • Reset at Developer Changed : (Yes)
• Maximum days for developer solution to

Max days : 7 days Max Days = 30 days be allowed to remain in the Processor.
- + • Range = 1 - 99
<< >>
return to main menu.
• Dev Exhausted alarm will be displayed
when Max Days is reached
Total Area Wash : 0.0 m2 • Running total of plate washed
<< >>
• Maximum area for wash water to be

used since last water change.
Max m2 Wash = 300 m2 • Range = 10 -5000
Max m2 Wash : 300 m2
- + • Press þ to set new value and
<< >> return to main menu.
• Wash Water Exhausted alarm will be
displayed when Max Days is reached.
abc
AUTOLITH TP
5.12 Viewing and setting the developer parameters
Overview The developer menu is used to set a number of developer

parameters.
Accessing the developer The developer menu is accessed by selecting MENU from any
menu screen and then pressing the >> Key until Developer is displayed.
5.12.1 Dwell time and temperature
Overview The Processor will develop plates at the dwell time specified. The
developer temperature may also be specified from this menu, and
the actual developer temperature can be viewed.
Developer
<< << >>
• View and set the dwell time

Dwell Time : 22 Sec Dwell Time : 22 Sec • Range = 10 - 40
<< << - <<

>> + return to sub-menu.
• View and set the developer temperature

Set Temperat : 25.0 c Set Temperat : 25.0 c • Range = 18 - 30
<< << >> - << +

return to sub-menu.
• View actual developer temperature

Act Temperat : 24.0 c
<< << >>
abc
AUTOLITH TP
5.12.2 Conductivity
Overview The conductivity of the developer can be viewed and a conductivity

limit can be set. The conductivity can be viewed as a value (in
ms/cm), and as a percentage (100% being uncontaminated
developer solution).
Developer
<< << >>
• Press >> key until Conduct message

appears
Dwell Time : 22 Sec
<< • View the current conductivity value (in
<< >> mS/cm)
Conduct : 0.7 mS/cm

• View current conductivity as a
<< << >> percentage (100% is uncontaminated
developer solution)
Conduct : 95 %
• View and set the conductivity limit
<< << >> • Range = 0 - 100
• When the conductivity reaches this limit,
the Developer Exhausted warning
Conduct Limit : 84 % Conduct Limit : 84 % message will appear.
<< << >> - << +
abc
AUTOLITH TP
Page 50 April 2001

November 2000
5.12.3 Viewing and setting the developer replenishment rates
Overview The Processor will add Replenishment solution to the Developer bath
2
based on the m of Plate Processed or on a time period for which the
Processor has been Idle. These are Factory Preset rates and can be
viewed on the display.
Accessing the The Developer exhaustion menu is accessed by selecting MENU from
Replenishment Rates any screen and then pressing the >> Key until Developer is
displayed. The two Replen rates are Factory Preset at the values
displayed.
How the Processor calculates the replenishment rates.
1. The Replenishment rate (plate area based)
• The plate size to be processed is entered into the Format menu,
plate length x width.
• When a plate is processed as it exits the Processor it passes over
a sensor. From the time it takes to pass over the sensor, the
control system calculates the length of the plate.
• The length is then compared to the format list and if there is a
match then, using the width information, the Processor calculates
the area.
• This figure is then stored, if it is greater than 1m² then the
replenish pump adds in the required amount of replenishment
2
defined in ml/m .
• If the figure is less than 1m² then this figure is stored as more
plates are processed until 1m² is reached, then replenishment is
added.
2. The Standby Replenishment rate ( time based)
• The Sby Replen rate is applied during Processor Wake Up Cycles
• The Processor performs wake up cycles when it is in the Inactive
mode
• The Sby rate defines how much developer replenishment is added
per wake up cycle which occurs for one minute every five minutes
• The Sby Replen rate is therefore defined in ml/hr
abc
AUTOLITH TP
Developer
<< << >>

• Press >> key until Repl. rate message
appears
• View and set the replenishment rate

Repl. rate : 150 ml/m2 Repl. rate : 150 ml/m2 • Range = 0 - 5000
<< << >> - << + • Press þ to set new value and
• View and set the standby replenishment

Sby. repl : 50 ml/hr Sby. repl : 50 ml/hr rate
• Range = 0 - 5000
<< << >> - << + • Press þ to set new value and
abc
AUTOLITH TP
Page 52 April 2001

November 2000
5.13 Viewing and setting the wash save
Overview The wash save function is used to restrict the water use in the wash
section;
0% = no water saved (full water replenishment)
100% = water is fully saved (no water replenishment)
Accessing the wash save The wash menu is accessed by selecting MENU from any screen
menu and then pressing the >> Key until Wash is displayed.
Wash
<< << >>
• View and set the wash save value

Wash Save : 50 % Wash Save : 50 % • Range = 0 - 100
<< << - <<

>> + return to main menu.
abc
AUTOLITH TP
April 20012000
November Page 53
5.14 Operating the Processor
First read ‘Major Safety and Handling Instructions’ on page 3 as well as

‘Prescriptions and Precautions’ on page 17, and ‘How to Perform an Emergency
Stop’ on page 6.
How to manually Follow the procedure below to process printing plates:
process printing plates
Step Action Comment

1 Check that the printing plate is not Damaged printing plates may jam or
damaged. even damage the Processor.
2 Make sure that the Processor is in Please refer to ‘Start-Up Problems’ on page 109
‘Ready’ mode. if the Processor does not enter ‘Ready’ mode.
3 Position the printing plate to register Positioning the printing plate correctly on the
against a the left hand or right hand input table will ensure even processing.
guide, and push it gently against the feed-
Never attempt to pull back a printing
in rollers.
plate once it has been taken up by the
Wait until the Processor picks up the Processor. If you do, you may damage
printing plate. the printing plate and moisten the feed-
in rollers.
Always clean moistened or soiled feed-in rollers.
4 Wait until the Processor is in ‘Processing This will avoid overlapping of printing plates. If
& Ready’ mode again. printing plates overlap, the Processor will detect
an unknown format or a too long printing plate.
5 Insert the next printing plate. Never insert more than one plate at a
time.
6 Remove processed printing plates from This will avoid scratches.

the delivery table before the next printing
Wait until the plate has fully exited the
plate exits the Processor.
Processor.
abc
AUTOLITH TP
Page 54 April 2001

November 2000
5.15 Rewashing Printing Plates
What is rewash The rewash section allows you to re-insert a printing plate into the
Processor, while by-passing the developing section.
When to rewash It is necessary to rewash a printing plate:
If ... Then ...

You have made corrections The corrector is cleaned off.
manually
Refer to ‘Safety Instructions concerning Plate Input’ on page 5

before rewashing a printing plate.
How to rewash a printing Follow the procedure below to rewash a printing plate:
plate
Step Action Comment

1 Check that the printing plate to be Damaged printing plates may jam or even damage
rewashed is not damaged. the Processor.
2 Make sure that the Processor is in Please refer to Starting up the AUTOLITH TP on
‘Ready’ mode. page 33 if the Processor is not in ‘Ready’ mode.
3 Check there are no plates being Rewashing a plate on top of a processing plate may
processed. damage both plates.
4 Position the printing plate under the Positioning the printing plate in the middle of the
re-entry sensor in the middle of the re-entry will ensure an even rewash operation.
re-entry lid, and push it gently against
the wash section entrance rollers.
abc
AUTOLITH TP
April 20012000
November Page 55
Edition The table below lists all pages in Operating the AUTOLITH TP with their
edition :

31 April 2001 46 April 2001
38 April 2001 53 April 2001
abc
AUTOLITH TP
6 Maintenance
Introduction This chapter contains the information on when and how to maintain
the AUTOLITH TP 85/105.
Topic See
Golden Rules Page 57
Before Starting Maintenance Page 58
Valves and Drains Page 60
Replacing the Developer or Finisher Bottle Page 62
Replacing the Waste / Developer Overflow Bottle Page 63
Cleaning Frequency Page 63
Draining Tanks before cleaning Page 65
Developer Tank Plate Guide Page 67
Cleaning Rollers and Tank Components Page 68
Cleaning Tanks Page 69
Cleaning the Circulation Circuits Page 71
Preparing for Inactive Periods or Holidays Page 73
Checklist after Maintenance Page 76
Please refer to the instructions in ‘Prescriptions and Precautions’ on

page 17
abc
AUTOLITH TP
6.2 Golden Rules for Autolith TP
WARNING! Before handling or using any graphic art material, please read the Material Safety Data Sheet if necessary. Disconnect the Processor from the main power
supply. If changing the chemistry please wear glasses, gloves etc.
Developing Rinsing Gumming Final drive Time
( 6)
Check container contents/water level Daily Daily Daily Approx. 2 min.
(5)
Clean transport rollers, lubricate bottom bearings , Weekly Weekly Weekly Approx. 10 min.
(1)
Clean scavenger roller , divert rollers Daily
(2)
Change the water Daily Approx. 15 min.
Filter elements With dev. change Approx. 10 min
Clean spray bar ( holes clear ) Inspect Daily Inspect Daily Approx. 5 min.
(3)
Clean gum pipe clean weekly clean weekly Approx. 10 min
Clean tank and overflow pipe with 10% citric acid solution After dev.change. Approx.45 min.
and rinse thoroughly with water
Thorough clean After dev. change Weekly Weekly Monthly Approx.15 min.
Main clean Monthly or every Approx.120 min.
rd
1 x with 10% citric acid solution 3 dev. change
1 x with Satec T 235 and
1 x rinse thoroughly with water.
(4)
Cleaning ( Scrub-brush rollers ) . After dev. change Weekly Approx.10 min.
Plate guide After dev. change Weekly Approx.10 min.
( 1 ) - Take off and clean in the sink with Satec T235 or warm water. ( 2 ) - Clean according to plate consumption. ( 3 ) - As required
( 4 ) - Inspect and clean gum from rubber and plastic rollers ( 5 ) - Silicone Grease ( 6 ) - Check water level in Chiller Unit
abc
AUTOLITH TP
6.3 Before Starting Maintenance
Maintenance Required When the Processor has reached its recommended maintenance
schedule as indicated on the Golden Rules, or when a warning is
indicated on the Control Panel.
Maintenance Mode Before you start maintenance, you have to activate the
maintenance menu.
How to enter Maintenance Proceed as follows to enter Maintenance Mode:
Mode
Step Action
1 Enter the Menu system
Press the right Programmable Key (>>) on the
Control Panel until “Maintenance” is displayed
2 Press the Accept Key þ on the Control Panel to
enter the Maintenance Mode.
• The operator can select any or all of the three
maintenance routines presented in the following
menu
3 To clean the Dev tank:
Drain dev tank
Press the Accept Key þ followed by the + key,

followed by the Accept Key þ to change the
developer and clean the developer tank and
components.
4 To clean the wash tank:
Drain wash tank
Press the Accept Key þ followed by the + key,

followed by the Accept Key þ to change the
wash water and clean the wash water tank and
components.
abc
AUTOLITH TP
How to enter maintenance mode (continued)
5 To clean the Finisher tank:

Press the right Programmable Key (>>) on the
Control Panel until the following appears:
Clean fin tank
Press the Accept Key þ on the Control Panel to

Change the finisher and clean the finisher tank and
components within.
abc
AUTOLITH TP
Page 60 November
April 2000
2001
6.4 Valves and Drains
Illustration The illustration below indicates the valves and drains of the
AUTOLITH TP 85/105.
Item Description
Number
1 Developer Spraybar Valve
2 Finisher Flow Valve
3 Wash Water Drain Valve
4 Rear Developer Drain Valve
5 Developer Drain Valve
abc
AUTOLITH TP
April 20012000
November Page 61
6.5 Replacing the Developer or Finisher Bottle
When replacing You have to replace an empty (or aged) bottle:

• Developer: After one week (aged developer decreases
processing quality)
• Finisher: After one month (aged finisher decreases processing
quality)
• When Developer or Finisher bottles are empty the following
typical message will appear on the display.
FINISHER LOW - FILL
Bottles It is important that you use a standard 20 litre bottle with the
AUTOLITH TP 85/105. This will avoid problems with the level
probes.
How to replace a Developer Follow the procedure below to replace a Developer or Finisher
or Finisher Bottle Bottle:
Step Action
1 Place a full bottle on the floor, remove the cap from
the bottle
2 Carefully remove the probe assembly from the empty
bottle and allow excess chemistry to drain from the
probe assembly.
Do not lay the probe assembly down after removing
it from the empty bottle.
3 Insert the probe assembly into the full bottle

immediately.
Carefully store the cap of the full bottle in order to re-
use it to close full waste bottles.
4 Check the probe assembly is secure in the full bottle

5 Press the þ key to confirm the developer or finisher
bottle has been replaced.
Keep in mind that Developer and Finisher Bottles appear similar.
Check the labels before use.
abc
AUTOLITH TP
6.6 Replacing the Waste / Developer Overflow Bottle
When You have to replace a Waste / Developer Overflow Bottle when it

is full. The following message will prompt you to do so:
REPLACE WASTE / TOP-UP
Disposal of Full Waste / Full bottles have to be collected by an authorised waste treatment
Overflow Bottles company, or disposed of as agreed by the local water authority.
Refer to ‘Handling Instructions concerning Chemicals’ on page 8.
How to replace a Full Waste Follow the procedure below to replace a Full Waste / Overflow
/ Overflow Bottle Bottle:
Step Action
1 Place an empty bottle next to the Processor
2 Lift the probe assembly out of the full bottle
Do not lay the probe assembly down after

removing it from the waste bottle
3 Insert the probe assembly into the empty waste /

overflow bottle, secure with the 2 thumb screws.
4 Close the full waste / overflow bottle using a cap.
abc
AUTOLITH TP
April 20012000
November Page 63
6.7 Cleaning Frequency
Why cleaning To retain processing quality, cleaning is essential and must be

considered the very issue in maintaining your AUTOLITH TP. You
will avoid a lot of problems when you clean the Processor as
described in this section.
Consequences of bad or lack of cleaning may be:
• Low image quality after processing
• Visible marks on the image side of the plate
Three levels of cleaning Three levels of cleaning have to be considered when it comes to
maintaining the optimum processing results of the AUTOLITH TP:
• Daily cleaning (approx. 15 minutes) each day irrespective of
processed m².
• Weekly cleaning (approx 2 hours) every developer change
•
rd
Monthly cleaning (approx 4 hours) every 3 developer change
Daily cleaning Clean the AUTOLITH TP daily irrespective of the processed m².
What to do Topic
Clean roller Cleaning Scavenger Roller
Weekly cleaning Proceed as follows to clean the AUTOLITH TP every week or every
developer / water change.
What to do Topic
Drain developer tank Drain before cleaning
sections
Drain water tank Drain before cleaning
Remove rollers Removing rollers
Clean rollers Cleaning rollers
Drain filter bowls, Drain before changing filters
replace filter
elements
Clean plate guide Clean plate guide assembly
assembly
Clean roller Cleaning gum roller
Clean water scrub Cleaning scrub roller
roller
abc
AUTOLITH TP
Monthly cleaning Proceed as follows to clean the AUTOLITH TP every month or

rd
every 3 developer change
What to do Topic
Main tank clean Main tank cleaning
abc
AUTOLITH TP
6.8 Draining tanks before cleaning
Manual Draining At regular intervals, all tanks need cleaning. Consequently, tanks
need to be drained and refilled after cleaning.
Frequency of manual draining Tanks need cleaning after 300 m² of plates are processed, or after
a period of 7 days if less plates are processed.
Waste bottles Please check that empty waste bottles are available before any
tank draining operation takes place.
How to drain tanks Follow the procedure below to drain the tanks of the AUTOLITH TP
85/105:
Step Action
1 Press the right Programmable Key on the Control
Panel 7 times to reach Maintenance Mode.
2 Press the Accept Key þ to enter Maintenance
Mode.
The following screen appears:
DRAIN DEV TANK
3 Please follow the screen prompts

3 Open the pair of doors to gain access to the tank drain
valves on the AUTOLITH TP 85/105
Refer to ‘Valves and Drains’ on page 60.
5 Open the developer drain valve to drain the developer

tank.
Open the rear developer drain valve to drain the rear
section of the developer tank.
6 Open both of the developer filter bowl drain valves and
drain the contents into a suitable container.
abc
AUTOLITH TP
Step Action
7 Unscrew the filter bowls using the key provided and
safely disposal of the filter elements.
8 Replace with new filter elements, refit the bowls and
close the drain valves.
Take care that the filter bowl ‘o’ rings are correctly
seated before tightening the bowls.
9 Close both the developer drain valves when the

developer tank has been fully drained.
10 Open the wash water drain valve to drain the wash
tank.
When the handle is horizontal the wash water drain
valve is closed.
When the handle is vertical the wash water drain valve
is open.
11 Close the wash water drain valve again when the
wash tank has been fully drained.
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AUTOLITH TP
6.9 Developer Tank Plate Guide
Maintenance After every developer change, you must rinse the developer plate
guide to retain high quality processing results
How to rinse developer tank Proceed as follows to rinse plate guide:
plate guide
Step Action
1 Drain the developer tank sections, and close the
drain valves.
Please refer to ‘Draining tanks before cleaning’ on
page 65 .
2 Remove the used developer filter elements for safe

disposal, refit the filter bowls and close both the filter
bowl drain valves.
Please refer to ‘Changing Developer Filters’ on page

65
3 Rinse the developer plate guide with warm water,

continue filling both sections of the developer tank
up to the normal operational levels as indicated by
the developer level probes.
Be careful to include the developer rear section
overflow pipe.
The wash down hose can be used to fill the
developer tanks with water as required.
4 Turn on the Processor to circulate the water.

5 After circulating for 15 minutes, the water can be
drained from the developer tanks and developer filter
bowls. The tanks should then be thoroughly rinsed
with water from the wash down hose.
6 Once the water rinsing is complete, remove any
excess water from the developer tanks and
developer filter bowls. Replace with new developer
filter elements.
7 Close all drain valves.
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AUTOLITH TP
6.10 Cleaning Rollers and Tank Components
Monthly Tank components must also be cleaned regularly, ie. Every month
or after total processed plate surface exceeds 900 m², in order to
maintain favourable processing conditions.
Dirt and sludge may stick to the rollers or developer plate guides
and must be removed.
Use warm water for cleaning purposes, never use soap, detergents,
abrasives or chlorinated solvents for cleaning tank components.
Also avoid using fluffy sponges or coarse fabric.
How to clean components Follow the procedure below to clean rollers as well as other tank
components:
Step Action
1 Clean the sink in which you wish to clean rollers and
tank components.
2 Press the On/Off key to deactivate the Processor.
3 Enter Maintenance Mode
Refer to ‘Before Starting Maintenance’ on page 58.
4 Clean all rollers and tank components using warm

water.
5 Dry all rollers and components using a clean cloth.
6 Re-install all rollers and tank components.
Refer to ‘Re-installing Rollers’ on page 80.
Refer to ‘Cleaning Frequency’ on page 63 for information on when

to clean components.
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AUTOLITH TP
6.11 Cleaning Tanks
Monthly Chemicals pollute the tanks and the rollers. Hence, regular
cleaning is essential to retain optimum washing and developing
conditions.
Use warm water for cleaning purposes, never use soap, detergents,
abrasives or chlorinated solvents to clean tanks. Also avoid using
fluffy sponges or coarse fabric.
Wash tank vs. other tanks The cleaning procedure for the wash tank slightly differs from that of
the developer and finishing tanks.
How to clean the wash tank Follow the procedure below to clean the wash tank:
Step Action
1 Make sure ‘Maintenance’ mode is activated.
Refer to ‘Before Starting Maintenance’ on page 58.
2 Carefully remove the rollers and other components

from the wash tank.
Refer to ‘Removing Rollers’ on page 79.
3 Drain the wash tank but do not press the þ key.

Refer to ‘Draining Tanks before Cleaning’ on page
65.
4 Place the wash down hose in the wash tank, and fill
the wash tank with 1cm of fresh water.
5 Clean the wash tank using a soft brush.
6 Remove water and sludge using a non fluffy sponge
or wipes.
7 Rinse the wash tank using the wash down hose in
order to remove remaining sludge or dirt.
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AUTOLITH TP
Step Action
8 Open the wash water drain valve and drain the
remaining waste water from the wash water
circulation circuit.
9 Close the wash water drain valve as well as both
doors.
10 Press the þ key to confirm that maintenance
is terminated.
The Processor will automatically refill tanks and re-
enter ‘Ready’ mode.
How to clean the finisher To clean the finisher tank, proceed as described below.
tank
Step Action
1 Replace the finisher bottle with a full bottle of clean
water.
Refer to ‘Replacing the Developer or Finisher Bottle’
on page 61 .
2 Turn on the Processor and run the finisher pump for

15 minutes to circulate the clean water.
3 Switch off the Processor, disconnect the probe
assembly from the water bottle and replace with a
fresh bottle of finisher.
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AUTOLITH TP
6.12 Cleaning the Circulation Circuits
When You have to clean one or more of the circulation circuits when the
developer, waste and / or finisher bottles have been interchanged
accidentally.
Which circuits do you have to Use the table below to decide which circulation circuits you have
clean to clean:
If … Then you must clean …
The developer solution is the developer circulation circuit
contaminated
The wash water is the wash circulation circuit
contaminated
The finishing solution is the finisher circulation circuit
contaminated
A wrong bottle has been the developer circulation circuit
connected to the developer
bottle probe
A wrong bottle has been the finisher circulation circuit
connected to the finisher
inlet probe
A wrong bottle has been the developer circulation circuit
connected to the developer
waste probe
How to clean the circulation Follow the procedure below to clean one or more circulation
circuits circuits:
Step Action
1 On the main screen, press the right Programmable
Button on the Control Panel to enter ‘Inactive’ mode.
2 Drain the tanks to be cleaned
Refer to ‘Draining Tanks before cleaning’ on page
65.
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AUTOLITH TP
Page 72 April 2001

November 2000
Step Action
3 Make sure all drain valves are closed properly.
4 Open both lids.
5 Fill the tanks to be cleaned with water using the
wash down hose until the water level reaches the
overflow.
6 Close all lids.
7 On the main screen, press the On/Off key to re-
enter ‘Ready’ mode. The Processor will now circulate
the water.
8 After 15 minutes, press the On/Off key again to
enter ‘Inactive’ mode again.
9 Press the maintenance menu key to enter
‘Maintenance’ mode.
10 Drain the tanks that were filled with water.
65.
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AUTOLITH TP
6.13 Preparing for Inactive Periods or Holidays
Holiday filling Solutions that remain in the tanks during a long period of inactivity
will start producing odours. To avoid problems a holiday filling is
required when the Processor will not be used during a longer
period of time ie. Longer than one week.
Inactive during less than one If the AUTOLITH TP 85 / 105 remains unused during less than
week one week, it is sufficient to switch to ‘Inactive’ mode. The
Processor will then manage everything by itself, ie. Replenishing,
refilling and optimising solution temperatures.
Refer to ‘De-Activating the Processor’ on page 32.
How to prepare the Processor Follow the procedure below to prepare the AUTOLITH TP 85 /
for period of inactivity > 1 105 for a long period of inactivity:
week
Step Action
1 On the main screen, press the On/Off key to enter
‘Inactive’ mode.
2 Execute all maintenance and cleaning activities
listed under ‘Monthly cleaning’ on page 64.
3 Fill all tanks with water using the wash down hose.
4 Close all covers.
5 Switch the Processor off using the main switch.
Refer to ‘How to switch the Processor off’ on page
35.
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AUTOLITH TP
After holiday Follow the procedure below to start up the Processor after a
holiday:
Step Action
1 Drain water from all tanks without switching the
Processor on.
65.
2 Switch the Processor on.
abc
AUTOLITH TP
6.14 Chiller unit preventative maintenance
Scope The equipment has been designed to operate satisfactorily with the
minimum of maintenance.
Performing maintenance on a scheduled basis minimises the
chance of equipment failure and loss of Processor activity.
Preventative maintenance should be performed only by persons
who are familiar with the equipment, as well as its operational
characteristics, and maintenance requirements.
Preventative Maintenance DAILY
Schedule
• Check water level in tank – top up if necessary.
WEEKLY
• None
MONTHLY
• Disconnect the Chiller Unit from the electrical supply.
• Remove all dust and fluff from all of the ventilation slots and the
condenser fins with a stiff (non metal) brush., vacuum the
debris from the fins.
Note: Care should be taken not to damage the fins of the
condenser.
Visually check hoses for damage, and hose connections for leaks.
Tighten any loose connections.
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November 2000
6.15 Troubleshooting
Problem Probable Cause Solution

Water not cold Water level low Top up water tank
Condenser fins blocked Clean condenser fins
Chilled water pump fails to pump Low water level Top up water tank
Processor switched off Check Processor isolator
6.16 Checklist after maintenance
After the Processor has been turned on and all error messages
have been cancelled, please note the following points:
Things to check before you Do not forget to check the following before you start processing
start processing again again:
• close all drain valves behind the doors.
• connect all tanks to the corresponding probes/bottles
• connect the water supply
• close all lids
• press the On/Off key to enter ‘Ready’ mode
• confirm Developer Replenishment bottle is full
• confirmed Developer Autofill/Waste bottle is empty
• confirm Finisher bottle is full
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AUTOLITH TP
November
Edition The table below lists all pages in Maintenance with their edition :

abc
AUTOLITH TP
7 Assembly of section components
Introduction This chapter informs you how to re-install rollers after cleaning
tanks of the AUTOLITH TP.
Topic See
Removing rollers Page 79
Re-installing rollers Page 80
Assembling the Developer Section components Page 82
Assembling the Water Section components Page 84
How to assemble the Guide Plate Wash Page 86
Assembling the Finishing Section components Page 89
Read the instructions in ‘Prescriptions and Precautions’ on page 17.
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AUTOLITH TP
7.2 Removing rollers
Why remove tank All tanks need cleaning regularly. To clean tanks efficiently, you
components must remove all rollers and guides. Thus, you will be able to
properly clean all tank sides.
Refer to ‘Prescriptions and Precautions Concerning Rollers’ on
page 21.
How to remove Top Rollers Follow the procedure below to remove Drive Rollers
Step Action
1 Open lids.
2 Release the roller pressure by rotating the lever (A)
90° at both ends of the top drive rollers
3 Slide top drive roller (B) to the right hand side and
disengage the drive pin from the drive stub (C) on the
left hand side
4 Lift left hand end of rollers, and lift clear of right hand
end bearing (D)
Take care not to damage roller gears or the rollers
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Page 80 April 2001

November 2000
How to remove the bottom Follow the procedure below to remove the bottom rollers
rollers
Step Action
1 Lift the right hand end of the roller (E) out of the right
hand side bearing (F).
2 Slide the roller (E) out of the left hand side bearing
(G).
Take care not to damage the roller gears or the
rollers
3 Pull the roller towards the right hand side to lift the
left hand side of the roller out of its bearing
4 Lift the roller out of the tank
7.3 Re-installing rollers
Introduction A total number of 17 rollers and various other components must be

re-installed to their correct places after you have cleaned the
AUTOLITH TP and it can enter an active state again.
For safe and trouble free operation, it is essential that the rollers
and the other components should be placed into their bearings
correctly.
Refer to ‘Prescriptions and Precautions Concerning Rollers’ on

page 21 for more information on rollers positions
Any bottom nip roller must be replaced in the AUTOLITH TP with
its spur gear located on the left hand side of the Processor.
Each roller is identified with a numbered disc on the right hand end
of the roller.
Please refer to the yellow information chart that indicates the
correct position of the rollers.
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AUTOLITH TP
How to install bottom rollers To install bottom rollers, proceed as follows:

Step Action
1 Place the shaft of the bottom roller (F) into its
bearing at the left hand side of the Processor.
2 Lower the roller to the level of its bearing (G) at the
right hand Processor side.
3 Place the shaft of the bottom roller into its bearing
(G) at the right hand side of the Processor.
How to install top rollers To install top rollers, proceed as follows:

Step Action
1 Place the shaft of the top roller (B) into the plastic
bearing at the right hand side of the Processor.
2 Push the roller into the bearing and lower the left
hand end to align the roller with coupler stud (D) on
the left hand side.
3 Engage the roller drive pin into the coupler stud.
4 Push the roller towards the left hand side as far as
possible.
Make sure that any gears on the top roller engage
properly with the gears on the bottom rollers.
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Page 82 April 2001

November 2000
7.4 Assembling the developer section components
Introduction The Developer Section consists of the following components:

• Developer Scrub Roller
• Developer Guide Plate Assembly
• Top and Bottom Nip Rollers (2 of each)
• Developer Spray Bar Assembly
• Front Diverter Roller
• Anti oxidation cover
How to assemble the To assemble the Developer Section components, proceed as
Developer Section follows:
components
Step Action
1 Install the bottom nip roller into its bearings.
Refer to ‘How to Install Bottom Rollers’ on page 80
Make sure the roller number indicated on the right

hand roller side corresponds with the number on the
yellow indicator chart.
nd
2 Install the 2 bottom nip roller into its bearing.
3 Lower the Developer Plate Guide Assembly into
position.
Do not attempt to fit the Developer Plate Guide
Assembly incorrectly. The Assembly is handed, and
will only fit in one position.
4 Install the developer spray bar, location is on the left
hand side.
5 Enter the developer spray bar into its right hand side
connector, then lower the left hand end into its
location.
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AUTOLITH TP
April 20012000
November Page 83
Step Action
6 Install the developer scrub roller into the tank.
7 Place the scrub roller into the keyhole housing on
the right hand side of the Processor.
8 Move the roller to the left hand side, and locate the
end of the shaft into the drive stub of the scrub
gearbox assembly.
9 Secure the scrub roller with the clamp plate, tighten
the thumb screw.
Make sure the thumb screw is tight as this locates
the scrub roller correctly over the developer plate
guide assembly
10 To assemble the front diverter roller, proceed as

follows:
• Install the roller assembly into its bearing on
the left hand side of the Processor
• Align the roller with the divert slide bearing
right hand and slide the sleeve onto the roller
• Secure the sleeve with the thumb screw.
11 To install the oxidation cover, locate the cover over
the heads of the spring blocks on the scrub
gearbox assembly end plate.
Lower the right hand end carefully into the
Processor.
When the developer tank is full, the oxidation cover
will displace developer as it is lowered into position.
This is normal.
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AUTOLITH TP
Page 84 April 2000

November 2001
7.5 Assembling the Water Section Components
Introduction The Water Section consists of the following components:

• Scrub Roller – Scrub Water
• Upper Water Spraybars (2)
• Lower Water Spraybar
• Top and Bottom Nip Rollers (2 of each)
• Pressure Roller
• Plate Guide
How to assemble the Water To assemble the Water Section components, proceed as follows.
Section components
Each spraybar is identified with a numbered disc. Using the ‘yellow

information chart’, you can select the correct spraybar and its
location.
Step Action
1 Install the lower water spray bar
2 Identify the single row water spraybar, remove the
black hexagon gland nut, black seal, and white ring
from the gland and loosely place on the lower water
spraybar
3 Align the lower water spraybar with the lower gland
on the right hand side of the Water Section. Push
the lower water spraybar into the gland
4 Align the left hand end of the water spraybar with the
location hole in the left hand side of the Water
Section, push the water spraybar into the location
hole
5 Push the black seal and white ring into the gland,
and secure with the black hexagon gland nut, hand
tighten.
Make sure you do not overtighten the black hexagon
gland nut
6 Lower the Water Section plate guide into position

over the location pins at both sides of the water tank,
and over the lower water spraybar assembly
7 Install the upper water spraybars
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AUTOLITH TP
Step Action
8 Identify the correct spraybars to correspond with the
locations on the tank sides, remove the black
hexagon gland nuts, black seals, and white rings
from the glands and loosely place on the upper water
sprays
9 Align the upper water spraybars with the glands on
the right hand side of the Water Section. Push the
upper spraybars into the glands.
10 Align the left hand end of the water spraybars with
the location hole in the left hand side of the Water
Section, push the water spraybars into the location
holes.
11 Push the black seals and white ring into the glands,
and secure with the black hexagon gland nuts, hand
tighten.
Make sure you do not overtighten the black hexagon
gland nut, no tools are required.
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AUTOLITH TP
7.6 How to assemble the Guide Plate Wash
To assemble the Guide Plate To assemble the Guide Plate Wash

Wash
Step Action
1 Lower the Guide Plate Wash into position over the 2
support pillars and the lower water spraybar.
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AUTOLITH TP
How to assemble the To assemble the Pressure Roller:

Pressure Roller
Step Action
1 Lower the pressure roller (A) into its plastic bottom
bearings (B), the roller will fit either way round.
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Page 88 April 2001

November 2000
How to assemble Scrub To assemble Scrub Water Roller proceed as follows:

Water Roller
Step Action
1 Place the shaft of the Scrub Water Roller (C) into the
bearing block (D) at the right hand side of the
Processor.
2 Push the roller into the bearing block and lower the left
hand end to align the roller with the drive stub (E) on
the left hand side. The drive pin should align with the
cut-out in the drive stub.
3 Push the roller into the drive stub until the drive pin is
fully engaged.
How to install bottom rollers To install bottom rollers, proceed as follows:

Step Action
1
Refer to ‘How to install bottom rollers’ on page 81.
How to install top rollers To install top rollers, proceed as follows:

Step Action
1
Refer to ‘How to install top rollers’ on page 81.
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AUTOLITH TP
7.7 Assembling the Finisher Section Components
Introduction The Finishing Section consists of the following components:

• Meniscus Roller
• Top & Bottom Finisher Nip Rollers
• Finisher / Gum Pipe
How to install Finisher To install Finisher Bottom Rollers, proceed as follows:
Bottom Rollers
Step Action
1
Refer to ‘How to Install Bottom Rollers’ on page 81.
How to install Finisher Top To install Finisher Top Rollers, proceed as follows:
Rollers
Step Action
1
Refer to ‘How to Install Top Rollers’ on page 81.
How to install Meniscus To install Meniscus Roller, proceed as follows:

Roller
Step Action
1 The Meniscus Roller can be fitted either way round.
Position one end into the Meniscus Roller Carrier, and
lower the other end into the opposite Meniscus Roller
Carrier and locate fully.
2 The spring action of the Meniscus Roller Carriers will
ensure the Meniscus Roller is in contact with the Top
Finisher Roller.
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AUTOLITH TP
How to position the To position the Finisher / gum Pipe, proceed as follows:
Finisher/Gum Pipe
Step Action
1 Lower the Finisher / Gum Pipe until it is just clear of
the Finisher Top Roller.
2
For trouble free operation, the Finishing / Gum Pipe
must not make contact with the Finisher Top Roller.
Any subsequent damage to this roller will have a direct
effect on the cosmetic appearance of the finished
Thermal plate and its ability to be correctly baked.
abc
AUTOLITH TP
November
Edition The table below lists all pages in Assembly of Section Components
with their edition :

82 April 2001 91 April 2001
83 April 2001
84 April 2001
85 November 2000
86 November 2000
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AUTOLITH TP
8 Troubleshooting
Introduction This chapter provides you with information on what you must do if
problems occur.

Topic See

Messages on the Display Page 93
Status Messages Page 94
Operator messages Page 98
Error Messages Page 106
Fatal Errors Page 108
Clearing Jammed Plates Page 108
Power Problems Page 109
Start-Up Problems Page 109
Other Problems Page 109
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AUTOLITH TP
8.2 Messages on the display
There is a message on the In some cases, a message appears on the display. Depending on
display the kind of problem, the operator must:
• take action himself, or
• contact Agfa service
Types of messages There are four types of messages:
Type of message See
Status messages: See status messages on page
94
• these inform the operator of
the Processors' current state.
The operator is not required to
take action
Operator warning messages: See ‘Operator Warning
Messages’ on page 98
• these require the operator to
take action
Operator queries: See ‘Operator Queries’ on
page 101
• these require responses from
the operator
Error messages: See ‘Error Messages’ on page
106
take action
Fatal error messages: See ‘Fatal Errors’ on page 108
contact Agfa service
About multiple messages on Sometimes several error messages are on the display at the same
the display time. However, you will only see the most recent since the previous
lie underneath the most recent one. Proceed as follows to see the
underlying messages:-
By pressing the ý key while a message is displayed will cause

any previous message to appear. The display will revert to the
original (latest) message after a time delay. If there were no
previous messages then the display will not change.
Message n
Press ý to view the previous
<< >> message
abc
AUTOLITH TP
8.3 Status messages
What are Status messages Status messages provide the operator with information about the
current operation that the Processor is performing.
Overview The table below explains the meaning of the status messages:
Status Message Explanation
INACTIVE The Processor is in an inoperable state during which the power consumption
is reduced to an absolute minimum.
The inactive state corresponds to the OFF mode. The state of the Processor
can be determined by visually examining the message in the display and/or
indicator above the ON/OFF key.
Some alarm messages may be displayed in this mode.
The Processor will enter a Wake Up Cycle at regular intervals. During this
Wake Up Cycle the developer recirculation pump will run. Also a small amount
of developer replenishment will be added to the developer tank at certain
intervals during the Wake Up Cycle. The amount of developer replenishment
will be set on the touch panel and displayed under the SET DEV REPLEN
screen,
POWER IS STILL APPLIED TO THE PROCESSOR WHEN IN THE
INACTIVE STATE. FOR SAFETY DURING MAINTENANCE, REFER TO
PAGE 4
The Processor enters the INACTIVE mode in one of the following cases:
• When the Processor is turned off by means of the “On/Off” key.
• When the Processor enters a pre-programmed inactive period by means
of the agenda function.
• If the Processor has recently had power applied by switching on the mains
supply switch. After displaying the Set-Up screen, the display will show
the Developer Changed? Screen. If NO or YES is selected then the
Processor will enter the INACTIVE mode.
Note: If YES is selected this will reset the plate counter, plate area total and
the days total. If after this no plates are processed and the power is then
switched Off and On again, the display will go from SET UP to INACTIVE
without asking if the developer has been changed. This is because as the
Processor has not seen any plates, it assumes that the developer has not
been changed. You will need to press the ON/OFF key once to move onto the
WAIT mode.
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AUTOLITH TP
April 20012000
November Page 95
Status Messages (continued)

WAIT The Processor is not ready to operate and cannot accept a printing plate.
This may indicate an alarm condition and an alarm message on the display.
The developer temperature is now controlled. Heating or cooling will take place, and
the developer circulation pump will run until the required temperature is achieved. In
this state the transport rollers are running at low speed continually. The Processor
will also go into WAKE UP cycles, but chemistry levels are monitored, the scrub
motor and the finisher pump will also run.
READY The Processor is now ready to accept a printing plate.
During the READY mode the chemistry levels and the temperature of the developer
are constantly monitored.
The plate Processor will enter a wake up cycle at regular intervals, during this
wakeup cycle the drive rollers will rotate and the finisher and developer recirculation
pumps will run. A small amount of developer replenishment will be added to the
developer tank at regular intervals during wake up cycle. The amount of developer
replenishment will be set on the touch panel and displayed under the REPLEN
RATE screen.
The Processor will enter the READY mode in one of the following cases:
• The Processor has been turned On with the ON/OFF key from the INACTIVE
mode, and the chemistry levels and developer temperature are correct.
• The Processor has been turned On by the pre programmed AGENDA function,
and the chemistry levels and developer temperature are correct.
• The Processor is ready and is not processing a plate.
• The Processor is not in an alarm condition.
PROCESSING When a plate enters the Processor, and providing the Processor is in the READY
mode, the Processor will start to process the plate.
The drive rollers start rotating and the developer circulation pump runs. When the
plate is approximately halfway through the developer section, the finisher pump
starts and then just before the plate enters the wash section, the spray bars are
switched On. The plate drier is then turned on, as the plate clears each section the
functions are switched off. Finally, the drive rollers will stop rotating.
The temperatures will be maintained and level conditions will be monitored. Should
an alarm condition occur as a result of an incorrect temperature or levels the
Processor will not enter the WAIT mode until after the Processor has finished
processing the plate.
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AUTOLITH TP

PROCESSING & When the plate has cleared the entry nip rollers of the Processor, the display
READY message will change from “PROCESSING” to “PROCESSING & READY”, this
is the signal that you may safely enter a second plate for processing.
REWASHING The Autolith TP Processor has the ability to rewash and apply finisher to a
plate that has been corrected. A plate has been inserted in the re-entry
section.
A PLATE MUST NOT ENTER THE RE-ENTRY SECTION WHILE A PLATE
IS BEING PROCESSED THROUGH THE NORMAL DEVELOPING CYCLE.
WAIT UNTIL THE DEVELOPED PLATE HAS COMPLETELY EXITED THE
PROCESSOR BEFORE ENTERING A PLATE INTO THE RE-ENTRY
SECTION.
During a plate REWASHING cycle the calculation for the total plate area will
not be incremented, therefore the developer replenishment rate will not be
affected.
MAINTENANCE This message is displayed to inform the operator that the Processor has been
DEV put into maintenance mode. In this mode the operator can
• Drain the Developer solution
• Auto fill the developer section
WASH put into maintenance mode. In this mode the operator can
• Drain the Wash section water
• Auto fill the wash section
FIN put into maintenance mode. In this mode the operator can
• Drain the Finisher section
• Clean (circulate) cleaning fluid through the finisher section
FLUSHING This message is to inform the operator that a plate is being flushed through
the Processor by the Operator selecting Manual Operation on the control
panel.
abc
AUTOLITH TP

JAMMED This message is displayed when the Processor has entered the jammed
mode. This occurs when the Processor has detected a plate jam – a plate has
entered the Processor but has not left the Processor within the allowed time
period for processing. See “plate jammed” error message later in this chapter.
EMERGENCY This message is displayed to inform the operator that the Machine has
STOP performed an Emergency Stop.
• The Processor will enter the EMERGENCY STOP mode if either of the
emergency stop keys are operated while processing a plate during a
normal developing or a rewashing cycle.
• To clear the plate from the Processor (that may have jammed) the
operator must:
1. Reset the Emergency Stop switch
2. When the display shows “Open the lids” the operator must open the lid
and inspect the condition of the plate inside the Processor . If the plate
has jammed or is likely to jam when the Processor starts the transport,
then the operator MUST remove the plate from the Processor.
3. If the plate appears undamaged and not likely to jam proceed to 4
below.
4. Close the lids, the display will show “Flush plates now Yes/No” the
operator should select “Yes” to eject an undamaged plate and select
“No” if the damaged plate has been removed from the Processor.
• When the flushing cycle has finished or “No” chosen above then the
Processor will either enter the WAIT or READY state dependent on
temperatures and levels.
abc
AUTOLITH TP
8.4 Operator warning messages
What are operator warning Operator warning messages appear on display to inform the
messages operator about an event detected. No service intervention is
required.
Overview The table below shows all operator warning messages and the
operator actions required:
Operator Warning Cause Operator Action required

Message
Plate not allowed The Processor has detected The operator should take the following action:
a plate on the input sensor
while:
• The Processor has the • Remove the service Key (service engineer
service key in place only)
• A plate is already being • Wait until the rewash plate has been
rewashed expelled from the rear of the Processor
• The Processor is in the • Place the Processor into the READY mode
INACTIVE mode by pressing the On button of the control
panel
• The Processor is in the • Wait until the Processor becomes READY
WAIT mode
Re-entry not The Processor has detected The operator should take the following action:
allowed a plate on the input sensor
while
• The Processor has the • Remove the service Key (service engineer
service key in place only)
• A plate is already being • Wait until the rewash plate has been
rewashed expelled from the rear of the Processor
• A plate is being • Wait until the processed plate has been
processed expelled from the rear of the Processor
• The Processor is in the • Place the Processor into the READY mode
INACTIVE mode by pressing the on button of the control
panel
• The Processor is in the
WAIT mode • Wait until the Processor becomes READY
abc
AUTOLITH TP
Operator Message Cause Operator Action required

Cleaning tank The Processor is Wait for the cleaning cycle to complete. The Processor
cleaning the finisher will inform the operator by displaying the “Cleaning
tank complete” query.
Wash tank filling The Processor is Wait for the wash tank filling cycle to complete. The
waiting for the wash Processor will inform the operator when the cycle is
tank to fill complete by displaying its next message
Draining Wash The Processor is Wait for the wash tank to empty. The Processor will
waiting for the wash inform the operator when the cycle is complete by
tank to empty displaying the query ”Autofill Wash now?”
Dev tank filling The Processor is Wait for the Developer tank filling cycle to complete. The
waiting for the Processor will inform the operator when the cycle is
Developer tank to fill complete by displaying its next message
Draining Developer The Processor is Wait for the wash tank to empty. The Processor will
waiting for the inform the operator when the cycle is complete by
developer tank to displaying the query ”Autofill Dev now?”
empty
Transport running The Processor is doing Wait for the plate flushing cycle to complete. The
a flush cycle Processor will inform the operator when the cycle is
complete by displaying its next message
Plate jam - lift lid The Processor has The operator should take the following action:
detected a plate which
Open lid of the Processor and remove the plate.
was in the Processor
when the Processor Note that this message does not necessarily mean that a
was switched off plate is jammed; it only indicates that a plate was not
completely out of the Processor when the Processor was
switched off.
Developer exhausted The Processor has The operator can chose one of two actions:
detected that the life
developer solution has • The operator can stop the Processor and change the
developer either manually or by selecting the Drain
expired
Dev Tank option in the maintenance menu.
• The operator can clear this message, if it occurs
during a batch of plates, by pressing the continue
2
key. The message will re-occur after 5 m of plate
has been processed
The operator must change the developer at the earliest
time after the Developer Exhausted message appears.
Although the Processor will continue to process plates,
the quality of the plate image can not be Assured once
this message has been displayed
abc
AUTOLITH TP
Operator Message Cause Operator Action required

Wash water The Processor has The operator can choose one of two actions:
exhausted detected that the life
wash water has expired • The operator can stop the Processor and change
the wash water either manually or by selecting the
Drain Wash Tank option in the maintenance menu.
• The operator can clear this message if it occurs
during a batch of plates by pressing the continue
2
key. The message will re-occur after 5 m of plate
has been processed
The operator must change the wash water at the
earliest time after the Wash Water Exhausted
message appears. Although the Processor will continue
to process plates, the quality of the plate image can not
be assured once this message has been displayed
Open lid The Processor has The operator must lift the lids of the Processor to see if
detected that a plate there is a plate inside.
may be in the machine
If a plate is found and it is damaged or likely to be
since the last time the
damaged when the transport starts moving then it
power was switched off
MUST BE REMOVED.
If the plate appears to be undamaged and will pass
safely out of the Processor when the transport starts,
then the operator may close the lids.
The Processor will display the query “Flush Plates
Yes/No"
See query detail later in section
Safety Circuit opened The Processor has Check that the Processor lids are all fully closed
detected that the rear lid
Check that both the Emergency stop switches are
has been lifted
released.
The Processor will then be ready to use
abc
AUTOLITH TP
8.5 Operator Queries
What are Operator Queries Operator queries present the operator with choices to
guide the control system through the current task that the
Processor is performing.
Overview The table below explains cause and the actions the
operator can take in response to the operator queries that
appear on the display panel.
Query Cause Operator Action Required
Changed Developer ? The Processor power The operator must answer Yes or No to this
has been switched off query so that the Processor can keep an account
Yes No
of the developer solution lifetime.
OR
• When the operator answers NO then the
the MAINTENANCE
Processor will carry on incrementing the days
DEV function has been
used record and the accumulated plate area
used to change the 2
in m record for subsequent plates. This will
developer while the
be added total area held on record since the
power is applied to the
last time the power was removed from the
Processor.
Processor.
• When the operator answers YES then the
accumulated plate area and days used record
will be set to zero and a plate count will
commence.
Changed Wash Water? The Processor power The operator must answer Yes or No to this query
has been switched off so that the Processor can keep an account of the
Yes No
wash water lifetime.
OR
• When the operator answers NO then the
The MAINTENANCE
Processor will carry on incrementing the days
wash function has
used record and the accumulated plate area
been used to change
in m² record for subsequent plates. This will
the wash water while
be added total area held on record since the
the power is applied to
last time the power was removed from the
the Processor
Processor.
• When the operator answers YES then the
accumulated plate area and days used record
will be set to zero and a plate count will
commence.
abc
AUTOLITH TP
Operator Queries (continued)

Replen pump Fault The Processor has The operator should contact Agfa service or fit a
Continue detected that the replacement pump. The operator can select
2
Replenishment pump is Continue to process a further concession of 5m
not functioning correctly. of plates. The query will appear every time the
2
5m concession expires.
Absolutely sure The Processor requires The operator can select one of two options:
further operator
Yes No When the operator selects Yes option
confirmation.
The counters will be reset and the Processor will
This query appears when
assume that dev bath is full with new developer
the Processor is about to
reset the current plate When the operator selects the No option, the
2
counter, the m counter Processor will not reset the counters and will
and the Developer life assume that the developer solution in the dev
(days). bath is unchanged. Further plates processed from
this point on will be accumulated to the existing
bath life record
Open Dev Drain The Processor displays The operator can select one of two options:
this query when the
Yes No When the operator selects the Yes option, the
operator has selected the
operator informs the Processor that the Developer
MAINTENANCE DEV
tank drains are to be opened. The operator must
mode.
now open the developer drains and the Processor
will continue with the Dev maintenance routine.
When the operator selects the No option the
Processor will return to the maintenance menu
and abandon the MAINTENANCE DEV mode.
Close Dev Drain? The Processor has The operator MUST press the Yes key to confirm
detected that the that the Developer tanks are completely empty
Yes
Developer tank is now and that the operator has closed the Developer
empty. It is waiting for the tank drains ready for auto filling.
operator to confirm that
the dev drains are closed
Autofill Dev now? The Processor is ready to The operator MUST press the Yes key to allow
auto fill the developer the Developer tanks to fill.
Yes Tanks now
abc
AUTOLITH TP

New Dev Bottle The Processor The operator must select Yes to confirm that the
requires confirmation Correct Developer solution is in place ready to fill
Yes
that the operator has the Developer tank.
placed the correct
Developer bottle
ready to autofill.
Place Empty Bottle This query is The operator MUST place an empty waste / top
displayed when the up bottle and select Yes .
Yes
developer tank auto
filling routine has
finished.
Open Wash Drain The Processor The operator can select one of two options:
displays this query
Yes No When the operator selects the Yes option, the
when the operator
operator informs the Processor that the Was tank
has selected the
drain is to be opened. The operator must now
MAINTENANCE
open the Wash Drains and the Processor will
WASH mode.
continue with the Wash maintenance routine.
When the operator selects the No option the
Processor will return to the maintenance menu
and abandon the MAINTENANCE WASH mode.
Close Wash Drain? The Processor has The operator MUST press the Yes key to confirm
detected that the that the Wash tank is completely empty and that
Yes
Wash tank is now the operator has closed the Water tank drain
empty. It is waiting ready for auto filling.
for the operator to
confirm that the dev
drains are closed
Autofill Wash now? The Processor is The operator MUST press the Yes key to allow
ready to auto fill the the Wash tank to fill.
Yes
Wash Tank now
abc
AUTOLITH TP

Cleaner in place The Processor is The operator can select one of two options:
ready to start the
Yes No When the operator selects Yes option then the
Finisher Cleaning
finisher bottle must be replaced with a bottle of
routine. This query is
suitable cleaner solution. The Processor will then
displayed when the
proceed to circulate the cleaning solution for 5
Processor is in the
minutes. The display will show “ cleaning tank”
MAINTENANCE FIN
mode When the operator selects the No option then the
Processor with abandon the MAINTENANCE FIN
mode
Cleaning complete The Processor has The operator Must confirm that the cleaning
requires the operator routine is finished
Yes
to confirm that the
Finisher Cleaning
has finished.
Finisher in place? This query is The operator MUST replace the bottle of cleaning
displayed when the solution with a bottle of finisher solution and select
Yes
cleaning is complete Yes .The Processor will then terminate the
and a new bottle is MAINTENANCE FIN mode.
in place
Flush plates This query is The operator can chose one of two options:
displayed after the
Yes No When the operator selects the yes option, the
Open Lid message.
Processor will activate the transport system at low
speed for 5 minutes.
When the operator selects the No option , the
Processor will proceed to the WAIT or READY
mode depending on the state of developer
temperature and levels etc.
Dev level low The Processor has The operator MUST first check that the waste /top
detected that the up bottle contains suitable developer to top up
Fill
Developer tank level the Developer tank. The operator MUST then
is low and requires a press the Fill key.
to up with used
developer
abc
AUTOLITH TP
Wash level low The Processor has The operator MUST press the Fill key to remove
detected that the this warning
Fill
Wash tank level is
low and requires a
top up
Service plug in OK The Processor has The Service Engineer MUST press the OK key
detected that the
service plug is in
position and requires
confirmation by the
service engineer to
proceed in this mode
abc
AUTOLITH TP
Page 106 April 2000

November 2001
8.6 Error Messages
What are Error messages Error messages indicate a system error requiring service
intervention.
Overview The table below gives an overview of the possible error messages:
Error Message Cause Action
Dev temp.high The Processor The operator should perform the following
has detected that action:
the Developer
Solution • check the water level in the Chiller Unit
Temperature is tank, top up if necessary with clean water
too high. • check the Chiller Unit condenser fans are
not blocked with dust – clean if necessary.
If these checks does not cure the problem
there may be a fault within the Chiller Unit and
a Service Technician should be called
Dev temp.low The Processor The operator should wait for the Processor to
has detected that reach the correct temperature.
the Developer
Solution
Temperature is
too low
Dev repl.tank empty The Processor The operator should perform the following
the Developer
Solution • replace the fill bottle with one which
Replenisher/fill contains suitable developer solution
bottle is empty
Replace waste/top-up The Processor The operator should replace the waste /top-up
has detected that bottle fill with one which is empty or contains
the waste /top-up less waste
bottle is full
Fill bottle empty The Processor The operator should perform the following
has detected that action;-
the developer fill
bottle is empty. • Replace the fill bottle with a new bottle
containing suitable Developer solution
abc
AUTOLITH TP
Developer low - fill The Processor The operator should perform the following
has detected the action:
developer tank
level is low • Top up/fill the developer tank.
Finish tank low The Processor The operator should perform the following
the finisher bottle
level is low • Replace the finisher bottle with a new one.
Unknown Format The Processor The operator should perform the following
has detected an action:
unrecognised
plate length • Check that the length entries in the format
dimension table are correct
abc
AUTOLITH TP

April 2001
8.7 Fatal Errors
When do fatal messages Fatal errors appear in a pop-up window on the display and indicate
occur a serious hardware failure. The Processor enters ‘Fatal Error’ mode
and service intervention is essential.
All motors are switched off, but the waste pump may still be
activated when necessary.
Overview The table below gives an overview of the possible fatal errors:
Fatal Cause Operator Action Required

Error
M1:1 Bad contact to motor (No Current) Contact Agfa service
M1:2 Overload (excessive current to motor) Contact Agfa service
M1:3 Stopped (Motor is not turning) Contact Agfa service
M1:4 No power Contact Agfa service
8.8 Clearing Jammed Plates
Plate jam If a plate is jammed, check the following:
Cause Solution
A plate has not reached Open lids, identify position of plate.
the exit sensor within Release the nip rollers, and carefully
the specified time remove the plate.
Reset the nip rollers, close the lids,
enter the Flushing mode, flush
Processor.
When attempting to remove damaged
plates you should wear protective
gloves. The plate could have
developer/water/gum on its surface/back
side. Take necessary precautions when
handling chemistry.
abc
AUTOLITH TP
April 20012000
November Page 109
8.9 Power problems
NO POWER SUPPLY If there is no power supply, check the following:

Cause Solution
The main switch is not Turn on the main switch.
turned on.
A circuit breaker has Switch any tripped circuit breakers
tripped. back on.
Cables have not been Check cables for proper connection
connected properly. or damage.
If the power cable is damaged,
please contact your local electrician.
There is no mains supply Check mains supply for correct

voltage.
8.10 Start-Up Problems
THE PROCESSOR IS NOT IN The table below tells you why the Processor may not be in ‘Ready’
‘READY’ MODE mode, and what you can do about it:
Cause Action
The covers are open. • Close the covers.
• Press the button to activate
the Processor.
The Processor is in ‘Wait’ Wait until the Processor enters
mode. ‘Ready’ mode.
8.11 Other Problems
NO WATER SUPPLY If there is no water available, check the following:

Cause Solution
The manual water valve is not Open the valve.
opened.
abc
AUTOLITH TP
Page 110 November

April 2001 2000
Edition The table below lists all pages in Troubleshooting with their edition :

95 April 2001 106 April 2001
100 November 2000
101 November 2000
102 November 2000
abc

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AUTOLITH TP

November 2000 Page 1

1 Major safety and handling instructions ................................................................ 3

1.1 What is in this chapter ..................................................................................... 3

3 Prescriptions and precautions ............................................................................ 17

3.1 What is in this chapter ................................................................................... 17

5 Operating the AUTOLITH TP................................................................................ 26

Page 2 November 2000

7 Assembly of section components ...................................................................... 78

7.1 What is in this chapter ................................................................................... 78

1 Major safety and handling instructions

1.1 What is in this chapter

Introduction This chapter lists general safety prescriptions to be taken into

Take a few minutes to read this chapter carefully. Thus, personal

Please refer to Maintenance on page 56 and Troubleshooting on

Page 4 April 20012000

1.2 General safety measures

Read the following safety measures carefully before you start

Unless explicitly stated in this Instruction Manual, never open or

Only Agfa service technicians are allowed to open areas marked

1.3 Safety instructions concerning plate input

Use of safety gloves is recommended with all printing plates. Also

1.4 Safety instructions concerning plate output

Final drive rollers

Keep fingers away from Final Drive Assembly.

Page 6 April 2001

1.5 Performing an emergency stop

SAFETY CIRCUIT OPENED

2 To reset, rotate the red push knob clockwise to unlock.

After the Processor has reached all its operational

Please refer to ‘De- Activating the Processor' on page

November 2000 Page 7

An emergency stop by Follow the procedure below to perform an emergency stop by

SAFETY CIRCUIT OPENED

2 To reset, close lid.

Page 8 November 2000

1.6 Handling instructions concerning chemicals

Page Edition Page Edition

Page 10 April 2001

2.1 What is in this chapter

Introduction This chapter provides you with general information on the

Take a few minutes to read this chapter carefully. Thus, personal

Please refer to Section 1 - Technical Specifications

November 2000 Page 11

2.2 About Agfa AUTOLITH TP

AUTOLITH TP The Agfa AUTOLITH TP is a high-speed Processor for digital

Page 12 November 2000

2.3 Parts of the AUTOLITH TP

November 2000 Page 13

2.4 Processing printing plates using the AUTOLITH TP

Schematic representation The basic functioning of the AUTOLITH TP is represented in the

Page 14 April 2000

Stage Corresponding Section Description

1 In-feed Section The plate enters the Processor, either automatically

Stage Corresponding Section Description

Wash Section – Mains wash

4 Gum/Finisher Section A pump draws finisher from a bottle situated under

Page 16 April 2001

7 Plate Re-entry The re-entry facility allows plates to be re-washed