LITHOSTAR LP82 2 Instruction Manual AGFAOoLITHOSTAR LP82 Instruction Manual 2 Jan. Summary 4. Introduction 2. Consumables 3. Operation of the processor 34. Prescriptions and precautions 3.2. Configuration 3.3. Basic operation 3.4, User interface 35. Preparing the processor for operation 3.6. Operating the processor 37. Treatment of the AGFA LITHOSTAR printing plates after processing 3.8. Replacement of the containers 3.9. Chemicals and water consumption 4. Manipulation of the consumables 4a. Manipulation of the AGFA LITHOSTAR chemicals 42, Manipulation of the unexposed AGFA LITHOSTAR printing plates 5. Programming the processor 5.1. Programming the printing plate sizes 5.2, Programming the time 5.3. Programming the active and inactive periods 5.4. ‘The system control feature 6 Maintenance 6.1. General safety measures 6.2 Software-maintenance function 6.3. Cleaning the processor 7. Waste treatment mM AGFA's environmental guidelines 72. Collecting the chemical waste 72: Treatment of the different types of waste ‘7 10 13 17 19 23 24 26 28 28 28 29 29 30 31 34 at at at 45 53 53 53 55 AGFALITHOSTAR LP82 2 Instruction Manual 8. 84 8.2. 8.3. 8.4. 8.5. 8.6. 87. Nov. ‘98, ‘Trouble-shooting ‘A warning is indicated on the display ‘An overtemperature is detected in one of the trays of the processor Other messages Power problems Problems when inserting a printing plate Other problems Trouble-shooting matrix 56 56 65 66 68 68 69 69 AGFA &LITHOSTAR LP82 Instruction Manual 2 4. Introduction AGFA LITHOSTAR is a high-speed platemaking system for both analogue and digital plate exposure. It combines the ease of handling and the stability of aluminium printing plates with the speed and quality of the silver halide technology. LITHOSTAR plates are based on Agfa's DTR (Diffusion Transfer Reversal) process, used in high-quality products for many years. ‘The AGFA LP82 is a plate processor elaborated for AGFA LITHOSTAR offset printing plates. It has been designed 1o obtain the highest quality, productivity, reliability and facility of use. If properly used and maintained, the processor will prove to be an efficient plate production tool for many years. Jan. '97 AGFA &LITHOSTAR LP82 2 Instruction Manual Nov. ‘98 Consumables + Lithostar aluminium printing plates : ° LAP-B © LAP-O Agia offers a wide variety of printing plate sizes please ask for more information. Thickness 0.15 / 0.20 / 0.30 mm (6/8/12 MIL) Sizes on demand 0.35 & 0.40 mm on request * Printing plate correctors + * Negative corrections (wiping the image) : = Corrector pen : FNBYV = Corrector fluid (100 cc): FX8BU * Positive corrections (adding image) : "+" corrector pen (3 pieces): FRETK © Developer + L5000b Capacity of a developer container : 20 | * Finisher: —L5300b Capacity of a finisher container : 20 | * Waste container labels: 3ZNWW. (60 pieces) LITHOSTAR its oes wast sale san p> 7 UtesaVeateungscistide- aac Ling pH et>7 ‘ites care Lita son akainomsp spi 87 Uitostarvemerngsae-Akaische opassg p »7 Fen celpeowso tes Soin aia p> 7 Fes tatareo tes -Sosne aia congt> 7 For more information about the waste container labels, refer to ‘7.2. Collecting the chemical waste’ * Plate cleaner: G642b AGFALITHOSTAR LP82 Instruction Manual 2 3. Operation of the processor 3.1. Prescriptions and precautions 3.1.1. Prescriptions ‘The following prescriptions should be read attentively before using the processor * Follow the instructions given by Agfa When working with the processor AGFA LITHOSTAR LP82, take into account all the instuctions and safely ‘measures given in this manual and other Agfa publications in order to avoid problems with quality, heath, safety and/or environment. Do not forget to read attentively the directives given in “6.1. General safety measures’. * Only use AGFA LITHOSTAR consumables Jn order to ensure a permanent high quality when processing printing plates, only AGFA LITHOSTAR chemicals and products should be used. * Handle the chemicals with care Consult the appropriate M.S.D.S. (Meterial Safety Data Sheets) before handling chemicals and always follow the safely instructions given on the labels of the chemicals. * Collect the waste for treatment The addresses of authorised waste collecting and treatment companies can be obtained from the local Agfa representative. © If the processor has been provided with the optional on-line bridge AGFA LITHOSTAR OLB&2 and/or with the optional stacker AGFA LITHOSTAR LS82, read attentively the corresponding prescriptions, precautions and safety information In case of the User Manual, refer to chapter 5 ‘Notes’, In case of the Service Manual, refer to chapter 9 “Adgitional Information’. AGFALITHOSTAR LP82 2 Instruction Manual 2.6.00 Nov. '98 3.1.2. Precautions This paragraph gives an overview of the different points which should be taken Into account when using the processor or when carrying out an Intervention on it * Before the processor enters an active state, ensure that : - the lower (L) and upper (U) rollers are placed at their correct location (ensure that the numbers on their right side correspond to the ones on the right side of the frame of the processor) : ta & SSoTOOT Sen8- So8- o-8- —Q ® ©:© :@: @ 4] A AMARA A +L ORRRRAR A = all the lower rollers have been installed Poter has ben dled correctly and pushed as far as possible towards the left side. If a lower roller has been provided with a gear, ensure that:this gear engages correctly when installing the corresponding upper roller. ~ all the upper rollers have been installed correctly and pushed as far as possible towards the left side. Also ensure that the ring at the right side of the rollers fits correctly into its holder (refer to the diagram) and that their gear(s) engage(s) correctly. AGFA &LITHOSTAR LP82 Instruction Manual. 2 = the two white bushings (one for the rollers system and one for the rear roller) at the right side of the diffusion section fit correctly into their holder. = the three white bushings at the right side of the wash section conveyor rollers fit correctly into their holder. = the gutter system and the separate gutters of the rinsing and finishing sections fit correctly into position. = the two-piece suction unit is correctly: installed on the bottom of the wash tray. = the two partition plates of the wash section fit correctly into position. = the printing plate guide at the rear side of the diflusion section fits correctly into position = the printing plate guide on the bottom of the developer tray has not been positioned upside down and that it fits correctly into the grooves of the tray. = the anti-oxidation cover of the developer section has been installed correctly. Before starting the operation of the processor, especially when one or more trays have been drained, ensure that the four manual drain valves behind the right cover as well as the four manual drain valves underneath the processor are closed. After having carried out a maintenance or a servicing operation, ensure that : = no tools or foreign matters remain in the processor. Jan. ‘97 2.7.00 = the spray nozzles assembly of the wash section has been re-installed. Do not forget to check if the seal has been provided when re-installing the spray nozzles assembly. Before turning off the main switch, ensure that the processor Is in the OFF-mode. The rollers should always be in the open condition when turning off the power supply towards the processor. Before closing the front upper cover, ensure that the rewash flap is closed correctly Never (re-Jinsert damaged printing plates into the processor. Never remove the inside protection plate which can be found behind the right cover and the four manual drain valves : this may only be done by an Agfa service technician. Never interchange the developer, finisher and waste containers. It the containers have been interchanged accitlentally, the corresponding circulation circuits should be cleaned by using the circulation feature of the software-maintenance function (refer to °6.3.3, Circulating water in order to clean the circulation circuits). In order to avoid mixing of the different solutions inside the processor, never open all the manual drain valves together but drain the trays separately. If the trays are not filled directly after they have been emptied, it is recommended to clean them, AGFALITHOSTAR LP82 2 Instruction Manual 2.8.00 Jan. ‘97 + If a ‘waste container full’ condition is detected during the operation of the processor (the waste container is then filled by means of the overflows of the different trays), the operation of the processor will be halted after 1 m2 has been processed in order to avoid an overtiow of the waste container. If a ‘waste container full" condition is detected when emptying the trays (this is done by using the manual drain valves), THE VALVES SHOULD BE CLOSED MANUALLY. It the manuel drain valves are not closed in time, the waste container will overfiow. Therefore, before emptying a tray, always ensure that there is enough room in the waste container and avoid leaving the processor alone when emptying the trays. ‘* The diffusion tray has not been provided with @ manual drain valve. Winen using the diffusion tray to clean the ‘components of the processor, take into account that the cleaning water will directly be drained towards the waste container : ensure thet there is ‘enough room in the waste container to accept the cleaning water (also refer to the previous remark). * When the rollers have been taken out of the processor, be careful not to damage them : - Never place the rollers so that their rubber surface rests onto the edge of a sink, a tray, a - When placing the rollers upon each other, ensure that there is no contact between the gears and the rubber surfaces. Never lubricate a roller cams shaft or the main Grive shaft : if one or more of the solutions of the processor have been soiled with oil or Grease, the corresponding trays and circulation circuits should be cleaned thoroughly (refer to § 6.3.3.). The feed-in rollers should never come into contact with developer or any other liquid in order to avoid that the printing plate sticks ‘onto the rollers instead of being conveyed towards the developing section. For this reason, and if @ printing plate jam has ‘occurred in the developing section, open the rollers and then remove the plate by pushing or pulling it towards the rear side. NEVER pull back a printing plate once it has been taken up by the feed-in rollers, {i the processor will not be used for @ long time (holidays, ...), "Holiday filling’ (refer to § 6.3.4.) should be carried out in order to avoid smell problems. When replacing a fuse, ensure that the new fuse is of the same type and has the same rate as the old one : ‘CAUTION For continued protection ‘against fre, replace only with ‘Same type and rating oF fuse, Ensure that the processor is no longer under tension before touching areas marked by the following symbol : AGFA @LITHOSTAR LP82 Instruction Manual 2 van. '97 2.9.00 3.2. Configuration 1 Emergency stop knob 7 Waste container 2 Control panet 8 Developer container 3 ‘Rewash start/stop" switch 9 Wash water drain valve 4 Rinsing solution drain valve 10 Developer drain valve 5 Finisher drain valve 11 Main switch 6 Finisher container AGFA}LITHOSTAR LP82 2 Instruction Manual 2:10.00 Jan. ‘97 3.3. Basic operation ‘The basic operation of the processor AGFA LITHOSTAR LP82 is illustrated in the following cross- sectional view : 1 Feed:in section 2 Developing section 3 Diffusion section 4 Rewash section 5 Wash section Water supply Developer container oe 6 Rinsing section 7 Finishing section 8 Drier section 9 Exit section © Waste container d Finisher container AGFA @LITHOSTAR LP82 Instruction Manual 2 3.3.1. Feed-in section ‘The feed-in section is used to insert a printing plate into the processor. ‘The presence of a plate on the feed-in table is detected by means of an optical sensor. 3.3.2. Developing section In the developing section, the (exposed) printing plate is developed. The plate is first submerged in the developer tray and the excess of developer on the plate is then pressed off by means of a pair of squeegee rollers. 3.3.3. Diffusion section The developed printing plate is conveyed on a rollers system in order to allow the diffusion of the silver. 3. Rewash section Can be used to re-insert a printing plate into the processor. ‘This can be necessary to : * clean the corrector off the printing plate if manual corrections have been made * clean off the gum-layer and re-hydrophobise printing plates which have been stored after a process operation Jan. ‘97 2.41.00 3.3.5, Wash section The printing plate is washed by means of tepid water under high pressure in order to remove the gelatine layer and the barrier layer. Before leaving the wash section, the excess of water is pressed off the plate by means of a pair of squeegee rollers. 3.3.6. Rinsing section ‘The washed printing plate is rinsed with finisher coming from the finishing section. The rinsing section avoids that the finishing section is excessively soiled by gelatine in order to ensure that the hydrophobising effect of the finisher lasts longer. Before leaving the rinsing section, the excess of rinsing solution is pressed off the plate by means of a pair of squeegee rollers. 3.3.7. Finishing section The finishing section ensures the hydrophobising of the silver image on the printing plate and applies a gum-layer to avoid oxidation of the printing plate. Before leaving the finishing section, the excess of finisher is pressed off the plate by means of a pair of squeegee rollers. AGFALITHOSTAR LP82 2 Instruction Manual 2.12.00 Jan. ‘97 3.3.8, Drier section Both sides of the printing plate are dried by means of hot air, The air stream is generated by means of a centrifugal ventilator. Two electrical heaters ensure that the air is heated. 3.3.9. Exit section ‘The processed printing plate is fed out of the processor. AGFA @LITHOSTAR LPs2 Instruction Manual 2 3.4, User interface Jan. '97 2.13.00 ‘As shown in the following diagram, the contro! panel of the processor AGFA LITHOSTAR LPE2 consists of a display and seven keys : If the display contrast is too low or if the display is unreadable, hold down the »-key and then depress the A-key several times. 1, alter more than 16 depressions of the A-key, the display is still unreadable, there might be a problem with the display. Ifthe display contrast is too high, use the »-key in ‘combination with the V -key. This procedure to change the display contrast can ‘only be used when the basic screen (the screen on Which “wenu" can be selected) is indicated, The key located at the right side of the display can be used to illuminate the display : the display then remains illuminated until the key is depressed again or until the processor is turned off. In most cases, the selection of an item on the display occurs by a b-cursor (which can be moved by using the A- and V-keys) and then depressing the OK-key. ‘The upper left comer of the display shows the following items : = The mode into which the processor is presently - The selected function and/or subfunction(s) of the menu ‘The upper right comer of the display shows the ‘cursor keys which can be used on the screen which Is presently indicated, AGFA &LITHOSTAR LP82 2 Instruction Manual 2.14.00 Nov. '98 3.4.1, Modes of the processor ‘The processor AGFA LITHOSTAR LP82 can be in. ‘one of the following four modes : © The READY-mode The processor is ready to accept a printing plate. During the READY-mode, the levels as well as the temperatures in the different trays are constantly checked and, if necessary, corrected. ‘The READY-mode is set in one of the following cases : = When the processor is warmied up and ready after it has been made active by using the ‘on/off"-key = When the processor is warmed up and ready after it has entered an pre- Programmed active period The WAIT-mode The processor is not ready to operate or cannot accept a printing plete. ‘The reason is always indicated by means of a message. The different possible messages are : “WAIT + Starting vp" “WAIT : Rewash open - Rewash busy" “WAIT 1 Processor ie stil busy" “WAIT + Roller cams are moving” "WAIT : Temp. developer too high* “WAIT : Temp. developer too low” “WAIT : Level developer too low” “WAIT : Replenishing developer" “WAIT : Temp. wash water too high" CWAIT : Temp. wash vater too low’ ‘WAIT : Level wash water too Low" ‘WAIT : Replenishing wash vater* ‘WAIT : Temp. rinse too high’ “WAIT : Temp. rinse too lov" “WAIT + Level rinse too low “WAIT : Tomp. finisher too high’ ‘WAIT : Temp. finisher too los" ‘WAIT : Level finisher too low’ “WAIT + Replenishing finisher" ‘waIT : Temp. drier section too nigh" ‘WAIT : Temp. drier section too low" ‘WAIT + Imager requests processing’ (") "WAIT : Plate coming from imager" (*) “WAIT : Starting up stacker" (**) (Can only be indicated if the processor is on-line with an imager (with or without the optional on- line bridge OLBB2). (") Can only be indicated it the optional stacker LS82 has been installed, For more information, refer to the appropriate operating instructions. AGFALITHOSTAR LP82 Instruction Manual 2 * The OFF-mode ‘The processor enters an inoperational state where the power consumption is reduced to an absolute minimum (only the electronics are in stand-by). When the processor enters the OFF-mode, the rollers are opened. In order to avoid damage (sticking together or deformation) of the rollers, they should always be open before turing off the main switch of the processor. Witis necessary to turn off the main switch, frst enter the OF F-mode, walt approx. § sec in order 10 allow the rollers 10 open and only then tum off the switch. If one tries to insert a printing plate by way of the feedin table during the OFF-mode, a beep signal is generated and the warning "Plate Anput not accepted’ is indicated in order to warm that the rollers are not closed. This is done because, in this case, the printing plate could reach the developer through the ‘opened feed:in rolers : pulling back the plate would then result in moistening the feed-in rollers and this should always be avoided. The processor enters the OFF-mode in one of the following cases : = When the processor is turned on by using-the main switch - When the processor is made inactive by using the “on/off'-key - When the processor enters a pre- programmed inactive period ~ When selecting "Maintenance" on the basic screen van. '97 2.15.00 * The NOT READY-mode ‘The processor cannot operate : an action is expected from the operator (for instance the replacement of a container). In most cases, the NOT READY-mode will be preceded by a warning on the display and the processor will only enter the NOT READY- mode if the action required by the warning is not carried out. In order to avoid that the processor enters the NOT READY-mode, do not wait too long before carrying out the action required by a warning. In case of a more serious problem, the NOT READY-mode will be entered immediately. ‘The warnings can be indicated in the four modes. For a list of the different possible warnings, refer to "8.1. A warning is indicated on the display’. AGFA &LITHOSTAR LP82 2 Instruction Manual 2.16.00 van, ‘97 3.4.2, Menu of the processor ‘The menu of the processor can be entered by depressing the OK-key when ‘Menu’ is selected. ‘enw’ is almost alvrays indicated when the menu of the processor has not been entered. W ten" should be selected, use the A- and ¥ keys. The following screen is then indicated : tine soe (ote maintenance ser Systen control Exit ‘The following seven functions are available Maintenance" Used to proceed to the maintenance screen (the OFF-mode will automatically be entered). For more information, refer to § 6.2. * ‘Single program" Allows re-programming the processor in case of days off, overwork or special use without having to change the week program. For more information, refer to § 5.3.2 * ‘Week progrant Used to program the active and inactive periods for each day of the week. For more information, refer to § 5.3.1. © Plate sizes’ Used to program the printing plate sizes, For more information, refer to § 6.1. * "Time set* Used to set the date and/or the time. For more information, refer to § 52. * "system control” Used to set the language, the display contrast, the beep duration, the measurement setup, the acceptance delay and the maintenance info screen. Also used to read the temperatures of the solutions in the trays as well as the production data. For more information, refer to § 6:4 "exit" Used to leave the menu and to return to the basic screen, Each screen representing a (sub)funetion of the menu offers the possibility (normally “sxxie* or “pone’) to return to the preceding screen. When returning to a preceding screen, the cursor will almost always be positioned before the ‘gxit" line of that screen. As a result, itis in most cases possible to go back to the basic ‘screen by successive depressions of the OK-key and without having to select “sxte" on each intermediate screen. Important ! ferently, the menu and its different functions and subfunctions can be entered in each mode of the processor: Depending on the mode, the corresponding ‘screens might be slightly different (especially the top line of the screen), In order to avoid too complex illustrations when explaining the (sub)functions of the different ‘modes, only the screens for the READY-mode will be represented. AGFA &LITHOSTAR LP82 Instruction Manual 2 3.5. Preparing the processor for operation 3 Turning the processor on and off The processor is turned on and off by using the main switch which can be found at the right side of the front legs assembly. It is recommended that the main switch remains on at all tines : management of the power consumotion can be regulated by programming active and inactive periods (refer to § 3.6.2.) which also allow an efficient use of the processor. Important ! Ifit is necessary to turn off the main switch, ensure that the rollers are open. For opening the rollers, first enter the OF F-made by depressing the ‘onvoff-key and then wait approx. § sec in order to allow the rollers to open. If the rollers remain closed, they may be damaged by the pressure (sticking together or deformation), When the main switch is turned on, the processor enters the OFF-mode : ‘The processor enters the OFF-mode, even if the ain switch is turned on during a pre-programmed active period. During the OFF-mode, messages can already be indicated on the display. If the maintenance info screen has been set, the ‘wenu" screen also shows the maintenance information (also refer to § 5.4). Jan. ‘97 2.47.00 3.5.2. Emergency stop The screen described in this paragraph also applies when the upper covers are not closed (correctly). ‘An emergency stop knob has been provided on the front right side of the feed-in table. Push on the knob if, for any reason, it is necessary to interrupt the operation of the processor. It an emergency stop is required on a processor installed as a two-room configuration (lightroom + darkroom), the emergency stop knob on the feecin table can be used in tho darkroom while the main switch can be used in the lightroom. If the ‘rewash not allowed" indicator incorporated in the ‘rewash startéstop" switch (located at the right side of the rewash feed-in table) lights up, the ‘operation of the processor can also be interrupted by pushing on the switch (refer to §.3.6.4). When the emergency stop knob is pushed, the knob locks itself and the following screen is, indicated Open the rollers Chose the roiiers [Soneinue > unlock oneraone: Using the A- and Y-keys, make the appropriate selection and then depress the OK-key. Do not forget to unlock the emergency stop knob by turning it slightly in the clockwise direction (direction of the arrows), AGFA >LITHOSTAR LP82 2 Instruction Manual 2.18.00 Jan. ‘97 3.5.3. Emptying all the trays of the processor This paragraph should only be carried out if the trays of the processor contain solutions which should be replaced. If the trays are already empty or ifthe solutions in the trays should not be replaced, directly proceed to "2.6. Operating the processor’, ‘* Ensure that the waste container is (almost) empty and that it is placed correctly. Important ! Take into account that the total contents of all the trays of the processor slightly exceeds 20 |. It will therefore be necessary to replace the waste container while emptying all the trays, especially when the container is not empty when starting the operation. Emptying the trays is carried out by manual drain valves : if the waste container is full, this will be detected and a warning will be indicated, BUT THE VALVES SHOULD BE CLOSED MANUALLY. Also note that, if the main switch is not tured on when emptying the trays, a warning will not even be indicated when the waste container is full, In order to avoid mixing of the different solutions inside the processor, never open all the manual drain valves together but open them one by one (wait until a specific section is empty and close the corresponding valve before opening a next one). * Open the right cover of the processor and, using the developer drain valve, drain the developer from the developer tray and the corresponding circulation circuit. 1 Finisher drain valve 2 Rinsing solution drain valve 3 Wash water drain valve 4 Developer drain valve ‘* When all the developer has been drained, close the developer drain valve and then repeat this operation successively in order to drain the wash water, the rinsing solution as well as the finisher. * Close the right cover of the processor. Important ! If the trays will not be filled directly after they have been emptied, it is recommended to clean them. If the processor will not be used for a long time (holidays, ...), a "Holiday £i11ing’ (refer to § 6.3.4.) should be carried out in order to avoid smell problems, AGFALITHOSTAR LP82 Instruction Manual 2 3.6. Operating the processor 3.6.1. Activation of the processor When the “on/off'-key is depressed or when reaching a pre-programmed active period, the processor enters the WA\T-mode in order to warm up and to carry out some preliminary checks : When the processor enters the WAIT-mode, a beep is generated, Ensure that the four manual drain valves behind the right cover as well as the four manual drain valves underneath the processor are closed. W the rays are empty or if they do not contain ‘enough solution, the processor will start to fil them automatically. ‘Normally, the processor needs 20 - 30 minutes to be ready. If the maintenance info screen has been set, the ‘Nenu" screen also shows the maintenance information (also refer to § 5.4). ‘When the processor is ready to accept the first printing plate, it changes to the READY-mode : At the same time, a beep is generated. Jan. ‘97 2.49.00 3.6.2. Active and inactive periods In order to allow power consumption control as well as efficient use, the processor can be in one of the two following states : = The active state Normal operation of the processor with checking and, if necessary, also correcting the levels as well as the temperatures in the different trays. When the processor becomes active, it wil first enter the WAIT-mode in order to warm up and to cay out some preliminary checks, - The inactive state Inoperational state during which the power consumption is reduced to an absolute minimum. The inactive state corresponds to the OFF ‘mode (the rollers of the processor are open). ‘The state of the processor can be determined by : - simply depressing the ‘on/off'-key on the control panel of the processor = programming the functions "Week progran’ andjor ‘Single program of the menu Ten minutes before entering a pre-programmed inactive period, the message ‘OFF AT : Day hi in the bottom line of the screen starts blinking. If there is stil a printing plate inside the processor when an inactive period should be entered, “OFF AFTER PLATE" is indicated in the right part of the bottom line of the screen, Wore aster piars*is indicated, itis sill possible to insert a following printing plate as long as the trailing ‘edge of the previous plate has not left the processor AGFA}LITHOSTAR LP82 2 Instruction Manual Jan. ‘97 3.6.3. Processing printing plates Ensure that the processor is in the READY-mode. Position the printing plate centered against the feed-in rollers. After the pre-programmed acceptance delay, the printing plate is automatically fed into the processor. The acceptance delay can be programmed by using ‘accept deiay" of the system control feature (refer 10§ 5.4). Important ! Never pull back a printing plate once it has been taken up by the feed-in rollers, Pulling back a printing plate could result in damage to the plate and in the moistening of the feed-in rollers. Never (re-Jinsert a damaged printing plate into the Processor. When operating the processor, take into account the following points : * If the processor changes to the NOT READY- mode when trying to insert a printing plate, carefully pull out the plate : the processor will indicate the reason why the printing plate has not been accepted, * Ifa printing plate jam occurs, always open the rollers before removing the jammed printing plate. * Ifa printing plate has jammed in the developing section, and in order to avoid moistening of the feed-in rollers, always remove the plate by pulling it towards the rear side. It the feed-in rollers are soiled or moistened, ALWAYS clean them, * When continuously inserting printing plates, ensure that they never overlap each other : wait until the processor is again in the READY- mode (a beep is generated !) before inserting new printing plate. It the plates overlap, the processor will operate but an unknown format or a too long printing late will be detected, * In order to ensure an even processing, the center of the feed-in table should be used as reference when a plate is fed into the processor. * In order to avoid scratches on a previous printing plate, remove that plate from the exit guide before the arrival of a following one. AGFALITHOSTAR LP82 Instruction Manual 2 3.6.4. Rewash system The rewash system has been incorporated in the ‘font upper cover of the processor. 1 the optional ‘kit LP82 plates 0.4 mm’ has been provided, a new front upper cover has been installed (on the processor: this cover does not have an incorporated rewash system. The rewash section offers the possibility to re- insert printing plates into the processor (without passing through the developing section and the diffusion section) in order to * a = clean the corrector off the printing plate If manual corrections have been made - clean off the gum-layer and re-hydrophobise printing plates which have been stored after a process operation The possibility of carrying out a rewash operation is indicated by the red *rewash not allowed” LED which has been incorporated in the ‘rewash starl/stop* switch located at the right side of the rewash feed-in table : - If the LED lights up, this indicates that the rewash flap may not be opened (a printing plete is passing through the diffusion section or the processor is not ready for operation). The LED also lights up during the whole rewash operation. = If the LED doas not light up, a rewash operation may be carried out: Nov. 2.21.00 ‘+ Ensure that the processor is in the READY- mode and that the “rewash not allowed" indicator does not light up. Important 1 Never pull back a printing plate once it has been taken up by the wash section entrance rollers. Pulling back a printing plate could result in damage to the plate. * Open the rewash flap. AGFALITHOSTAR LP82 2 Instruction Manual 2.22.00 Jan. ‘97 * Position the printing plate centered against the stationary wash section entrance rollers. If the printing plate is not positioned against the wash section entrance rollers, it wil not be taken up during the following step. In order to ensure an even rewash operation, the center of the revash feed-in table should be used as reference. ‘* Push on the “ewash start/stop" switch in order to initiate the rewash operation. Itit is necessary to interrupt the rewash operation, push on the ‘rewash start/stop” ewiteh once again. It the printing plate jams, always open the rollers before removing the plate. Interrupting the operation of the Processor by means of the “rewash start/stop" switch ‘The “rewash start/stop" switch can be used to interrupt the operation of the processor whenever the “rewash not allowed" indicator lights up. When the operation of the processor has been interrupted by pushing on the switch, the following screen will be indicated : ARE) STOP" SWITCH PRESSED Clore the rollers Using the 4- and Y-keys, make the appropriate selection and then depress the OK-key. AGFA &LITHOSTAR LP82 Instruction Manual 2 3.7. Treatment of the AGFA LITHOSTAR printing plates after processing For more information about the manipulation of the unexposed printing plates, refer to “4.2. Manipulation of the unexposed AGFA LITHOSTAR printing plates”. 3.7.1. Corrections on the printing plates '* Negative corrections (wiping the image) If necessary, images can-be wiped-off the processed printing plates by using a corrector en or corrector fluid (also refer to “2. Consumables’). Immediately after the correction, the corrector should be cleaned off by rewashing the plate or by using a cotton swab moistened with finisher L5300b. The corrector should never dry on the printing plate ! © Positive corrections (adding image) Hf necessary, a "+" corrector pen can be used to add image on the processed printing plate {also refer to "2. Consumables’). The corrector should be totaly dry before using the printing plate for a printing operation ! van. ‘97 2.23.00 3.7.2. Storage of the processed printing plates before the printing operation Before the printing operation, the processed Printing plates should preferably be stored in a dry and heated place : - Temperature between 18°C and 24°C - Relative humidity between 40 % and 70 % = Image side against image side If the printing plates have been stored for more than one month or in case of doubt about the storage temperature and humidity, itis recommended to rewash the plates before printing. 3.7.3. Treatment of the printing plates after printing After a printing operation, remove the ink by using plate cleaner G642b, carefully clean the plate by using finisher and then wipe it dry by using a cotton pad. If itis necessary to keep the printing plates for later use, store them under the same conditions as the ones given in the previous paragraph. AGFA &LITHOSTAR LP&82 2 Instruction Manual 2.24.00 Nov. "98, 3.8. Replacement of the containers 3.8.1. Replacement of the developer and finisher containers ‘The necessity to replace a developer or a finisher container is indicated by a warning (refer to "8.1. A warning is indicated on the display’). When the warning is indicated, it wil stil be possible to process 1 mé. If, after that, the container has not been replaced, the processor enters the NOT READY-mode. ‘The finisher container (with label LS300b) is the one located at the rear side while the developer container (with label L5000p) is the one located at the front side. The middle container is the waste container (refer to the next subparagraph). In order to ensure a correct installation of the containers, the developer immersion system has been provided with a red label and the indication L5000b while a blue label and the indication L5300b can be found on the finisher immersion system, Important ! Never interchange the developer, finisher and waste containers, Wf the containers have been interchanged accidentally, the corresponding circulation circuits should be cleaned by using the circulation feature of the software-maintenance function (refer to "6.3.3. Circulating water in order to clean the circulation circuits") * Taking care not to damage the iubes connecting the immersion system of the container, take the container out of the drip tray underneath the processor. * Unscrew the cap of the container and then carefully take the immersion system (for an entity with the cap) out of the empty container. * Take a new container, remove its cap by using the special tool supplied with the - processor and then insert the immersion system into It oo * Screw the cap of the onto the container. \mersion system firmly * Ensure that the immersion system touches the bottom of the container. I not, carefully push down on the immersion ‘system until it touches the bottom of the container. If the immersion system does not touch the ‘bottom of the container, an empty condition will be detected before the container is really empty. * Carefully place the container back into the drip tray underneath the processor. AGFA &LITHOSTAR LP82 Instruction Manual 2 3.8.2. Replacement of the waste container The necessity to replace the waste container is Indicated by a warning (refer to 8.1. A waming is indicated on the display’). The waste container can be filled in two ways : - By way of the overflow pipes in the different trays When a ‘waste container full condition is dotected, a warning ia incioatod. Aho same time, the processor stops all the replenishing eperations so that no mare solution wil flow into the overflow pipes. It will however still be ppossiblo to process 1 m?. afer that, the waste container has not been replaced, the processor enters the NOT READY:mode. - By opening the manual drain valves in order to empty the trays When a ‘waste container ful" condition is detected, a warning is indicated (if the main ‘switch is turned on) but THE VALVES ‘SHOULD BE CLOSED MANUALLY in order to avoid overflow. * Taking care not to damage the tubes connecting the immersion system of the waste container, take the container out of the drip tray underneath the processor. * Unscrew the cap of the container and then carefully take the immersion system (which forms an entity with the cap) out of the full container. Nov. "98 2.25.00 + Empty the container or take an empty one Ensure that a full waste container is correctly closed before putting it away. Empty developer or finisher containers can be used as waste container : ensure that the waste container has the appropriate label (refer to “7.2. Coltecting the chemical waste’). © Insert the immersion system into the empty container, * Screw the cap of the immersion system firmly onto the container. + Carefully place the waste container back into the drip tray underneath the processor. * If the waste container has been replaced in response to @ warning indicated on the display, do not forget to confirm its replacement by depressing the OK-key. AGFA &LITHOSTAR LP82 2 Instruction Manual 2.26.00 Jan. ‘97 3.9. Chemicals and water consumption The values given under ‘Chemicals and wator consumption" in “Specifications* (part 1) apply to a processor which is used regularly and processes approx. 10 wPiday, {In case of low production or long periods of inactivity, some additional replenishing operations are cartied out. 3.9.1. The developer tray ‘The developer tray is only replenished with developer. ‘The developer is replenished in function of the processed plate surface (200 mim?) and, in order to avoid oxidation, also in function of the time (100 mifhour). When canying out a rewash operation, no developer wil be replenished into the developer tray. A very small amount of developer is also replenished into the wash tray (refer to the next subparagraph). ‘The developer replenishing algorithm assumes that dally at least 10 m? (= 2 | of developer) are processed. Mt, during a working dlay, less than 10 m® have been processed, an additional replenishment A compensating the m® which have not been processed will take place when warming up for the (rst) active period of the next working day. It the processor has not left the active state, this operation will take place at § am of the next ‘morning. Further, 2.4 | (= 24 hours x 100 minour) of developer are daily replenished for antt-oxidation Purposes. While the processor is active, 100 mi of developer are replenished every hour. It the processor has left the active state, an additional replenishment 8 compensating the inactive hours will take place when warming up for the (fist) active period of the next working day. The total amount of developer replenished during the additional replenishments A and 8 will never exceed 5! which is the capacity of the developer tray. It the processor has not been used for more than 72 hours, 4 message will ask to drain the developer tray ‘80 that fresh developer can be supplied to the tray. Wnecessary, remove the sludge trom the developer tray by using a soft brush and then rinse the tray after draining. In order 0 avoid processing problems due to aged developer, an opened developer container should be replaced after a week. Considering the information given above, the minimal daily developer consumption of a normally operating processor is 4.4 |. The following diagram illustrates how the daily developer consumption depends on the processed plate surface : 4 day “4 2 10 8 6 4 g wiiday Sp 5 10 15 20 25 30 35 40 45 60 AGFA}3.9.2. The wash tray The wash tray is replenished with water and a ‘small amount of developer. A very small amount of developer is supplied to the wash tray in order to avoid the formation of bacteria and/or the deterioration of the wash water. Replenishing of the wash tray will also take place during a rewash operation. The water is replenished in function of the processed plate surface (200 mlm2). ‘The following diagram illustrates how the daily water consumption depends on the processed plate surface : aay 5 10 15 20 25 30 35 40 45 50 LITHOSTAR LP82 Instruction Manual 2 Jan. '97 2.27.00 3.9.3. The isher tray The finisher tray is only replenished with finisher. The finisher is replenished in function of the processed plate surface (100 mim). When carrying out a rewash operation, finisher will be replenished into the finisher tray. The finisher replenishing algorithm assumes that daily at least 10 m2 (= 11 of finisher) are processed. 1, during a working day, less than 10 m? have been processed, an additional replenishment compensating the m? which have not been processed will ake place when warming up for the (rst) active period of the next working day. I the processor has not left the active state, this ‘operation will ake place at § am of the next ‘morning. In order to avoid processing problems due to aged finisher, an opened finisher container should be replaced within 30 days. The following diagram illustrates how the daily finisher consumption depends on the processed plate surface : t Niday 8 8 : ae = miiday 5 10 15 20 25 30 35 40 45 60 AGFALITHOSTAR LP82 2 Instruction Manual 2.28.00 Jan. ‘97 4. Manipulation of the consumables 4.1. Manipulation of the AGFA LITHOSTAR chemicals For the manipulation of the chemicals, always follow the instructions on the labels on the containers, ‘Once a container has been opened, it should be used until it is empty (never store a container which has already been opened). In order to avoid processing problems due to aged developer, an opened developer container should be replaced after a week. It is recommended to replace an opened finisher container within 30 days. {tthe processor has not been used for more than 72 hours, a message will ask 1 drain the developer tay 0 that fresh developer can be supplied tothe tray. necessary, remove the sludge fiom the developer tray by using @ soft brush and thon rine the tray after draining. If the period of inactivity exceeds a month, itis recommended to replace all the solutions. 4.2. Manipulation of the unexposed AGFA LITHOSTAR printing plates The printing plates should be stored in a dry location at a temperature laying between 20°C and 32°C. ‘Never expose the printing plates to temperatures ‘exceeding 32°C for more than 24 hours, If the plates have been stored at low temperatures, and in order to avoid condensation, it is recommended to leave them at least one hour in the darkroom before using them. The printing plates should not be processed at temperatures exceeding 35°C. ‘Always put the unexposed printing plates back into their light-proof bags (ensure that the bags are correctly closed) or into the Agfa plate safe. AGFA >LITHOSTAR LP82 Instruction Manual 2 5. Programming the processor |. Programming the printing plate sizes Start from the basic screen : Say Shae Fe AT) bay Shim Depress the OK-key in order to enter "Menu" and then use the a- and v-keys in order to select "plate sizes" Single program Wook program } Place sires Time eet sete eh Bae system control xis, Enter ‘plate sizes" by depressing the OK-key : aaa or eait a piate size Delete a plate size Exit, kdaor edie printing plate sim For a detailed description of the different Possibilities, refer to the following subparagraphs. Nov. ‘98. '* Adding a printing plate size to the programi or changing an existing one Ensure that the cursor selects "Add or edit a plate size’ and then depress the OK-key : A slightly different screen will be indicated if ‘anglo" has been selected for the measurement setup. Enter or change the printing plate size : ~ If necessary, use the 4- and ¥-keys to select the desired printing plate size number - Use the »- and <-keys to select the values determining the length and the width (or to eave them) = Use the 4- and ¥-keys to increase or decrease the value selected in the previous ‘step (autorepeat : faster increase or decrease when the key remains depressed) The length may be set between 0.310 m and 1.130 m while the width may be set between 0.225 m and 0.820 m. 1, during autorepeat, a maximal (minimal) value is reached, the autorepeat operation continues starting from the minimal (maximal) value. AGFALITHOSTAR LP82 2 Instruction Manual 2.30.00 Jan. ‘97, * Deleting a printing plate size from the program Using the A- and V-keys, select ‘Delete a plate size": Add or edit a platé’size Delete plate size Bete Beteta a printing plate sive Depress the OK-key : SARS Tenge x maaen 8-0 2008 a: Blea0 slese = 8888 cam [Select sive to delete ana press “Ox™ A slightly different screen will be inaicated it ‘angio" has been selected for the measurement setup. *.. empty" will bo indicated if there are no programmed printing plate sizes. Using the A- and Y-keys, select a printing plate size ('02" for the following diagram) and then depress the OK-key : x taeh e.600 2:68 1600 Cam REALLY DELETE 7 Tf Depress the OK-key once again to confirm that the printing plate size may be deleted. Otherwise, use the A-key or the V-key to return ‘othe "piace sizes" soreen After having deleted a printing plate size, the aumbering of the sizes will be adapted. 5.2, Programming the time Start from the basic screen : Depress the OK-Key in order to enter ‘Menu’ and then use the 4- and V-keys in order to select “Time set": Waintenance Single program week progean Plate sizes tine set syst Beit control. Enter ‘time set" by depressing the OK-key : REE Do/MH/YYTY Dar, 4a/an/yyvy hhimm A slightly different screen will be indicated if “angio” has been selected for the measurement setup. If necessary, change the time and/or the date : = Use the »- and ~-keys to select the items forming the date and the time (autorepeat) The selection occurs as follows : day => month -> year -> hour -> minutes -> » -> day The name of the day is set automatically. - Use the 4- and ¥-keys to increase or decrease an item (autorepeat) - The Ok-key can be used instead of "exit" AGFALITHOSTAR LPs82 Instruction Manual 2 5.3. Programming the active and inactive periods 5.3.1. Week program ‘The week program allow’s programming the active and inactive periods of the processor for each day of the week. As long as a day has not been programmed as “spoctal' or “ors” by using ‘single progran (refer to the following subparagraph), the processor will be active and inactive as programmed in the week program. 3 In order to reduce the total consumption of power ‘and chemicals, itis recommended to use the ‘single progran' feature in case of a foreseeable period of inactivity. Start from the basic screen : Depress the OK-key in order to enter "Menu and then use the A- and V-keys in order to select ‘Week program: Maintenance Single program pweck progran Plate sizes Time 2st [rogram the active and inactive system control aaie Enter ‘week program" by depressing the OK-key (the following diagram shows an example) : van. '97 2.31.00 PRN If it is necessary to change the active and inactive periods for a day of the week, select the day (‘Mon" for the following diagram) by using the 4- and Y-koys and then depress the Ox-key : ‘The time of the day can be selected by using the new A-cursor which can be moved, in steps of 1/2 hour, towards the left and the right by means. of the »- and <-keys. In order to program an active period, move the cursor towards the desired starting time and then depress the A-key. As a result, the 1/2 hour following the starting time will be activated (shown in black). Each depression of the - or --key will now activate a following or preceding 1/2 hour. If it is necessary to program an inactive period, carry out the same procedure by using the V-key. If the day has been programmed correctly, confirm by depressing the OK-key : returning to the ‘week program" screen can now occur by using "Exit" which is selected automatically. AGFA &LITHOSTAR LP82 2 Instruction Manual 2.32.00 Jan. ‘97 5.3.2. Single program ‘The week program determines the active and inactive periods for each day of the week. In order to avoid that the week program should be re-programmed in case of days off, overwork (oF special use of the processor, the single program has been provided. Taking into account that the changes in the single program will only be carried out once (afterwards the week program is set again), the single program offers the following possibilities (which are explained in the following subparagraphs) : = Prolongation of the active period into which the processor is at present - Reprogramming one or more days of the ‘coming week * Prolongation of the active period into which the processor is at present Start from the basic screen : CE CREMEFVEETET Depress the OK-key in order to enter “Menu” and then use the &- and ¥-keys in order to select ‘Single program": Maintenance Single program Wook program Plate sizes ime set System control Bxie Enter ‘single program’ by depressing the OK-key (the following diagram shows an example) and then select the line ‘ada 30 min to present active period’ by using the A- and V-keys : Padd 30 min to present active period Mon WoekPE. iii1s) Seis Toe Off ed WeekDr. (iiii11; mE Ls Thu Weekpr: C1) —__——-LC000 Fei Spectal 7 Sat special Gavia Mm Sun Weekpes Se Bete Each depression of the OK-key will now result in the prolongation of the present active period by one 1/2 hour. ‘The new time at which the active period will be terminated is given in the lower right comer of the screen. If the processor is not in an active period when selecting the line mentioned above, the message ‘Adding 30 min only possible if active" will be indicated on the display. AGFALITHOSTAR LP82 Instruction Manual 2 * Reprogramming one or more days of the coming week Start from the basic screen : GE a} Day Bnew Depress the OK-key.in.order-to enter ‘Menu and then use the A- and ¥-keys in order to select ‘Single program’: J Singie program Wook program Ht [rogram special days of saa i/? hour system control Bale Enter “Single program by depressing the Ok-key (the following diagram shows an example) : READYsHENUsSTNGLE PROGRAW ‘Add 30 min to precont active period |-Non w; T T Togram special days of coming week Wed WeekPes (iitt 1) TL The Weer) CCC —_/0CC00 Fei Spactal Ss Sat special Be Ban Woekpe. Bide Jan. '97 2.33.00 If it is necessary to temporarily change the active and inactive periods for a day of the coming week, select the day (‘Mon’ for the following diagram) by using the A- and Y-keys and then depress the OK-key : The following subparagraphs explain the different possibilities offered by the above screen : - Making the selected day inactive (for instance in case of a day off) : Ensure that ‘of£" is selected and then depress the OK-key. The overview screen will again be indicated with the selected day programmed as inactive. - Setting the selected day back to the week program : Select "weekpr." by using the 4- and ¥- keys and then depress the OK-key. The overview screen will again be indicated with the selected day as programmed in the week program. AGFA &LITHOSTAR LP82 2 Instruction Manual 2.34.00 Jan. ‘97 = Making a special program for the solected day : Select "special" by using the A- and ¥- keys and then depress the OK-key. The following screen is indicated : The active and inactive periods of the selected day can now be programmed as described for the week program. If the present day is programmed as ‘ors" or "special", the single program will be carried out immediately and the processor will change back to the week program at the end of the day. Using the “on/off'-key to set the processor from inactive to active or vice versa will not affect the week program or the single Program, {Ifthe processor is made active (inactive) by using the ‘on/off-key in an inactive (active) period, it will return to the inactive (active) state when reaching the next programmed inactive (active) period. 5.4, The system control feature The system control feature allows carrying out one of the following operations : ~ Changing the language = Changing the display contrast = Changing the beep duration = Changing the measurement setup = Changing the acceptance delay - Setting or cancelling the maintenance info screen - Reading the temperatures of the solutions in the different trays = Reading the different production data - Enabling or disabling the optional stacker - Entering the service mode (only for the Agfa service technician) Start from the basic screen : | [bay hin OEE AT? bay hl Depress the OK-key in order to enter "Menu" and then use the A- and Y-keys in order to select "system control": Week program Plate sizes Times. b system controt (So to the epsten contror bing screen Single program AGFA}Another depres: following screen = of the OK-key shows the Pranguase Display contrast Beep duration Dnies Recest delay [ress “on™ for settin Vasntenance info screen ow Tenperatures Production data Stack Servic: Bie : Enabled ‘The function "stacker" is only indicated if the optional stacker AGFA LITHOSTAR LS82 has been provided and it allows enabling or disabling the stacker. For more information, refer to the appropriate operating instructions. The function will not be indicated any more in the screens represented in the following subparagraphs. ‘The function "Service" can only be accessed by the Agfa service technician in order to enter the service mode (a special code is needed). When the function is selected, ‘service only for Agfa service techaictan’is indicated in the bottom line of the screen. wing subparagraphs explain the other ies offered by the system control setting screen, LITHOSTAR LP82 Instruction Manual 2 Jan. '97 2.35.00 ‘© Changing the language This feature allows changing the language used on the display of the processor. Besides ‘tagiish’ the processor offers the possibility to use two additional languages. For more information, ask the Agfa service technician, Using the a- and v-keys, select ‘Language" and then depress the OK-key : Eangusge PEnglish Sona Language" w3re languages Exit “end Language’ and "3rd Language’ stand for the ‘wo additional languages mentioned above. Use the A- and Y-keys to select the desired language and then depress the OK-key. AGFALITHOSTAR LP82 2 Instruction Manual Jan. ‘97 © Changing the display contrast 4H, and only it, the basic screen is indicated, the display contrast can also be changed by holding down the »-key and then depressing the A- or V-ey one or more times. Using the A- and Y-keys, select ‘Display contrast’ Tangvage }Sisplay contrast, Beap duration Unies Aecept delay English 60. Moerie 2.9 sec [press “ox= for setting display contrare Maintenance info screen : ow Temperatures Production data Exit Depress the OK-key Language Display contrast Beep duration Onite Accept delay E Sa “OK for setting display contrast Maintenance info.screen : oN Temperatures Production data Service Exit Using the a- and ¥-keys, increase or decrease the display contrast and then depress the OK-key. The display contrast can be set in 16 steps. * Changing the beep duration Using the duration’ - and V-keys, select ‘Beep Bispial splay contrast, Beep duration omits R2cept delay Maintenance info screen: oN Temperatures Production data Service Bait Depress the OK-key Tangu: men Dispay Beep duration Onite Metric Accept delay 2:3 0c tenance info screen ow Temperatures Production data Service Beat Using the 4- and ¥-keys, increase or decrease the beep duration and then depress the OK-key (a beep with the last determined duration will be generated). The beep duration can be set between 0 and 2 sec. Beeps are generated in the folowing eases : - tbeep : The processor enters the WAIT-mode or the READY-mode + 2beeps : Waring, jam, rewash operation or emergency stop = Sbeeps : Error condition A continuous beep is generated when inserting @ printing plate in the OFF-mode or when the processor is stil processing a previous plate. A repeated beep indicates that the waste container should be replaced. AGFA &LITHOSTAR LP82 Instruction Manual 2 * Changing the measurement setup Using the A- and Y-keys, select "units" : nguage Display contrast Beep duration -onits Accept delay Tat Fie or Angio Jan. ‘97 2.37.00 © Changing the acceptance delay Using the 4- and V-keys, select ‘Accept delay": Tanguage A 13y contract ? 62 Beep duration Bo sec baits Metric fxccepe deter Bro sec Maintenan: Temperatures Production data Service Beit info sereen + OW Depress the OK-key : ‘Unies MeEriC, Metric (in md Anglo” (in fen Brie (er-unite 1 wetrie or Angie 4 [Press “Oke for sereim Maintenance info screen : ON Fomperacures Production data Exit Depress the OK-key : Tanguage Display contrast : Beep duration Onits Accept delay Use the A- and ¥-keys to select the desired measurement setup and then depress the OK- key. Maintenance info screen + ON Tonporatares Production date Baie Using the A- and ¥-keys, increase or decrease the acceptance delay and then depress the OK-key. The acceptance delay can be set between 0 and § sec. AGFALITHOSTAR LP82 2 Instruction Manual 2.38.00 Jan. '97 © Setting or cancelling the maintenance info screen This feature allows to determine it maintenance information is indicated on the “wenu* screen. Using the A- and Y-keys, select “Maintenance info screen": Boop duration Unies Accept delay pHatntenance info seri Temperature 0-5 see Motrie Oro tec Production data Service Exit Language : English Display contrast : 9B Depress the OK-key : Maintenance info screen t ON ON Beit ean RENEE] ‘The maintenance info screen can be set / cancelled by selecting ‘on* /‘oFe* and then depressing the OK-key. If the maintenance info screen has been set, the ‘wenu* screen looks as follows Maintenance rate Processed plates The soreen now represents the number of printing plates processed since the last plate counter reset (refer to § 6.2). The screen also gives and visualises the necessity for the maintenance by means of a so- called ‘maintenance rate" (100% = 800 plates). ‘* Reading the temperatures of the solutions in the different trays This feature has been provided in order to be able to check if the temperatures of the different solutions of the processor do not differ too much from their target value (the screen does not allow any setting or calibration). Using the A- and Y-keys, select “Temperatures’: Accept delay : Maintenance info se pTenperatures Production data Service Bie Language Display contrast, Beep duration Depress the OK-key : The first column shows the temperature which is presently measured for the corresponding section. ‘The second column shows the target temperature for the different sections. Leave the screen by depressing the OK-key. AGFA @LITHOSTAR LP82 * Reading the different production data This feature has been provided in order to be able to ask for the aiferent production data of the processor (the screen does not allow any resetting). Using the A- and V-keys, select "Production data" vaies Aecept delay Maintenance info ser peratures |- Production data Service Exit Language Display contrast Beep duration Depress the OK-key : PSST Devel. /day i/day|— éd/mnm/yyyy waver i Sayman/¥999 Rater/day ivday| Gayman yyyy Fintshes i Sa/mam/Yyty Fintes/aay Tyaay| daymmn/yyoy Exe. For'a1i plates’, ‘All rewash’, Developer’, ‘water’ and ‘Finisher’, the five last reset values are kept in memory. For ‘piates/day’, “Rewash/day’, Dovel./éay, ‘water/day’ and “Finis. /day’, the five last daily values are kept in memory. Instruction Manual 2 Jan. ‘97 2.39.00 The five values which are kept in memory for each item can be obtained as follows Ensure that the item is selected (“erates/aay" for the following diagram) and then depress the »-key in order to select the date : Places/aay All rewash aaznmn/y¥y3) davmmn/ 7993 8d /mmn/ 9993] See iiday|dd/mam/yyyy i Sa/mnn/}339 Water/day Isday| — daymam/¥999 Finisher i Sayan /y39¥ Finis. / aa: Lvaay| aaymnn/y 999 Exit A number (from 1 to 5) representing the memory willbe indicated before the date and the A- and Y-keys can be used to scroll through the momories. * ‘ALL plates" Indicates the total surface of processed printing plates since the value has been reset. © "Plates/day" Indicates the production of printing plates for the present day. © "ALL rewash* Indicates the total surface of rewashed printing plates since the value has been reset. AGFALITHOSTAR LP82 2 Instruction Manual 2.40.00 Jan. ‘97 * "Rewash/day" Indicates the surface of rewashed printing plates for the present day. Developer" Indicates the total consumption of developer since the value has been reset. © "Devel. /day" Indicates the amount of developer which has been consumed on the present day. * tWater* Indicates the total consumption of water since the value has been reset. * CWater/day" Indicates the amount of water which has been consumed on the present day. © "Finisher" Indicates the total consumption of finisher since the value has been reset. © "Finis. /day’ Indicates the amount of finisher which has been consumed on the present day. AGFA @LITHOSTAR LP82 Instruction Manual 2 6. Maintenance 6.1. General safety measures Read the following safety measures attentively before carrying out the maintenance instructions given In this chapter : * Consult the appropriate M.S.D.S. (Material Safety Data Sheets) before handling chemicals and always follow the safety instructions given on the label of the chemicals. © Itis recommended to wear glasses’or'safety goggles to protect the eyes against the splashing of chemicals. 1 the eyes have come into contact with chemicals, rinse them thoroughly with clean and cold running water. In case of iritation of the eyes, immediately consult an eye specialist * People who are sensitive to irritations or allergies should wear safety gloves when handling chemicals. Ifthe skin has come into contact with chemicals, wash thoroughly with clean running water. * Avoid the inhalation of chemical vapours and ensure that the room is well-ventilated. * Never by-pass or turn off the incorporated safety and security devices. © When carrying out a software-maintenance procedure, the processor automatically enters the OFF-mode (do not cut off the power), For all the other interventions, ensure that the power is cut off. * Trouble-shooting and repairs should only be carried out by an Agfa service technician. dan. ‘97 2.41.00 6.2. Software-maintenance function ‘The software-maintenance function has been provided to assist the operator when carrying out the cleaning operations described further in this, chapter. It offers the following possibilities : - Reading and resetting the plate counter (only if the maintenance info screen has been set (refer to § 5.4) = Circulating water in one or more trays - Filling one or more trays When selecting ‘kaintenance’, the processor will automatically enter the OFF-mode (the rollers are pened). Start from the basic screen : It the maintenance info screen has been set, the ‘wenu" screen also shows the maintenance information (also refer to § 5.4). Depress the OK-key in order to enter "Menu" and then use the 4- and Y-keys in order to select “Maintenance® : Pusintenance Single program heck progeam Diste”sizes [Soto -paintenance seresm System contrel AGFALITHOSTAR LP82 2 Instruction Manual 2.42.00 Jen. ‘97 Another depression of the OK-key shows the maintenance screen : PLATE Press "On" to reset the plate counter ‘Plate counter” is only indicated if tho maintenance info screen has been set (also refer to § 6.4). The different possibilities offered by the above screen are explained in the following subparagraphs. Contrary to the other screens described in this instruction manual, the "ta intenaace” screen will not be reset after § minutes. ‘+ Reading and resetting the plate counter This feature is only available if the maintenance info screen has been set (also refer to § 6.4). If represented on the maintenance screen, the item “Plate countex” gives the number of printing plates processed since the last. plate counter reset. In order to reset the plate counter, proceed as follows : - Ensure that the cursor selects "Plate countex" and then depress the OK-key : PSSST Plate counter = Reset counter Exit - Ensure that ‘Reset counter" is selected and then depress the OK-key : the plate counter will be reset. AGFA &LITHOSTAR LP82 Instruction Manual 2 * Circulating water or stopping the circulation of water in one or more trays Ensure that the cursor solects “circulate” and then depress the OK-key : Finisher (Tose cover (s) snd tare cireviation Done When procesding as described below, another message than the one on the above diagram could be indicated in the bottom line of the sereen (this also applies to the following screen) : © ‘Pi12 developer tray": There is not enough water in the developer tray to start the circulation ‘PLL wash tray": There is not enough water in the wash tray to start the ofreutation © Fi12 rinse tray": There is not enough water in the rinsing tray to start the circulation F812 eéndsner tray’ There is not enough water in the finisher tray to start the circulation © First turn maintenance filling off" One or more filing operations (refer to the following subparagraph) are still running Jan. °97 2.43.00 The preceding screen offers the following five possibilities : aaurt 2 All the trays ‘peveloper* : Developer tray ‘wasn water": Wash tray “Rinse” Rinsing tray ‘einisner’ Finisher tray Select one of the five possibilities by using the A- and Y-keys and then depress the OK-key (‘e02" stands for the selected possibilty) : an rox Orr Bete Select "on" or ‘or * and then depress the OK- key in order to activate or de-activate the circulation in the selected tray(s). Take into account that a circulation operation ‘can only be initiated if the upper covers of the processor are closed. Whnen leaving the maintenance screen by using ‘exie’, all the circulation operations are turned off, AGFA}LITHOSTAR LP82 2 Instruction Manual 2.44.00 Jan. ‘97 iling one or more trays Filing a tray is required by the processor ita level difference has been detected during cleaning (also refer to the messages asking for a filing operation in the previous subparagraph orto the waming ‘trays have not been filled since maintenance’) IFempty trays are filled, ensure that the corresponding manual drain valves are closed. Using the A- and Y-keys, select "Fil": Piate counter + Circulate pecia Exit Ste the Fiiiin: ‘control screen ‘plate counter’ is only indicated if the ‘maintenance info screen has been set (also refer to § 5.4). Depress the OK-key : re Holiday f411ing Developer 1 OFF Wash water on Rinse /Pinisher P BONE \eTose cower te Exit When proceeding as described below, another ‘message than the one on the above diagram could be ‘indicated in the bottom line of the screen (this also applies to the following soreen) : ‘First turn circulation off": (One or more circulating operations (refer to the previous subpéregreph) are stil running The preceding screen offers the following five possibilities : aut Filing all the trays “foliday filing" : Filing the wash tray with water and a certain amount of developer Developer" : Filling the developer tray ‘wash water" : Filling the wash tray “Rinse/Finisher’ : Filling the rinsing/finisher trays If a level difference has been detected by the processor during cleaning, “OFE* will ‘automatically be indicated for the corresponding tray(s) : the operator should then use the following screen to activate the filing operation. Whenever “oFF" is indicated, the corresponding tray should be filed as described below. If, after a filling operation, the level in a tray is correct, “DoE” will be indicated. Select one of the five possibilities by using the 4- and V-keys and then depress the OK-key (‘e9" stands for the selected possibility) : PETE Baie Select “on” or “OFF” and then depress the OK- key in order to activate or de-activate the filling operation. Take into account that a fling operation can only be initiated if the upper covers of the processor are closed, AGFA &LITHOSTAR LP82 Instruction Manual 2 6.3. Cleaning the processor In order to ensure a reliable operation of the processor in a professional environment, itis recommended to carry out the cleaning procedures given in the following subparagraphs. The mentioned cleaning periodicities apply to a processor operating under ‘normal conditions. Before draining the water and the chemicals, ensure that the waste container has been installed or that the processor is correctly connected to the local waste treatment system, For more information on emptying the trays, refer to “9.5.3. Emptying all the trays of the processor’ ‘The processor should be cleaned with pure cold (or tepid) water and a soft brush. First ty if the dirt can be cleaned off by simply rinsing the component or the tray. If necessary, carefully use a soft brush to wipe off the sticking ait. When cleaning the processor, ensure that the electrical equipment does not come into contact with water, In order to avoid damage to the processor, never use detergents, abrasives or chlorinated solvents + only use water! After having replaced the developer and/or the wash water, the printing parts on the first printing plates may have a pale, bronze appearance : this, is only a cosmetic effect which does not affect the lithographic properties of the plates. Jan. ‘97 2.45.00 6.3.1. Monthly cleaning The monthly cleaning operation is limited to a cleaning and rinsing of the developing, rinsing and finishing sections. © Select the ‘Maintenance" screen. As a result, the processor automaticaly enters the OFF-mode and the rollers are opened. * Raise the upper covers of the processor. * Developing section © Empty the developer tray as described in "3.5.3. Emptying all the trays of the processor’ * Close the developer drain valve. ‘* Remove the anti-oxidation cover from the developing section. * Using the hose with water tap, fill the developer tray until there is approx. 1 om water in it. * Using a soft brush, clean the dirt off the developer tray. * Open the developer drain valve and then wait until all the water has been drained from the developer tray and the developer circulation circuit. * Using the hose with water tap (and, if necessary, also the soft brush), rinse the developing section with water. ‘© Wait until all the water has been drained and then close the developer drain valve. AGFALITHOSTAR LP82 2 Instruction Manual 2.46.00 Jan. ‘97 * Rinsing and finishing sections ‘© Empty the rinsing and finisher trays as described in “3.5.3. Emptying all the trays of the processor’. ‘+ Raise the cover of the rinsing and finishing sections. * Carefully unhook and remove the gutter system (two gutters and one gutter frame) on top of the rinsing and finishing sections. * Open the rinsing solution and finisher drain valves. * Using the hose with water tap (and, if Necessary, also a soft brush), rinse the rinsing and finishing sections with water. + Wait until all the water has been drained from the rinsing and finisher trays and the corresponding circulation circuits and then close the rinsing solution and finisher drain valves. © Re-install the gutter system onto the rinsing and finishing sections. * Clean the printing plate exit rollers. * Filling the trays ‘* Ensure that all the drain valves are closed. * Ciose all the covers of the processor. * Using the 4- and Y-keys, select “Fi13" on the "Maintenance" screen : Circulate Fait Exit ontrel screen If the maintenance info screen has been set, the above screen also represents the plate counter. * Depress the OK-key and then use the A- and Y-keys, to select ‘A11*: Fait Holiday fitting Developer 2 OFF Wash water i OFF Rinse/Finisher 1 OFF eioss cover te Exit ‘* Depress the OK-key and then use the 4- and Y-keys to select ‘on" : * Depress the OK-key in order to initiate the filing ofall the trays : iL Holiday ss114ng Developer kash water Rinze/Finisne [eiose covers) ana stare Exit When a tray is filed, ‘pons will be indicated in the corresponding line. * Wait until ‘Done” is indicated for all the trays and then use "Exit" to return to the basic screen. AGFA @LITHOSTAR LP82 Instruction Manual 2 Nov, ‘98 2.47.00 6.3.2. Bimonthly cleaning or cleaning after each ® Standing at the right side of the processor, 800 m2 of processed printing plates remove all the upper rollers The bimonthly cleaning operation consists of the = With both hands, grip a roller and then following interventions : carefully pul it towards the right side in = Cleaning and rinsing of the developing, rinsing order to unhook it from its right holder. and fishing sections re. = Lift the right side of the roller approx. = Removing the sludge from the wash tay and 1 em out of is right holder. rinsing the wash section ‘© Select the "Maintenance’ screen. As a result, the processor automatically enters the OFF:mode and the rollers are opened. © Raise the upper covers of the processor. ‘* Empty all the trays as described in "3.5.3. Emptying all the trays of the processor’. * Removal and cleaning of the rollers, guides, * Raise the cover of the wash section and the cover of the rinsing and finishing sections. ~ Without further raising its right side, carefully pull on the roller in order to unhook its left side. '* Remove the following components : = The antl-oxidation cover of the developing section - Lift the roller up and out of the processor. - The two partition plates and the three . fe sure to remove the following upper rollers : conveyor rollers of the wash section Gs Cee eae = 3,rollers in the feedtin and developing sections ~ The two-piece suction unit on the bottom 2 é of the wash tray = 2 rollers in the wash section = 4 rollers in the rinsing and finishing sections (be careful not to damage the air lock on the rear 9 sections roller) + The gutter system on top of the rinsing and finis! + Toller in the exit section AGFALITHOSTAR LP82 2. Instruction Manual 2.48.00 Jan. ‘97 * Remove all the lower rollers : ~ Grip the left side of a roller and then unhook its left side by carefully lifting it by approx. 1 om. = Without further raising its left side, unhook the right side of the roller by pushing its left side into the hole provided for the left side of the corresponding upper roller. = Carefully pass the right side of the lower roller through the right holder of the corresponding upper roller (refer to the diagram). ~ Lift the roller up and out of the processor. Be sure to remove the following lower rollers: ~ 3 rollers in the feed-in and developing sections + 2rolfers in the wash section + rollers in the rinsing and finishing sections 1 roller in the exit section Remove the following components : - The printing plate guide of the developing section = The printing plate guide at the rear side of the diffusion section * Remove the rollers system as well as the rear conveyor roller of the diffusion section : Raise the rollers system. Grip the right side of the rollers system and then carefully unhook the white bushing by lifting the right side of the system by approx. 1 cm. = Without further raising its right side, carefully pull on the rollers system in order to unhook its left side. ~ Lift the rollers system up and out of the processor. - Proceed as explained for the rollers system in order to remove the rear conveyor roller of the diffusion section. * Thoroughly clean all the components removed up to now ina sink by using cold or tepid water and a soft brush It is also possible to clean the components in the diftusion tray by using the hose with water tap provided on the processor. In such a case, be careful that the waste container does not overttow. AGFALITHOSTAR LPs2 Instruction Manual 2 * Cleaning and rinsing the developing section Clean and rinse the developing section by following the procedure given under "Developing section® in "6.3.1. Monthly cleaning’. * Cleaning and rinsing the rinsing and finishing sections * Close the rinsing solution and finisher drain valves. * Using the hose with water tap, fill the rinsing and finisher trays until there is approx. 1m water in them. * Using a soft brush, clean the dirt off the rinsing and finisher trays. * Open the rinsing solution and finisher drain valves and then wait until all the water has been drained from the rinsing and finisher trays and the corresponding circulation circuits. * Using the hose with water tap (and, if necessary, also the soft brush), rinse the rinsing and finishing sections with water. © Wait until all the water has been drained and then close the rinsing solution and finisher drain valves. " Removing the sludge from the wash tray and finsing the wash section '* Raise the cover of the wash section. Jan. ‘97 2.49.00 * Close the wash water drain valve. © Using the hose with water tap, fill the wash tray until there is approx. 1 om water in it. * Using a water aspirator, remove all the water (end the sludge) from the wash tray. The waste solution in the water aspirator should be put in the waste container (use a funnel). * Open the wash water drain vaive and wait until the remaining water has been drained from the wash water circulation circu. © Using the hose with water tap, rinse the wash section with water. * Wait until all the water has been drained and then close the wash water drain valve. * Re-installation of the rollers, guides, ... Ensure that all the components removed at the beginning of this cleaning procedure are correctly cleaned and then re-install them by following "Removal and cleaning of the rollers, guides, ..." in reverse order. * Filing the trays Terminate the bimonthly cleaning operation by filing all the trays as described under ‘Filing the trays" in *6.3.1, Monthly cleaning’. AGFA}LITHOSTAR LP82 2 Instruction Manual 2.50.00 Jan. ‘97 6.3.3. Circulating water in order to clean the circulation circuits In caso of serious problems (e.g. an accidental interchanging of the developer, finisher and waste containers or soiling ofthe solutions with oil or {grease}, Water can be circulated in order to clean the ‘corresponding circulation circuits). * For the concerned sections, carry out the bimonthly cleaning operation but do not carry out ‘Filling the trays" yet. * Ensure that all the corresponding drain valves are closed. * Using the hose with water tap, fil the corresponding tray(s) with water until the level in the tray(s) reaches the overflow. * Close all the covers of the processor. * Using the A- and ¥-keys, select "circulate" on the "Maintenance" screen: (Se te the circulation control sereeh If the maintenance info screen has been set, the above screen also represents the plate counter, * Depress the OK-key and then use the 4- and Y-keys to make the appropriate selection (‘a22" for the following diagram) : Sec 7 Done * Depress the OK-key and then use the A- and Y-keys to select ‘ONn" : SSE AEE The above diagram shows the screen if ‘211° hhas been selected. * Depress the OK-key in order to initiate the circulation + ait Developer ton Wash water i oN Ringe f oN Pinishor ion Done The above diagram shows the screen if circulation has been asked in all the trays. In the other cases, ‘oFF* will sill be indicated for the sections for which no circulation was asked. If circulation is required in more than one but ‘notin all the trays, repeat the above software procedure in order to activate the circulation in the other ray(s) * After a few minutes, turn off the circulation in the tray(s) by repeating the above software procedure but selecting ‘orE* instead of ‘on" on the circulation activating screen, * Terminate the procedure by filing the tray(s) as described under ‘Filling the trays" in °6.3.1 Monthly cleaning’. A \ aeLITHOSTAR LP82 Instruction Manual 2 6.3.4. Holiday filing Uf the processor will not be used for a long time-period (holidays, ...), the following procedure should be carried out in order to avoid smell problems : the wash section will then be filled automatically with water and 2 small amount of developer. * Depending on the state of the processor, carry out the monthly or bimonthly cleaning operation without filing the trays. ® Close all the covers of the, processor. * Using the A- and Y-keys, select "F111" on the ‘Maintenance’ screer ‘control sereen If the maintenance info screen has been set, the above screen also represents the plate counter. © Depress the OK-Key and then use the 4- and V-keys to select “Holiday filling" sey Holiday £11ling eloper h water, Rinze/Finisher Exit © Depress the OK-key in order to initiate the holiday filling operation Jan. '97 2.51.00 © Wait until "pons" is indicated for all the trays. and then use "sxit" to return to the basic screen : the holiday filing operation is terminated and the processor can be turned off. AGFA &LITHOSTAR LP82 2 Instruction Manual 2.52.00 Jan. ‘97 6.3.5. 10 golden rules for a correct maintenance of the processor AGFA LITHOSTAR LP82 -— Basic Maintenance LITHOSTAR LP82 — ‘Additional cleaning instructions ‘ 10 Golden Rules Weekly cleaning (1 hour) ‘What do younced ?. water ~ brush ~ sponge (Spontex) 1. Empty the developer tray and rince throughly with water. 2. Clean the developer tray with a Bruch. 3. Clean the developing rollers with water and a sponge. 4. Empty the rinsing tray (the tay wih the olerss, 10 and"). 5. Clean the exit rollers (14) with water, 6. Carry out a vieual check of the equipment. Start the processor and watt unl the trays are flac. Bimonthly cleaning or after 800 m” (4 hours) What do younced? water ~ brush ~ rubber goves - sponge (Gpont=x) ‘water vacuum cleaner ~ software-mantenance function 7. Empty all the traye and rinse them with water. (9) lean the developer, rinsing and finisher trays with water: land a brush. 9..Clean the wach tray by using a water vacuum cleaner, 10, Fill the dovoloper, rinsing and finlehor traye with water and circulate during & min. (*) 8. ‘Stat the processor anc wat untithe trays re lad, () Von the nove wth water tap. tous the drain valve, place the water tapin the ‘tren hole ofthe tray and than rnae. Erapty the tray and clove the den vee. Never use detergents, abrasives or chlorinated solvents I Never use fluffy sponges or clothes | AGFA AGFALITHOSTAR LP82 Instruction Manual 2 Waste treatment 7.4. AGFA's environmental guidelines The AGFA LITHOSTAR processor LP82 and the LITHOSTAR consumables are designed, engineered and manufactured according to very strict internal Company Environmental Guidelines which are in conformity with the intemational rules and recommendations and with the E.£.C. and national regulations. AGFA-GEVAERT N.V. also signed the international "Responsible Care’ commitment. Whenever possible, the use of hazardous products has been avoided or reduced and the AGFA LITHOSTAR processor has been designed taking into account the expected legislation on recycling used equipment. Furthermore, AGFA-GEVAERT N.V. provides both means and information in order to ensure the safe handling of all its products and equipments before, during and after their use : prescriptions for safe installation and use of the equipment, labels. and MS.DS. (Material Safety Data Sheets) mentioning the appropriate health and safety precautions, ... Finally, and also according to the Agfa philosophy of care for the environment, everything possible has been done to reduce the overell waste flow generated by the LITHOSTAR system. Jan. ‘97 2.53.00 7.2. Collecting the chemical waste It is not allowed to drain used processing solutions into surface waters and, in the most environmentally conscious countries, it is legally forbidden to drain them into public sewer systems. ‘The composition of the chemical waste of the AGFA LITHOSTAR chemicals is largely ‘comparable to that of the solutions in their original state with the addition of a residue of gelatine, aluminium and silver from the printing plates, The three individual waste flows of the processor (developer, wash water and finisher) are collected In one single and correctly labeled (see further) waste container or are supplied all together to the local waste treatment system. Developer, wash water (containing small amounts of developer) and finisher can safely be mixed and collected in the same waste container, The collection of the three individual waste flows in the same container isnot only the best technically and environmentally justified solution but itis also the most costetfective one if storage, handling and ‘ansport are taken into account. The resulting waste solution can be safely mixed with waste solutions coming from ordinary black- white developers. On the other hand, it should never be mixed with fixers coming from film processors as this could result in the generation of arnmonia when the mixing occurs in the wrong proportions. Before mixing various waste solutions, ask the waste collecting company for advice, AGFA}LITHOSTAR LP82 2 Instruction Manual 2.54.00 Jan. ‘97 As described earlier, there are two possibilities for draining the chemical waste of the processor * The chemical waste is collected in a waste container Before a container is used as a waste container, stick a waste container label (refer to "2. Consumables") on it. It’s possible that the waste container labels Contain more information than the one shown in the diagram : some additional instructions concerning the local legal regulations may be added. These addtional instructions may differ from country to country. Normally the empty developer and finisher containers are used as waste container : in such a case, stick the waste container label onto the original label. Do not empty the waste container in the drain but send it to a waste collecting company for environmentally justified treatment. * The chemical waste is drained towards a local waste treatment system In any case, the local legal regulations applying to the treatment of (chemical) waste should be followed strictly. Based on the information given in *3.9. Chemicals and water consumption’, the following diagram illustrates how the daily amount of chemical waste depends on the processed plate surface : Uday 1 10 16 20 25 00 95 40 45 60 AGFA &LITHOSTAR LP82 Instruction Manual 2 7.3. Troatment of the different types of waste 7.3.1. Treatment of the liquid chemical waste The liquid chemical waste coming from the AGFA LITHOSTAR processor is an aqueous alkaline solution which can be treated by using the same technology as for classical developer waste. It is recommended to inform the waste collecting company about the nature of the AGFA LITHOSTAR liquid chemical waste. Waste treatment companies will first remove the gelatineous sludge, then precipitate the metallic silver and finally treat the resulting chemical waste together with other classical developer waste solutions. 7.3.2. The plastic containers ‘The developer and finisher containers (which are normally used as waste containers afterwards) are made from polyethylene and are perfectly recyclable after having been thoroughly rinsed. 7.3.3. The printing plates ‘The used AGFA LITHOSTAR printing plates can be collected and recycled using the same techniques as for conventional pre-sensitised offset plates. The very small amount of silver on the surface of the printing plates does not result in additional problems. van. ‘97 2.55.00 7.3.4. Printing plates packing material ‘The printing plates are supplied in polyethylene bags and cardboard boxes which are perfectly recyclable. Even the largest cardboard boxes do not require a wooden frame in order to strengthen them. AGFALITHOSTAR LP82 2 Instruction Manual Jan. ‘97 8. Trouble-shooting 8.4. A warning is int ated on the display This paragraph gives an overview of the different warnings which can be indicated on the display of the processor. The warnings can be indicated during the READY- ‘mode, the WAIT-mode, the NOT READY-mode or the OF F-mode, In case of a warning, a screen like the following ‘one is indicated : EOE Mens | Xxxxxxxenx WARNING rvyevryyyy apnaaaeae In most cases, “rrvvy rrr" indicates the problem while “zezzzzz222" and, if necessary, also ‘ezas2ae200" contain some instructions to recover the warming. ‘Some wamings require two lines to indicate the problem : the instructions, if any, will hen only be given in the bottom line of the screen, Wf the recovering of the problem requires a confirmation by the operator, this confirmation will bbe asked by the line “xxxxxxxxxx When a warning is indicated on the screen, the »-cursor will always be positioned in front of a line concerning the warning. If necessary, the A- and Y-keys can be used to select "Menu" : KXAIXXXK wARWING = vexvryyery zaznnezene ‘The “Menu” screen can then be accessed without having confirmed or recovered the warning. In most cases, the processor will not immediately enter the NOT READY-mode when a warning is indicated. The NOT READY-mode will only be entered it it has become impossible for the processor to ensure a correct processing of the printing plates. In such a case, try to recover the problem before the NOT READY-mode is entered. If a warning can not be recovered by carrying out the procedures described further, a more serious problem might have occurred : call the Agfa service technician. The different warnings which can be indicated for the processor AGFA LITHOSTAR LP82 are given and explained in the following subparagraphs. AGFA @© WARNING : Developer container empty Replace container ‘The developer container has run out of developer. Replace the empty developer container by a new one (refer to § 3.8.1). When the waming is indicated, it wal stil be possible to process 1 mi? before the processor ‘enters the NOT READY-mode. Try to replace the container before the processor enters the NOT READY-mode. * WARNING : Finisher container empty Replace container The finisher container has run out of finisher. Replace the emply finisher container by a new one (refer to § 3.6.1.). When the waming is incicated, it wil stil be possible to process 1 m® before the processor centers the NOT READY-mode. Try to replace the container before the processor centers the NOT READY-mode, © WARNING : Water pressure low Open valve(s) ‘The pressure of the water supply towards the Processor is too low. Check if all the valves and water taps ensuring the water supply are open. Mone of the valves or water taps is not opened completely, this message can also be indicated ‘due fo low pressure when using the hose with water tap provided on the processor. LITHOSTAR LP82 Instruction Manual 2 Jan. ‘97 2.57.00 © WARNING : Waste container full Replace container ‘The waste container is full The processor will immediately stop all the replenishing operations and, if the container is not replaced, the NOT READY-mode will be entered alter 1 m? of printing plate has been processed. It the processor is not in the NOT READY-mode, tty to replace the waste container before it enters the NOT READY-mode. When a “waste container full" condition is detected, the following screen is indicated : pwaste container replaced ? WARNING ? Waste container full Replace container Proceed as follows : * Replace the full waste container by an empty one (refer to § 3.6.2). * Ensure that ‘waste container replaced 7° is selected and then depress the OK-key in ‘order to confirm the replacement of the waste container. AGFALITHOSTAR LP82 2 Instruction Manual 2.58.00 dan. ‘97, ‘* WARNING : Plate input not accepted Remove plate This warning is indicated in one of the following cases : * When a printing plate is inserted into the feed-in section or into the rewash section during the WAIT-mode or the OFF-mode The waming has been provided because, in such a case, the printing plate could reach the eveloper through the opened feed-in rollers : pulling back the plate would then result in ‘moistening the feedtin rollers and this should always be avoided, The waming is also indicated if one tries to ‘manually insert a printing plate by way of the exit section of the optional on-line bridge when the processor is in the WAIT-mode or in the OFF-mode. * When a following plate is inserted before the feed-in rollers are halted after a preceding processing operation The warning will be cleared by pulling the printing plate out of the processor and waiting until the processor is in the READY-mode. * WARNING : Unknown plate size Program plate size This waming is indicated (when the printing plate leaves the exit section at the end of the processing operation) in one of the following cases : * The length of the printing plate was not pre- programmed * The printing plate (even with a pre- Programmed length) has been fed in skewed * Overlapping printing plates ‘The two last cases result in 2 faulty ‘measurement of the printing plate length. When a not pre-programmed length is detected, the following screen is indicated : WARNING + Uaknown Progeam The length measured by the processor (expressed according to the presently selected ‘measurement setup (refer to ‘2x is given in the bottom line of the screen. Maximum length : 1500 mm ‘The warning will be cleared automatically when a new printing plate is fed into the processor. If desired, a new printing plate size can be pro- grammed by using “eiate sizes" of ‘Menu" (refer to '5.1, Programming the printing plate sizes’). AGFALITHOSTAR LP82 Instruction Manual 2 * WARNING : Trays have not been filled since maintenance This waming can only be indicated in the NOT READY-mode when the processor tries to restart after a maintenance operation. It indicates that there has not been a "Fill" command after one or more trays have been emptied for a cleaning operation. The following screen is indicated : Proceed as follows : ‘* Ensure that the corresponding manual drain valves are closed. * Ensure that "Fill trays ? (to end maintenance)" is selected and then depress the OK-key in order to initiate the filing operation of the empty tray(s). * WARNING : Incorrect plate input Remove plate from feed-in section ‘The printing plate has not been inserted correctly. The warning will be cleared by pulling the printing plate out of the processor. van. ‘97 2.59.00 * WARNING : Processor is still busy Wait for OFF state This warning is indicated if there is still a printing plate inside the processor when the processor should enter an inactive period (pre~ Programmed, by using the “on/off'-key or when ‘entering the "Maintenance" screen). The warning will be cleared automatically when the present processing operation is terminated. If the warning is indicated, itis stil possible to insert a following printing plate as long as the trailing edge of the previous plate has not left the processor. © WARNING : Rewash flap still open Close the rewash flap The rewash flap is not closed (correctly) when trying to use the feed-in section. The warning will be cleared automatically when the rewash flap is closed (correctly). © WARNING No rewash allowed now When trying to use the rewash section, the processor is still carrying out a preceding processing operation. The warning will be cleared when the running processing operation is terminated. AGFALITHOSTAR LP82 2 Instruction Manual 2.60.00 Jan. ‘97 ® WARNING : Short or pulled back plate Push emergency stop knob in case of jam ‘This warning is indicated in one of the following cases : ‘* When the processor detects that the length of the printing plate is less than 370 mm ‘+ When a printing plate has been pulled back alter the initiation of the feed-in operation If the printing plate jams inside the processor, carry out an emergency stop (refer to § 3.5.2). If no printing plate jam has occurred, the warning will be cleared at the end of the processing operation (in case of a too short printing plate) or when a new printing plate Is \serted (after a printing plate has been pulled back). ° WARNING : There is still a printing plate in the processor This warning is indicated if a printing plate is still detected inside the processor after the Processor has stopped its operation. The warning can be cleared by removing the printing plate and then depressing the OK-key. © WARNING : Close developer valve (Filling developer took too long) The processor asks to check if the two developer drain valves have been closed correctly as it takes very long to fill the developer tray. The processor will immediately stop the filing operation of the developer tray, ‘The following screen is indicated : eloper valve ‘Zook too long) Proceed as follows : * Correctly close the developer drain valve(s). © Ensure that valve closed 2" is selected and then depress the OK-key in order to continue the filling operation. AGFA &LITHOSTAR LP82 Instruction Manual 2 © WARNING : Close wash water valve (Filling wash water took too Jong) ‘The processor asks to check if the two wash water drain valves have been closed correctly as it takes very long to fill the wash tray. The processor will immediately stop the fing operation of the wash tray. ‘The following screen is indicated : Menu pvsive c1osea 2 WARWING + Close wash water valve wash Water took too long) Proceed as follows : ‘* Correctly close the wash water drain valve(s). © Ensure that ‘Valve closed and then depress the OK-key continue the Jan. ‘97 2.61.00 © WARNING : Close finisher valve (Filling finisher took too long) The processor asks to check if the two rinsing solution drain valves and the two finisher drain valves have been closed correctly as it takes very long to fil the rinsing and finisher trays. The processor will immediately stop the fling operation of the rinsing and finisher trays. ‘The following screen is indicated : mene foElose finisher valve (filling finisher rook too long) Proceed as follows : * Correctly close the rinsing solution and finisher drain valve(s). * Ensure that ‘Valve closed 2" is selected and then depress the OK-key in order to continue the filling operation. AGFA}LITHOSTAR LP82 2 Instruction Manual 2.62.00 Jan. '97 © WARNING : Developer in tray is too old Drain it-by using the valve This warning is indicated when the processor enters the active stale after it has been inactive for more than 72 hours : the developer should be replaced. The warning is also indicated in case of an ‘empty developer container when a maximal replenishment of 5 | of developer is required. The following screen is indicated : ETT Mens Has the ¢: WARNING y already pe drained 2 Developer in tray is too old Drain it by using the valve lien ready, press OR Proceed as follows : * Open the developer drain valve and wait until all the developer has been drained. * If necessary, remove the sludge from the developer tray and then clean the tray. * Ensure that the developer drain valve is correctly closed, * Ensure that Has the tray already be drained 2 is selected and then depress the OK-key in order to start the developer filing operation, WARNING : Maintenance is recommended Do it now or press "OK" ‘This warning Is indicated when the processor assumes that a maintenance operation should be carried out Depress the OK-key and then carry out a maintenance operation. If the OK-key is depressed and no maintenance operation is cartied out, the message will again be indicated alter a short time-period. WARNING : Left cam motor consumes too much current WARNING : Right cam motor consumes too much current ‘These warnings are indicated in case of a problem at the left and right roller cams. Check if, at the corresponding side, there is no obstruction in the raising and lowering mechanism of the rollers. If the problem persists, call the Agfa service technician. AGFA &LITHOSTAR LP82 Instruction Manual 2 © WARNING : Skewed plate in bridge WARNING : Bridge cover is open Close the cover These two warnings can only be indicated if the processor is on-line with an imager with the optional on-line bridge AGFA LITHOSTAR OLBs2. For more information, refer to the appropriate operating instructions. * WARNING : Imager requests processing but processor is off This warning can only be indicated if the processor is on-line with an imager (with or without the optional on-line bridge AGFA LITHOSTAR OLB82), ‘The warning is indicated if the imager requests a processing operation when the processor is in the OFF-mode. The warning will be cleared automatically when the processor enters the READY-mode, Nov. ‘98 2.63.00 ‘* WARNING : Stacker trolley not in place Re-install the trolley WARNING : Stacker lift blocked Remove any jammed plates WARNING ; Stacker lift current too high Remove any janmed plates WARNING ; Stacker transport problem Remove any jammed plates WARNING : Stacker lift not fully down Remove any jammed plates These five warnings can only be indicated if the optional stacker AGFA LITHOSTAR LS82 has been installed. For more information, refer to the appropriate ‘operating instructions. AGFALITHOSTAR LP82 2 Instruction Manual 2.64.00 Jan. ‘97 © WARNING : NON FATAL ERROR 0xx ‘The processor detects that the temperature in one of its sections is not correct : optimum. processing cannot be guaranteed any more. As a result, the WAIT-mode will be entered in ‘order to allow the processor to correct the faulty temperature. Take into account that a 100 low temperature can ‘occur when the processor is used intensively at a low ambient temperature and that a too high femperature can occur by @ to0 high ambient temperature. When the temperature has been corrected, the processor will be able to continue its operation the warning will disappear. If the processor does not succeed to obtain a correct temperature, the warning will not be cleared and the processor will remain in the WAIT-mode. Wf th problem is caused by an overtemperature, it is possible that the processor changes to a protective state (reler to “8.2. An overtemperature is detected in one of the trays of the processor’). The following "non fatal" errorcodes can be indicated Temp. Linits developer exceaded 2 Developer heating failure Developer cooling failure : Temp, limits wash water exceeded + Wash water heating fatiure Tenp. Linits rinse exceeded 2 Rinsing solution heating failure Tonp. limite finisher exceeded Finisher heating failure 2 Temp, limite drier exceeded 1 Drier heating failure 2 Wash water cooling failure Errors applying to the optional on-line bridge AGFA LITHOSTAR OLB82 or to the optional stacker AGFA LITHOSTAR LS82 are also considered as ‘non fatal errors* ‘o3¢" : Bridge board not found 03s" : Stacker 1/0 board not found ‘ose? : stacker motor board not found ‘oes" : Bridge : motor speed problems “oes” : stacker : 1iftmotor problem AGFA &LITHOSTAR LP82 Instruction Manual 2 8.2. An overtemperature is detected In one of the trays of the processor If the temperature of one of the solutions of the processor exceeds the maximum allowed value for a ‘non fatal error’ warning, the processor changes to a protective state. In such a case, an appropriate message will be indicated together with the order to turn off the main switch of the processor and to call the Agia service technician. The following overtemperature messages are Possiole : * Overtemperature in developer tray The temperature of the developer exceeds the maximum allowed value for the “non fatal error’ 020. * Overtemperature in wash tray ‘The temperature of the wash water exceeds the maximum allowed value for the “non fatal error’ 024, * Overtemperature in rinse tray ‘The temperature of the rinsing solution exceeds the maximum allowed value for the “non fatal error* 027. © Overtemperature in finisher tray ‘The temperature of the finisher exceeds the maximum allowed value for the *non fatal error’ 029. Jan. ‘97 2.65.00 AGFA}LITHOSTAR LP82 2 Instruction Manual 2.66.00 van. ‘97 8.3. Other messages * A non-specified printing plate jam has occurred : Open the rollers Chose th follers ‘The printing plate has not reached the exit table within a pre-determined time-period or the printing plate is too short. Remove the printing plate (if necessary, open the rollers) and then continue by using the different possibilities offered by the screen. © The ‘rewash start/stop" switch has been depressed : Ope. Close the rollers Refer to *3.6.4. Rewash system’. ‘* Emergency stop or open upper covers : ST NEY rollers Close the rollers (continue > unlock energens ros eASe Refer to “3.5.2. Emergency stop" * A printing plate jam has occurred in the rewash section : continue Open the rollers Clore the rollers ‘Remove the printing plate (if necessary, open the rollers) and then continue by using the different possibilties offered by the screen, * A too long printing plate is detected : Spon the. rollers Clone the rollers Remove the printing plate (if necessary, open the rollers) and then continue by using the different possibilities offered by the screen, * There is @ problem at the right roller cams : Fe RE SUE SIGHD COE Open the roilers Close the rollers Using the A- and V-keys, make the appropriate selection and then depress the OK-key. I the problem cannot be solved by the processor, a fatal error will be indicated. AGFALITHOSTAR LP82 Instruction Manual 2 ‘* There is a problem at the left roller cams : Jan. ‘97 2.67.00 * A fatal error has occurred : ERROR. CODE cALL SERVICE iZonove plate Using the A- and ¥-keys, make the appropriate selection and then depress the OK-key. If the problem cannot be solved by the processor, a fatal eror will be indicated. ‘* A printing plate jam has occurred in the optional on-line bridge AGFA LITHOSTAR OLB82 : peontanse Open the rollers Cote the rollers For more information, refer to the appropriate operating instructions, fei aaas e900 05-05 Take note of the code, turn off the processor by using the main switch (walt approx. 5 sec in order to allow the rollers to open) and then cal the Agia service technician, AGFALITHOSTAR LP82 2 Instruction Manual 2.68.00 Jan. ‘97 8.4, Power problems Problem Cause Solution No power in the processor © The main switch is not turned on Tum on the main switch © One or more of the fuses. ---> Call the Agfa service have blown technician’ No power supply towards © There is a problem at the ---> Check if the electrical box the processor electrical box operates correctly ‘* There is a problem in the Check the cables connecting cables connecting the processor to the electrical box + Nomains supply => Check if the mains supply has the correct voltage 8.5. Problems when inserting a printing plate Problem Cause Solution ‘The printing plate is not ---> © The printing plate has not ---> Correctly position the taken up at the feed-in been pushed against the Printing plate against the section feed-in rollers rollers © The feed-in rollers are not ---> Correct the position of the Positioned correctly rollers The printing plate is not - * The printing plate has not ---> Correctly position the taken up at the rewash been pushed against the printing plate against the section wash section entrance rollers rollers * The wash section ---> Correct the position of the entrance rollers are not rollers positioned correctly AGFALITHOSTAR Lps2 Instruction Manual 2 Nov. ‘98 2.69.00 8.6. Other problems Problem Cause Solution The display is unreadable —---> The display contrast is not ---> Adjust the display contrast correct (refer to § 3.4 or § 5.4) No rinsing water available at ---> The manual valve at he ==> Open the valve the hose with water tap right side behind the front legs assembly is not open 8.7. Trouble-shooting matrix The following page represents a trouble-shooting matrix which can be used to determine the possible Causes and solutions for some of the problems which can occur when using the AGFA LITHOSTAR system. The numbers in the matrix indicate the probability rate : "5" : Most probable "1": Least probable AGFALITHOSTAR LP8&2 2 Instruction Manual 2.70.00 van. ‘97 AGFALITHOSTAR LP82 Instruction Manual 2 Edition Nov. '98 2.71.00 Edition 4th edition of the Instruction Manual This edition consists of the following pages : Page ni Date | {Page nr. Date _|[Page nr. Date 2.4.00 van.'37 || 229.00 Nov. ‘98. || 257.00 2.2.00 Nov. 's8 || 230.00 Jan.'97 || 2.58.00 23.00 ven.'97 |} 231.00 Jan.'97 || 2.59.00 2.4.00 Nov.'98 || 232.00 Jan.'97_ || 2.60,00 25.00 Jan.’37 || 2.33.00 Jan.'97 |} 281.00 2.6.00 Nov. "98 |] 23400 Jen.'97 |] 2.62.00 2.7.00 Jen.'37_ || 235.00 van.'97 |} 2.83.00 2.8.00 van.'97 |] 236.00 Jan.'s7 || 2.64.00 29.00 van.'97 || 237.00 Jan.97 |} 2.65.00 2.10.00 van.'97 |} 2:98.00 van.'97_ |} 2.68.00 2.11.00 Jan.'97 |} 2:39.00 Jan97 || 2.67.00 2.12.00 Jon.'97 || 2.40.00 van.'s7 || 2.68.00 2.13.00 Jan.'97_ || 2.41.00 van.'97 || 2.69.00 2.14.00 Nov. 98 |] 2.42.00 ven.'97 |} 270.00 2.15.00 Jan.’97 || 243.00 van.'97 || TS-matrix | Nov. ‘98 2.16.00 Jan.’97 || 2.44.00 van.'97 || 2.71.00 Nov. 98 2.17.00 van.'97 || 2.45.00 Jen. ‘97 2.18.00 dan.'97_ || 2.46.00 Jan.'97 2.19.00 van.'97 || 2.47.00 Nov. ‘98 220.00 van.'97 |} 2.48.00 Jan. '37 2.21.00 Nov.'ea |} 2.49.00 222.00 Jan.97 || 2.50.00 2.23.00 van.'97 |] 251.00 224.00 Nov.'98 |} 252.00 2.25.00 Nov.'s8 |} 253.00 2.28.00 Jan.97 || 2.5400 2.27.00 van.'97_ || 2.85.00 2.28.00 van.'97_|} 2.56.00 AGFA -Solution ‘Check and/or adjust the copyboard vacuum, Check the darkroom light with a half covered 0.10 pre-exposed sta IH of developer tray is < 12, refllthe tray every 20 sqm Drain and clean the corresponding tray(s) Wipe off the condensation in the diffusion section and make anew Drain all the chemicals, clean thoroughly and then refll Check the position of the rollers or install them if they are missing ‘Check the position of the roliers or install them if they are missing Check the position of the rollers or install them ff they are missing Check the position of the rollers or instal them if they are missing ‘Check the position of the rollers or install them if they are missing Check the position of the ralers or install them if they are missing Check the position of the rollers or install them if they are missing ‘Check the position of the rallers or install them if they are missing Remove the plate, drain the developer and clean the tray Remove the plate Decrease exposure time using a 0.10 step wedge (half reproduction of step 4) wedge and adjustif necessary ‘Check the darkroom leak with a half covered 0.10 pre-exposed step wedge and adjustif necessary Clean the corresponding circulation circuits (Software-maintenance function) Remove the spray nozzles assembly and then rinse the assembly inorder to lean the spray nozzles without removing them Process an old plate several times to clean the rollers. Ifineuficient, clean and rinss wash section and rolers Clean the rollers with a wet rag. I necessary, remove thom and clean them with warm water Tieat the plate 1 min with finisher on the press. If necessary, make a new plate Rewash the plate (if the plate is not bended yet). Ifnecessary, make a new plate late (the ambient temperature should exceed 16°O) AGFA LITHOSTAR Trouble-shooting matrix qn AGFA Novg938