AUTOLITH TP

Installation 5

November 2000 Page 1

1 About installation ................................................................................................... 2

2 General instructions............................................................................................... 3

3 Transporting the Processor to the installation site............................................. 4

3.1 What is in this chapter ..................................................................................... 4
3.2 Deliverable items ............................................................................................. 5
3.3 About the packing case ................................................................................... 6
3.4 Deciding on how to transport the Processor ................................................... 7
3.5 Unpacking the Processor ................................................................................ 8
3.6 Lifting the Processor off the wooden pallet ..................................................... 9

4 Setting up the Processor ..................................................................................... 11

4.1 What is in this chapter ................................................................................... 11

4.2 Levelling......................................................................................................... 12
4.3 Requirements for power supply..................................................................... 13
4.4 Requirements for water supply connection ................................................... 15
4.5 Assembling the feed table ............................................................................. 16
4.6 Assembling the delivery table........................................................................ 17
4.7 Moving the control panel ............................................................................... 18
4.8 Mounting the probe assemblies..................................................................... 20
4.9 Fitting developer filters .................................................................................. 21
4.10 Preparing the tank sections prior to filling with chemicals ............................ 22

5 Chiller unit ……………………………………………………………………………..23

5.1 What is in this chapter ................................................................................... 23

5.2 General description ....................................................................................... 24
5.3 Installing the chiller unit ................................................................................. 25

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1 About installation
Introduction This section contains the servicing instructions for the
AUTOLITH TP.

For whom is this manual
intended
Overviews and references
If you need more information
These Servicing Instructions are intended for:
• Agfa service technicians
At the beginning of each chapter, you will find:
• an overview of the information in that chapter;
• references to other parts of the service manual.
If you are not able to solve a problem yourself, or if you need
more information, please feel free to contact your local Agfa
service centre.

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November 2000 Page 3

2 General instructions
Introduction This section contains the general information about the
installation procedures for the AUTOLITH TP.
READ THIS SECTION CAREFULLY BEFORE CARRYING OUT
ANY INSTALLATION PROCEDURES ON THE PROCESSOR

WEAR SAFETY GLOVES, GLASSES AND SHOES WHEN

REMOVING THE EQUIPMENT FROM THE PACKING CASE.
BEWARE OF SHARP EDGES, SPLINTERS, PINCH POINTS
AND EXPOSED NAILS AND STAPLES WHEN REMOVING
THE CHILLER UNIT FROM THE PACKING CASE.
WHEN LIFTING AND MOVING THE PROCESSOR, MAKE
SURE THAT ONLY ESSENTIAL PERSONNEL ARE IN THE
AREA.

Always use the approved tools, and size of tools for the
maintenance task to be carried out.

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3 Transporting the Processor to the installation site

3.1 What is in this chapter

Introduction This chapter tells you about the unpacking of the Processor and
its optional parts.

Overview This chapter covers the following topics:

Topic See
What is in this chapter Page 4
Deliverable items Page 5
About the packing case Page 6
Deciding on how to transport the Page 7
Processor
Unpacking the Processor Page 8
Lifting the Processor off the wooden Page 9
pallet

For more information, refer also to the Section 3 - Pre-

installation Manual.

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Installation 5

April 20012000
November Page 5

3.2 Deliverable items

Main components The following components are delivered and are contained with
the main packing case:
• AUTOLITH TP85/105
• drip tray
• installation kit
• customer service kit
• interface kit
• chiller unit
• customer options
Optional components Depending on the customer requirements, the following
components can be delivered and are contained with the main
packing case:
• feed table
• delivery table

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3.3 About the packing case

Packaging The AUTOLITH TP and its components are packed in a plywood

case.
Before transport the Processor was mounted onto a pallet base,
which forms part of the packaging case.
The chiller unit, optional tables and spare parts are packed
underneath the AUTOLITH TP. All other components are
wrapped in BE-foam plastic.
Dimensions

Figure 3.3 Packing case

The packaging case has the following dimensions (l x w x h)
TP105; 2140 mm x 1355 mm x 1460 mm

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Installation 5

November 2000 Page 7

3.4 Deciding on how to transport the Processor

Processor case The AUTOLITH TP is screwed onto a wooden pallet for safe
handling and cushioned with BE-foam and polystyrene plastic. A
plywood packing case covers the entire unit and is secured with
case screws.
Check the Processor packing case carefully before unpacking
and report any damage to the complaints officer of the transport
company.

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3.5 Unpacking the Processor

Introduction Since the Processor is securely bolted to the pallet base, the
packing case must first be disassembled.

Tools required Phillips screwdriver, socket set, large adjustable spanner, safety
knife

WEAR SAFETY GLOVES, GLASSES AND SHOES WHEN

REMOVING THE EQUIPMENT FROM THE PACKING CASE.
BEWARE OF SHARP EDGES, SPLINTERS, PINCH POINTS
AND EXPOSED NAILS AND STAPLES WHEN REMOVING
THE CHILLER UNIT FROM THE PACKING CASE.
How to remove the packing To remove the plywood packing case covering the Processor,
case proceed as follows:

Step Action
Remove the Phillips head screws securing the top
1
cover to the front and side panels.
2 Carefully remove the top cover.
Remove the screws that secure the three cross-
3 braces, taking care not to drop the screws inside
the case, once removed.
Taking note of any specific instructions on the
outside of the packing case, remove the screws
4
securing the side panels to the pallet, and to the
adjacent panels.
5 Carefully remove the packing case side panels.
6 Remove the sealed bag that covers the Processor.
Lift off the plastic drip tray from the top of the
7
Processor, and remove the two wooden supports.
If using a safety knife, do not damage the paintwork when
removing the cling-film.

Remove the cling-film that protects the base unit of

the Processor. This will give access to all the
8
components (bottles, boxes, etc.) that are packed
with the Processor.
Carefully slide out all components from under the
9
Processor.
Dispose of the packing case components in an
10
environmentally friendly manner.

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November 2000 Page 9

3.6 Lifting the Processor off the wooden pallet

Introduction You need a forklift to lift the AUTOLITH TP off the pallet.

Figure 3.6 Position of forks on Processor

How to lift the Processor To lift the Processor from the wooden pallet, proceed as follows:
Step Action
1 Make sure all loose items that were packed in the
packing case are removed prior to lifting the
Processor.
2 Make sure that clear access is available for the
forks of the forklift (no hanging cables or hoses,
etc.)
3 Slide the forks of the forklift under the Processor
from front to back. See figure 3.6.
4 Remove the four bolts that secure the Processor on
to the pallet base.
5 Lift the Processor from the pallets base, and
remove the two cross braces from the base frame
by removing the four bolts.
6 Move the Processor to the correct location.

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Step Action
7 While the Processor is still raised, adjust the legs of
the Processor so that the Processor will be at the
correct height when placed next to the adjacent
equipment.
8 Put the Processor down on the drip tray.
9 Dispose of the packing case components in an
environmentally friendly manner.

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November 2000 Page 11

4 Setting up the Processor

4.1 What is in this chapter

Introduction This chapter tells you all about the siting of the Processor and its
optional components.

Overview This chapter covers the following topics:

Topic See
What is in this chapter Page 11
Levelling Page 12
Requirements for power supply Page 13
Requirements for water supply Page 15
connection
Assembling the feed table Page 16
Assembling the delivery table Page 17
Moving the control panel Page 18
Mounting the probe assemblies Page 20
Fitting developer filters Page 21
Preparing the tank sections prior to Page 22
filling with chemicals

For more information, refer also to the Section 3 - Pre-

installation Manual.

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November 2000

4.2 Levelling

Introduction It is essential that the AUTOLITH TP is levelled properly to

ensure optimum processing conditions.

How to level the Processor To level the Processor, proceed as follows:

Step Action
1 Adjust the four feet of the Processor until the
Processor is stable on the floor.
2 Final adjustment is to be carried out after the
developer section is full with developer, see
Instruction Manual.
3 If fitted on-line, a plate should be output from the
engine unit to confirm smooth entry intro the
Processor.
4 Any height adjustment should take place at this
time.

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November 2000 Page 13

4.3 Requirements for power supply

Introduction The customer is responsible for ensuring that a qualified electrician is in

Supplies
Cable resistance
Cable protection
attendance to connect the Processor to the services.
Provide for the supplies required to connect the Processor to the mains:
boxes, cables, tubing, fuses, etc.
These supplies are NOT delivered with the Processor.
Take the following into account when deciding what type of cable you are
going to use:
1) chemical resistance: chemicals may leak onto cables
2) mechanical resistance: the operator may step onto cables
Provide for additional cable protection, e.g. cable covers, when cables
are exposed to heavier transport such as fork-lifts.

Connecting cables and fuses The cable connecting the Processor to the mains must be a flexible,
round cable with an outside diameter between 14 and 18 mm (1/2” and
7/10”).
American guideline for Electrical installation must conform to the National Electrical Code (NEC).
selecting cables and fuses Please also consult local regulations and guidelines, if applicable
The type of connecting cable as well as the type of fuses must be
determined in accordance with the NEC (section 310.15). The table
below lists:
• minimum required cross section for conductors (American Wire
Gauge)
• maximum rating for the residual current circuit breaker (Fuse)
Cable
Supply Voltage Current Fuse
(AWG)
240V
1~ (+6% - 16A 12 20 A
10%)
208V
3~ (+6% - 12A 14 15 A
10%)

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European guidelines for Electrical installation must conform to local regulations and guidelines.
selecting cables and fuses
The minimum required cross section for conductors must be determined
in accordance with EN60204-1. Please also consult National guidelines if
applicable.
Cable
Supply Voltage Current Fuse
(AWG)
230V
1N~ 16A 2.5mm² 20 A
(±10%)
230V
3~ 12A 1.5mm² 16A
(±10%)
400V
3N~ 9A 1.0mm² 10A
(±10%)

Earthing The AUTOLITH TP (85 and 105) are Class 1 equipment. Therefore, the
Processor must be connected to earth, to avoid electrical shocks

High Leakage Current. Earth connection essential before connecting

supply.
Courant de Fuite Elevé. Raccordement à la terre indispensable avant le
raccordement au réseau.
Hoher Ableitstrom. Vcr Inbetriebnahme Erdungsverbindung herstellen.

Connecting the power supply
The Processor should be connected to the electrical supply using suitable
cables for the voltages and currents listed, conduit or flexible conduit is
recommended. If a multicore cable is used, it must be routed clear of
traffic and should not present a trip hazard.
Remove the mains isolator panel cover, situated on the left hand side of
the Processor, by removing the six fixing screws. Feed the supply cable
through the hole in the back of the enclosure, a cable gland is supplied if
required.
Terminate the supply cables at the isolator switch QS1 and connect for
the supply configuration of the country of use. Consult Electrical
Schematic A/LITH TP No. E952100 for information.
Locate the Prebox Control Enclosure to the right of the mains isolator,
remove the fixing screw and pull the unit out on its slides. Remove the
control box lid (4 screws) and locate terminal block XK1. Check that the
pin configuration is correct for the supply voltage to be used. Consult
Electrical Schematic A/LITH TP No. E952100 for information.
Ensure all cables are tightened and that the pins in XK1 are secure.
Replace all covers and push the control box back into place.

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Installation 5

November 2000 Page 15

4.4 Requirements for water supply connection

Mains water supply The customer is responsible for ensuring that a qualified
plumber (and electrician, if necessary) is in attendance to
connect the Processor to the services.
The plumbing installation should conform to the requirements of
the local Water Authority.
The connection to the machine is 15mm OD (½” OD – US )
copper tube.
A stop valve should be fitted in the supply in a convenient
position close to the machine such that the water can easily be
turned off when the machine is not in use.
Note: The use of flexible hose to connect the machine is not
recommended due to the inherent risk of puncturing and water
damage, etc.
If possible the supply should be taken from a source that is
unaffected by pressure drops due to the use of other outlets.
The machine is designed to operate with a maximum pressure of
7.0 bar (90 lbsf/in). If the supply pressure exceeds this limit a
pressure reducing valve must be fitted.
A clean supply of water is required, In some areas it may be
necessary to install a water filter.
The mains water connection is situated at the rear of the
Processor behind the rear base cover. Care should be taken
with the siting of the pipework to avoid trip hazards and damage.
Water drain The standard waste connection to the machine is OSMA 42mm
OD (1½" OD – USA).
If connecting into an existing waste drainage system it is
advisable to fit a bottle trap.
Ensure that there is sufficient fall in the pipework to discourage
any build up of solids and to prevent flow back to the machine.
The main drain connection is situated at the rear of the
Processor behind the rear base cover. Care should be taken
with the siting of the pipework to avoid trip hazards and damage.
It is recommended that (if possible) the Processor be situated
close to a large sink in order to facilitate the cleaning operations.

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4.5 Assembling the feed table

Introduction The feed table is a single assembly, with six attachment screws
and washers.

Figure 4.5 Assembling the feed table

How to assemble the feed To assemble the feed table, proceed as follows:
table

Step Action
1 Fit the feed table onto the Processor and secure
using six screws and washers.

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Installation 5

November 2000 Page 17

4.6 Assembling the delivery table

Introduction The delivery table consists of the following components;

• the delivery table, with four attachment screws and washers
• two support legs

Figure 4.6 Assembling the delivery table

How to assemble the To assemble the delivery table, proceed as follows:
delivery table

Step Action
1 Fit the support legs into the receptacles at the rear
of the Processor. Secure using grub screws.
2 Fit the delivery table onto the Processor and the
support legs. Secure on to the Processor using four
screws and washers. Secure on the support legs
using two grub screws.

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4.7 Moving the control panel

Introduction Depending on the requirements of the customer, it may be

necessary to move the control panel from one side to the other.

Figure 4.7 Control panel assembly

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November 2000 Page 19

The following procedure assumes that the control panel is being

moved from the right side to the left side. The procedure for
moving the control panel from the left side to the right side is
similar.
How to move the control To move the control panel, proceed as follows:
panel
Step Action
1 Switch off the Processor at the main isolator and
disconnect from power supply at source.
2 Open both lids.
3 Remove left and right upper covers.
4 Disconnect connectors P1 and P6 from the control
panel.
5 Remove two screws attaching the P-clips to the
blanking plate. Be careful not to lose the screws.
6 Remove the screws attaching the control panel
assembly to the frame and remove the control
panel assembly and blanking plate.
7 Remove the two screws securing the emergency
stop button to the blank pod on the left side.
Remove the two screws securing the blank pod to
the left side frame and remove the blank pod.
8 Fit the blank pod to the right side frame.
9 Fit the control panel assembly to the left side frame
and fit the emergency stop button to the control
panel assembly.
10 Remove the Processors lower front panel.
11 Pass the connectors P6 & P1 and cables through
the hole in the side frame. Cut the cable ties holding
the cables to the main wiring loom, which runs
under the front of the Processor, to free the cable.
Use cable ties to attach the main loom back to the
front panel.
12 Pass the connectors and cable through the hole
between the side frame and tank at the front, run
the cable to the control pod. Secure the cables to
the base of the pod by the two clips and plug in the
connectors P6 and P1 to the side of the control pod.
13 Fit the front and upper side panels.

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4.8 Mounting the probe assemblies

Introduction Once all components have been assembled, the probe

assemblies must be placed in the corresponding bottles.

Figure 4.8 Probe assemblies

How to assemble probe To assemble the probe assemblies, proceed as follows:
assemblies

Step Action
1 Remove the cap from the bottle
2 Place the probe assemblies into the opening of the
corresponding bottles.

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4.9 Fitting developer filters

Fitting developer filters Fit the filter elements into the filter bowls.
Ensure that the filters are the correct size - 75 micron.

Ensure that the filter bowl ‘O’ rings are in place and seated correctly.
Screw both filter bowls onto the filter housing, situated on the right hand
side of the Processor.
Make sure that both isolation valves on top of the housings are in the open
position, ie. small dot on the handle facing out.
Ensure that both filter bowl drain valves are closed.

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November

4.10 Preparing the tank sections prior to filling with chemicals

Introduction We recommend you to check all tank components, i.e. entrance,

squeegee and scrub rollers as well as plate guides, properly
before running the Processor. This includes the developer and
water sections, and the finisher meniscus roller.
Make sure that the rubber surface of a roller does not rest on
any edge and avoid contact between gears and the rubber
surfaces while placing rolls on top of each other.
How to arrange tank To arrange the tank components before filling with chemical,
components proceed as follows:

Step Action
1 Carefully unpack all components one by one.
2 Remove any cable ties that have secured loose
items during transit, using side cutters.
Refer to "Section 9 Assembly of Section Components" in the
Section 2 - Instruction Manual for detailed information on how
to install the rollers.

Make sure all drain valves / taps are closed prior to attempting
to run the Processor or filling with chemistry.

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Installation 5

April 20012000
November Page 23

5 Chiller unit

5.1 What is in this chapter

Introduction This chapter tells you all about the installing the chiller unit.
Although an optional item, it is essential that a chiller unit is fitted
to maintain the correct temperature settings of the developer.

Overview This chapter covers the following topics:

Topic See
What is in this chapter Page 23
General description Page 24
Installing the chiller unit Page 25

For more information, refer also to the Section 3 - Pre-

installation Manual.

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5.2 General description

Introduction The chiller unit provides chilled water to the Processor, to

remove excess heat from the developer.

THE CHILLER UNIT CONTAINS GAS UNDER PRESSURE,

CARE SHOULD BE TAKEN DURING SERVICING TO
PREVENT DAMAGE TO ANY METAL PIPEWORK.
THE CHILLER UNIT CONTAINS GAS SUVA HFC-134A. A
SAFETY DATA SHEET IS AVAILABLE ON REQUEST.

SWITCH OFF AND DISCONNECT THE POWER SUPPLY

BEFORE CARRYING OUT ANY SERVICING OF THE CHILLER
UNIT.
NO ATTEMPT SHOULD BE MADE TO SERVICE OR REPAIR
THE CHILLER UNIT BY UNTRAINED PERSONNEL.
UNAUTHORISED REPAIRS OR MODIFICATIONS TO THE
EQUIPMENT MAY IMPAIR THE FUNCTION AND/OR SAFETY
AND AFFECT EQUIPMENT LIFE.

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5.3 Installing the chiller unit

How to install the chiller unit To install the chiller unit, proceed as follows:

Figure 5.3 Chiller unit

WEAR SAFETY GLOVES, GLASSES AND SHOES WHEN
REMOVING THE CHILLER UNIT FROM THE PACKING CASE.
BEWARE OF SHARP EDGES, SPLINTERS, PINCH POINTS
AND EXPOSED NAILS AND STAPLES WHEN REMOVING
THE CHILLER UNIT FROM THE PACKING CASE.
Step Action
1 Position the chiller unit under the Processor, with
the hoses towards the left side of the Processor.
Make sure there is free airflow around the unit, and
access for filling and cleaning the unit.
2 Connect the chiller unit to the electrical supply (1).
The power supply cable of the chiller unit connects
into connector X9, located under the flat surface of
the Processor, on the left side.
3 Connect the chiller unit pump to the electrical
supply (1). The power supply cable of the chiller
unit connects into connector X4, located under the
flat surface of the Processor, on the left side.

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Step Action
4 Check that the cables between the chiller unit and
the Processor will not subject to mechanical
damage.
5 Fill the chiller water tanks through the filler hole (3)
on top of the chiller unit. Use a funnel and clean
water. Continue to fill until water comes out of the
overflow tube.
The operation of the chiller unit is fully automatic, and any
cooling demand is controlled by the Processor.

Refer to "Section 9 Assembly of Section Components" in the

Section 2 - Instruction Manual for detailed information on how
to install the rollers.

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Installation 5

April 20012000
November Page 27

Edition The table below lists all pages in Installation with their edition :

Page Edition Page Edition

1 November 2000 15 November 2000
2 November 2000 16 November 2000
3 November 2000 17 November 2000
4 November 2000 18 November 2000
5 April 2001 19 November 2000
6 November 2000 20 November 2000
7 November 2000 21 November 2000
8 November 2000 22 April 2001
9 November 2000 23 April 2001
10 November 2000 24 November 2000
11 November 2000 25 November 2000
12 April 2001 26 November 2000
13 November 2000 27 April 2001
14 November 2000

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