User’s GuidePlateRunner P24

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Manual NoticeXanté Corporation reserves the right to make changes to this manual and to the equipment described herein without notice. Every effort has been made to ensure that this manual is free of inaccuracies and omissions. However, Xanté Corporation makes no warranty of any kind including, but not limited to, any implied warranties of merchantability and fi tness for a particular purpose with regard to this manual.

Xanté Corporation assumes no responsibility for, or liability for, errors contained in this manual or for incidental, special, or consequential damages arising out of the furnishing of this manual, or the use of this manual in operating the equipment, or in connection with the performance of the equipment when so operated.

CopyrightThis manual is Copyrighted © 2007 by Xanté Corporation. All Rights Reserved. Printed in the USA. This manual may not be copied in whole or in part, nor transferred to any other media or language without the express written permission of Xanté Corporation.

Power Information220/240 V Version:220/240 VAC (198-264 V), 50/60 Hz (47-63 Hz), 3.2 A

Power CordThe power cord is the main disconnect device. It should be plugged into an easily accessible outlet.

For 230 Volt Confi gurationThe power cord to be used with 230 Volt confi guration is minimum type SJT (SVT) 18/3, rated 250 Volts ac, 10 Amps with a maximum length of 15 feet. One terminated in an IEC 320 attachment plug. The other end is terminated as required by the country where it will be installed.

Manufacturer’s Declaration of ConformityThe Product has been designed and manufactured in accordance with the following international standards:I, the undersigned, hereby declare that the equipment specifi ed above conforms to the above Directives and Standards

Robert C RossXanté Corporation Founder and CEO

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ContentsChapter 1: Introduction and Installation 5Installation Requirements 5Turning the PlateRunner On 5Start Up 7

Chapter 2: Control Panel 7Accessing the Controls 8Setting the Plate Counter 9Activating the Heaters 9Resetting the System 10Accessing the Functions 10Pre-Heat Parameters 11Setting Pre-Heat Temperature 11Setting Timing 12Developer Parameters 13Setting Developer Temperature 13Setting Developer Replenishment 13Manually Replenishing Developer 14Gum-Dryer Parameters 14Setting Gum Volume 15Setting Gum Dryer Temperature 1Gum Dryer Temperature 1Gum Dryer 5Manually Adding Gum 15Speed Parameters 15Setting Developer Time 16Setting Pre-wash Brush Speed 16

Setting Developer Brush Speed 1Developer Brush Speed 1Developer 6Standby Parameters 17Setting Standby 17Setting Standby Developer Volume 17Setting Standby Developer Timing 18Standby Gum Timing 18Selecting Plate Type 19Standby Plate Type Parameters 19Processing a Plate 20Nominal Operating Values 21

Chapter 3: Setting Brush Pressure 21Setting the Pre-wash Brush 22Setting the Developer Brush 22

Chapter 4: Setting Gum Quantity 24

Chapter 5: Basic Maintenance 25Maintenance 26Daily Maintenance 26Weekly Maintenance 27Monthly Maintenance 28Periodic Maintenance 28Cleaning the Rollers 30Removing the Brushes 30

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Replacing the Filter 30Changing Developer 31Replacing a Fuse 32

Chapter 6: Troubleshooting 34PlateRunner Specifi cations 34“Why isn’t the processor brush turning?” 35“Why is the developer pH too low?” 35“Why is the developer level falling below the drain slots?”

35“Why are the plates underdeveloped?” 35“Why is there no image?” 36“Why is there emulsion on the unimaged areas?” 36“Why do the dots appear scrubbed?” 36“Why aren’t the plates cleaned in the pre-wash section?”

36“Why isn’t the gum drying after processing?” 36“Why isn’t the gum evenly applied?” 36“Why does the wastewater level rise in the tanks?” 36“Why isn’t my plate coming out?” 36“Why aren’t the plates going through in a straight line?” 37“Why doesn’t “Ready” replace “Waiting for Temp” on the Status Display?” 37“Why are the plates light struck?” 37“Why can’t I get the developer residue off?” 37

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Chapter 1Introduction and InstallationInstallation Requirements

1. Electrical Requirements: Connect the processor to the main power line using a fl ame-resistant cable with a core not lower than 2.5mm, and interpose an interlocked outlet for 230 volts.

2. Plumbing Requirements: Water supply with a fl ow rate of 13.2 liters (3.5 gallons)/minute or more at 20 PSI.

3. Draining Requirements: Drain located within 1.2 meters (4 feet) and no more than 15.2 centimeters (6 inches) from the fl oor or at least 61 centimeters (24 inches) below the processor.

4. Environmental Requirements: Operating temperature between 18 - 23 degrees C or 65 - 78 degrees F with safe and proper lighting.

5. Chemical Requirements: Xante Product: Part Number:

HarmonyTM Violet CTP Developer 200-300047 HarmonyTM Violet CTP Replenisher 200-300048 HarmonyTM Litho Processor 200-300049 HarmonyTM Litho CTP Gum 200-300050

Turning the PlateRunner OnWhen fi lling the tank with the recommended developer, use a container, siphon hose, or funnel that allows you to pour the chemicals in the correct tank. Avoid splashing developer on the mechanical and electrical components. Clean up any spilled developer immediately.

Some developing fl uids foam easily, pour them carefully to avoid excessive foaming.

Wear protective glasses and gloves.

1. Check that the Developer Tank Drain Valve is shut off and the handle is horizontal. Then pour 15 liters of developer into the Developer Tank.

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2. Connect the PlateRunner to the electrical service and turn it on (the red power switch pointing to “1”).

3. Raise the Top Cover and set the Main Cover Switch in Service Mode

4. Turn on the water supply.

5. Wait until the processor is Ready.

6. Activate a processing cycle by holding a plate over the Input Detector for fi ve seconds.

7. When a processing cycle starts, wait a few seconds for the water to fl ow out of the spray bars. Observe the direction and strength of the Pre-wash and Rinse spray.

The Pre-wash sprays are directed on the brush.

The Rinse spray is directed onto the front respective roller. The inside top surface of the roller should be wet, but not fl owing over the top of the roller.

Directing it down into the tank will reduce the time that the plate is rinsed, and may cause foaming.

8. Adjust the fl ow rate using the water supply valve on the hose. The jets should be even along the bar and of moderate force. While the water is running, look into the tanks and make sure that they are draining.

9. Look at the Developer Tank and locate the two depressed drain slots located at the top of the tank front wall. These serve to drain excess developer fl uid. For proper operation, an equal amount of developer waste must drain from both the right and left slots.

10. Add developer so that it reaches and trickles through the drain slots.

11. Observing the two drain slots, adjust the right and left pairs of the PlateRunner’s legs until the developer drains equally from each slot. When adjusting the left side, turn both left feet an equal number of turns in the same direction. Similarly, when adjusting the right feet, turn both right feet an equal number of turns.

12. Make sure all the feet are in contact with the fl oor and the processor cannot be rocked.

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13. Verify the drain is free and clear and that no effl uent is escaping.

14. Check that the fi lter housing is fi rmly seated.

15. Check all the fi ttings, tanks, and seals for leaks.

16. Lower the Top Cover.

Start UpThe main power switch is located at the front below the Input Tray. The main switch activates all the sections of the PlateRunner Processor: the feed system, heaters, recirculation pumps, dryer, display, brush, etc. After a few seconds, the Status Window will appear in the display, indicating the status of the different sections of the Processor.

Turn on the water supply.

To verify the temperature is set correctly, attach one temperature strip on the back of the plate temperature strip on the back of the plate temperature strip on the back near each corner , and one temperature strip near the center of the plate. Process it as normal and check the temperature strips afterward to verify it is operating at the correct temperature.

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Status Display

The Status Display shows the temperature of the Preheat Sections (Pre1 and Pre 2), Developer Temperature Section (dev), and the Development Time. The number in the upper left corner shows what plate type the system is set up for.

The value displayed will be close to the set points. If the temperatures are not close enough to the values set, the “Ready” line will be replaced with “Waiting for temp.” Wait for “Ready” to appear.Wait for “Ready” to appear.W

Chapter 2Control Panel

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Description of Control Panel KeysThe four keys below the display are used to set the PlateRunner Functions. These are illustrated and described below.

MENU KEY Opens the main menu. When in the Menu Tree, it brings up the previous menu.

UP KEY Changes item selected on the menu shown by the cursor and increases the selected value. When pressed prior to any other key it brings up the Plate Type menu.

DOWN KEY Changes item selected on the menu shown by the cursor and decreases the selected value. When pressed prior to any other key it selects the Standby Parameters menu.

ENTER KEY Confi rms the parameter or value selected. If pressed before any other key, it opens the Controls Menu.

Using the control keys takes the operator to the various menus where the parameters can be controlled. Thinking of the menu as a horizontal tree extending to the right, the ENTER key steps to the right through the menu options and the MENU key retraces those steps.

In describing the menu options, and how to select and set values, the description is accompanied by an illustration. In each case the starting display is on the left, the action taken is in the middle, and the resulting display in on the right.

Accessing the Controls

Pressing the far right ENTER key accesses the Plate Counter, Heater Control, and System Reset.

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The left panel labeled DISPLAY is the starting menu, the middle panel labeled KEY specifi es which key to press, and the resulting display is on the right.

Setting the Plate Counter

With the cursor pointing to Counter, press the ENTER to bring up the Plate Counter Menu. The number shown is the number of plates processed since the counter was reset. The count can be reset to zero by pressing ENTER.

Activating the Heaters

The heaters can be turned on and off. There are two pre-heat panels, Pre-heat 1 and Pre-heat 2, the Developer Heater, and the Dryer for the gum station. Move the cursor

to On/Off Heaters using DOWN. Select that heater with ENTER.

The cursor before PRE-HEAT shows which heater is active. Pressing the ENTER KEY will toggle that heater ON and OFF.

The DOWN and UP keys move the pointer to the desired heater.

To turn the Developer Heater on, press the DOWN key twice which moves the cursor down two lines to Developer.

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Pressing the ENTER key will now toggle that function on.

A similar sequence will turn the other functions on and off.

Resetting the System

When a plate is placed on the Input Tray, and detected by the Input Detector for more than fi ve seconds, a sequence of events is initiated. The system comes out of standby and starts the operational sequences required to process the plate.

If it is necessary to reset the system before the cycle is completed, the operator may do so from the Control Menu. A reset is only accepted once the plate is past the Pre-heat Section.

Select Reset by moving the cursor to it and press the ENTER key. After Resetting, the Display will briefl y show “Complete”. If the plate is in the Pre-heat Section, and the Reset is not accepted, an Error message will briefl y be displayed.

Accessing the Functions

The four groups of parameters to access and set are found on the Function Menu. They are reached through the PRE-HEAT, DEVELOPER, GUM-DRYER, and SPEED PROGRAMS menus.

To reach them from the Status Display press MENU.

The rest of this section will describe how to access and set the processor parameters.

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Pre-Heat Parameters

Two independent heaters are used to complete the plate exposure by uniformly preheating the imaged plate. The two heaters are independently controlled and their temperature setting are accessed from the Main Menu by placing the pointer on PREHEAT and pressing MENU.

As these are controlling the temperature of the heaters, the values used will be higher than those desired for the plates.

Setting Pre-Heat Temperature

Pressing ENTER when the cursor is at PRE-HEAT accesses the functions Pre-heat 1, Pre-heat 2, and Timing.

Using UP and DOWN, place the pointer on the desired

Pre-heat Panel. Pre-heat 1 is shown as an example, and select with ENTER.

To deliver more heat to the plate, adjust the temperature setting, in Centigrade; using DOWN reduces the heat. Press ENTER to enter the value.

To return to the previous menu, PRE-HEAT, press MENU.

NOTE: Pressing MENU repeatedly will retrace your steps back through the Menu Tree until the Status Display is reached.

A similar process is used to set the temperature for the other heater. A nominal setting for Preheat One is 208 degrees Centigrade (C) and 200 C for Preheat Two. Chemical settings will change based on the chemicals and plates being used.

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Setting Timing

To assure an even temperature along the plate as well as across, the heater panel temperatures are modifi ed as the plate progress through. The temperature profi le is controlled by a few parameters set at the factory.

NOTE: Only adjust these settings when directed to by your service representative.

To access them from the PRE-HEAT Menu, below, scroll the pointer down to Timing and select with ENTER to bring up the Timing Menu.

Although called the Timing Menu, the values use both time and plate length. This assures that as different plate sizes and developing times are used, the heating profi le delivered to the plate will remain constant.

Delay is the delay from when the Input Detector senses the plate until the control algorithm starts to cycle the heaters. The heating cycle operates as the plate is passing through the Pre-heat Section, Active Length. Inactive is how long the heater is off and Active is how long the cycle operates.

The four algorithm windows are shown below. Access each from the Timing Menu by scrolling the cursor (asterisk), using UP and DOWN, and selecting with ENTER.

Again only change these at the direction of your service representative.

The values in each menu are changed using UP and DOWN.

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Use MENU to return to the previous display.

Developer Parameters

To assure optimum processing, the developer temperature is maintained at the manufacturers recommended value. As each plate processed reduces developer strength and removes a small amount of fl uid, the developer is automatically replenished. The amount of developer added each time a plate enters is specifi ed in milliliters.

To access these parameters, set the pointer to DEVELOPER on the Function Menu and select with ENTER.

Setting Developer Temperature

Selecting “Developer Temp.” with ENTER brings up the following display. The desired temperature value is set with UP and DOWN. The plate manufacturer specifi es the exact value set.

The PlateRunner’s Developer Heating System will automatically heat the developer to that temperature.

If the developer temperature is above the desired value due to a hot environment, the optional Chiller may be required. It one of these options has been installed, the temperature will be heated or cooled to maintain the set value.

Setting Developer Replenishment

Returning to the previous menu, set the pointer to Auto Replenish to access the amount of developer that is replenished when a plate enters.

As the amount required depends upon plate size, use UP and DOWN to set the value in milliliters per plate. If you do not know what that number is see the EXAMPLE.

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It is very important that the developing tank remains full during use, and that a small amount runs over the two waste slots and into the waste receptacle. If this does not happen as a series of plates are processed, increase the dose until developing solution consistently trickles over.

EXAMPLE:

The plate manufacture’s replenishment recommendations will likely be in milliliters per square foot (ml/ft2) or square meter of plate (ml/m2). The PlateRunner replenishment rate is set in units of milliliters per plate processed.

To get the number for your plate, your average plate area must be multiplied with the manufacture’s recommended replenishment dosage rate. For example, if your plate area, found by multiplying the plate dimensions, is 0.5 meters, and the recommended dosage rate is 10 milliliters per square meter, you would set the volume to 5 ml in the menu above.

Manually Replenishing Developer

When the developer level is low, it can to be added from the control panel. From the Developer Menu select

Manual Replenish.

Operate the pump using UP. It will continue to operate while UP is pressed. With the cover raised, look at the processor slots to determine when the developer is trickling over them.

Gum-Dryer Parameters

Gum is applied to each plate as it passes through the rear section of the processor. After the gum station the plate passes beneath the Dryer where heat is used to dry the gum. The time that gum is applied and the dryer temperature are set from the control panel.

To access these parameters from the Function Menu set the pointer to GUM-DRYER and select with ENTER.

Also located on this menu is a manual feed function for applying gum.

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Setting Gum Volume

Set the pointer to Gum Dose, and press ENTER to access the Gum Application Menu where the Gum Pump operation duration is set. As the in-line valve limits the pump fl ow rate, the time set needs to be determined by experimentation.

Set the value using UP and DOWN.

Setting Gum Dryer Temperature

After being gummed, the plate is dried with a heating lamp. The temperature of the dryer is set by placing the pointer on Dryer Temperature and selecting with ENTER.

Set the value using UP and DOWN, select with ENTER, and return with MENU.

Manually Adding Gum

Set the pointer to Manual Replenish, and using ENTER, bring up the Manual Gum Menu. Pressing UP manually adds gum while the key is depressed.

Speed Parameters

The development time and rotational speeds of the Pre-wash and Developer brushes are set from the SPEED menu.

To access these parameters on the Function Menu, set the pointer to SPEED and select with ENTER.

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Setting Developer Time

The development time is a function of the transport speed and length of the developer bath. Length of the developer bath is kept constant by paying attention to processing leveling at installation, and developer level daily.

To set the time of development, place the pointer on Development Time and use ENTER.

Use UP and Down to set the development time to the manufacturers recommended time for the developer temperature set. Return using the MENU key.

Setting Pre-wash Brush Speed

The rotational speed of the Pre-wash Brush is set for optimal processing. To change the speed, place the cursor

on Pre-wash Brush and press ENTER. The values entered are a percentage of the maximum speed.

The value is adjusted with UP and DOWN.

If some protective coating adheres to the plate after brushing, increase the speed. Refer to Chapter 6 for Troubleshooting tips.

Setting Developer Brush Speed

The rotational speed of the Developer Brush assembly is set for optimal processing. To change the speed, place the cursor on Developer Brush and press ENTER. The values entered are a percentage of the maximum speed.

The value is adjusted with UP and DOWN.

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Again, if some unexposed emulsion remains on the plate after brushing, increasing the speed in some cases can resolve the issue. Refer to Chapter 6 for more Troubleshooting tips.

Standby Parameters

To assure optimal processor performance the PlateRunner enters a standby mode when no plates are being processed. During the standby mode the rollers turn slowly, the developer brush turn intermittently, the developer pump continues to run and the developer is periodically added.

The values for when the PlateRunner enters Standby, the amount and frequency of developer addition, can be changed.

The Standby Menu is reached from the Status Menu by pressing DOWN.

Setting Standby

A length is used tA length is used tA length is used o program when you want the processor to go into standby mode. The processor is approximately 1,500 millimeters long. As you want the processor to go into standby just after the plate exits, set the value to 1550 mm.

On the Standby Menu, place the cursor on Processor Length and press ENTER.

Use UP and DOWN to change the value, and ENTER to accept it. If you will be feeding it plates frequently and do not want it to go into standby, set the value higher. Press MENU to return to the previous screen.

Setting Standby Developer Volume

The amount of developer added during a standby replenishment is set from the Standby Volume Menu. Place the cursor before it and ENTER.

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The amount specifi ed is dependent on the plate manufacturer’s recomendations, machine usage and environmental conditions. For example, in a hot dry setting, the evaporation is far greater than that experienced in cold and wet climate. Determine the amount based on your observed usage and how much fl uid must be added each morning.

The criteria used in setting this, and Developer Timing, is that the developer must trickle evenly over the two drain slots.

Setting Standby Developer Timing

Frequency of developer addition during standby is set from the Standby Interval Menu.

Again, the frequency is dependent on the climate so use both replenishment timing and volume to fi nd the correct balance for long-term use of the developer. The correct amount is determined by monitoring the pH and level of the developer bath. As the seasons change, the values will also change.

Use UP and DOWN to enter the desired value.

Standby Gum Timing

When the plate enters the processor, gum is applied to the rollers. As it requires a short time to reach an optimal spread and thickness on the plate, the timing of the Gum Dose can be adjusted. If the dose appears to be applied too soon, the point at which it occurs can be set further into the machine.

A setting of zero millimeters (0.0 mm) the gum would be applied as the plate’s leading edge enters the PlateRunner, a higher value will apply gum after the plate has entered the machine and it has moved closer the Gum Section.

Set the pointer to Gum Delay and bring up the Gum Delay Menu with ENTER.

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In this example, a value that is closer to the Gum Roller has been entered. Again, this has to be determined by trial and error and is dependent on the Gum Dose settings.

Selecting Plate Type

The processing parameters can be set for two plate thicknesses. For instance, you may process both 6 and 8 mm plates, plate type 01 and 02.

Press ENTER to access the Plate Type.

To change the plate type from 01 to 02, use UP.

Similarly, to change the plate type from 02 to 01, use DOWN.

Make sure that the plate type, 1 or 2, displayed on the Status Menu matches the plate type that is being processed.

Standby Plate Type Parameters

The default plate type is 01. All the parameters that have

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been entered when a 1 was displayed on the Status menu are used when a plate is processed.

To enter the parameters for a second plate type, use UP to select 02, two.

Now return to the Status Menu and set all the processing parameters described above to those recommended by the plate manufacturer.

Whenever plate type 02 is selected, it will appear on the Status Display and the parameters entered for 02 will be used in processing the plate.

Processing a Plate

You are now ready to process a plate. Look at the Control Panel and observe that the PlateRunner is in a ready state,

“Ready” on the Status Display, and that all the specifi ed parameters for your plate type are correctly entered.

Place a plate on the Input Tray emulsion side up. Center it and gently push it into the rollers. When the Input Detector is covered for fi ve seconds, or more, the processing cycle will start. The plate will be drawn into the PlateRunner and will emerge at the rear ready for printing.

If the plate is shorter than 38 cm (15 inches) rotate it until the diagonal length is 38 cm (15 inches) to assure that it will bridge the gap between the transport rollers.

When a plate is detected a hyphen, –, is added to the right of PlateRunner P20/24 and Ready disappears.

This shows that a plate is in the Pre-heat Section and another plate should not be submitted. Shortly before the system is ready to accept another plate, when all the plate is in the Pre-heat Section, ‘Ready’ will appear to indicate

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that the system is ready to accept another plate.

Nominal Operating Values

The processor is pre-confi gured to work with Xante plates and Xante chemistry. Remember that some of the values are climate dependent. Through trial and error the operator may fi nd other settings that give better results.

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Chapter 3Setting Brush PressureThere are three brushes used on the PlateRunner; one in the Pre-wash and two in the Developer Section. The Pre-wash Brush removes the plate’s protective cover before processing. In the Developer Section, two brushes assist the development by mechanically removing emulsion from unexposed areas.

The brushes are set at the factory to work with Xante materials. Their settings need to be checked as the type of plate and developer changes may require an adjustment.

The procedures for setting these brushes are described below.

NOTE: Correct brush pressure is critical to optimal performance of the PlateRunner. Brush pressure must be adjusted as part of the processor setup procedure. A 5 and 6 mm Allen wrench, some un-imaged plates, and one imaged plate are required.

Read through the entire procedure before attempting to set the brush pressures.

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Setting the Pre-wash Brush

1. Bring the Processor to operating temperature and raise the top cover. Remove the side covers of the processor and put the Main Cover Switch in Service Mode. Remove the Pre-wash Splashguard and place it on the input tray to trigger the sensor.

2. Turn off the water supply and remove the Spraybar. Removing the roller assembly may make it easier to perform the oeprations.

3. Set the RPM between 110 and 120 (approximately 80% for U.S. confi gurations). On the front panel, select SPEED then select PREWASH BRUSH. PREWASH BRUSH. PREWASH BRUSHThe UP and DOWN arrows will allow you to set the RPMs.

4. Place the Xante Tension Strip under the prewash brush and adjust the screws on each end of the brush until the roller barely touches the Tension Strip. Then increase the pressure by turning the screw 1/4 turn counterclockwise. Be sure that the pressure is even across the length of the brush.

Turning the adjustment screws clockwise will decrease the brush pressure. Turning the screws counterclockwise will increase the brush pressure.

5. Replace the spraybar, splashguard, and roller assembly (if removed). Reinstall the side covers and turn on the water supply.

Setting the Developer Brush

1. Bring the Processor to operating temperature and raise the Top Cover. Remove the Side Covers of the processor and put the Main Cover Switch in Service Mode. Remove the Developer Splashguard and place it on the input tray to trigger the sensor.

2. Turn off the water supply and remove the rollers located before and after the developer brush rollers. (If the developer tank does not

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have developer or is a new installation - fi ll the developer tank with water to set the brush pressure.)

3. Set the RPM between 110 and 120 (approximately 54% for U.S. confi gurations). On the front panel, select SPEED then select DEVELOPERBRUSH. The UP and DOWN arrows will allow BRUSH. The UP and DOWN arrows will allow BRUSHyou to set the RPMs.

4. Feed the Tension Strip under the front of the brush and attach the AccuWeigh scale to the Tension Strip.While the processor is running, set the scale’s pressure to 12.5oz. Hold the scale at a steady point and allow the Tension Strip to feed under the roller. Adjust the screws on either end of the brush until the Tension Strip begins to “slip” at 12.5oz. (or around 355g.). If using water in the developer tank - set the pressure to 14.5oz. (or 410g.).

Adjust both sides and check the pressure again after the adjustments are made. Check the pressure under each side and in the middle (the middle may be slightly different than the side measurements).

5. The second brush is set similarly, however, the Tension Strip must be fed from the back of the brush because of the spin direction of the brush.

Feed the Tension Strip under the back of the brush while the processor is running and set the scale’s pressure to 9.5oz. (270g.). Hold the scale at a steady point and allow the Tension Strip to feed under the roller. Adjust the screws in the brush pan, until the Tension Strip begins to “slip” at 9.5oz. (or around 270g.). For water, set the pressure to 10.5oz. (or 300g.).

Turning the adjustment screws clockwise will decrease the brush pressure. Turning the screws counterclockwise will increase the brush pressure. The adjustment screws for the second brush are located in the brush pan, as shown in the photo above.

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Chapter 4Setting Gum QuantityGum is applied to the plate after it has been developed and rinsed. The amount of gum applied is controlled from the front panel by setting the pump duration, interval, and the inline Gum Valve that reduces the pump fl ow rate.

1. To set gum fl ow, remove the Right Side Cover and locate the Gum Valve located at the right rear of the unit. Ideally, the pump duration and valve will be set so that the gum fl ow just fi lls the full length of the pinch between the rollers without spilling over and uniformly gums the plate.

2. Set the Gum Valve to its mid-position and activate the Gum Pump by covering the Input Detector for a period of fi ve, or more, seconds. Modify the gum pump timing until the above condition is most nearly met. Adjusting the valve will fi netune the fi nal gum application.

3. Observe the gum pumped into the pinch between the rubber coated driver roller and the Stainless steel metering roller. Set the fl ow to fi ll the full

6. Replace the rollers and splashguards. Reinstall the side covers and turn on the water supply.

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length of the pinch between the rollers without spilling over. Find the valve setting that fi lls the entire length of the pinch with gum, but where it does not drip out the ends.

4. When correctly set, note the valve setting for future reference. Replace the Right Side Cover.

This valve has been confi gured at the factory to work with the Xante gum.

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Chapter 5Basic MaintenanceAt the start of each day, check the developer level. Top off as required.

Present plates shorter than 38 cm (15 inches) rotated to the direction of travel so that they bridge the inner spacing of the nip rollers. Plates shorter than this in the feed direction may fall between the transport rollers and may be diffi cult to recover (some disassembly may be required).

After turning on the processor let it run for at least ten (10) minutes, or until the control panel indicates “Ready”, before processing a plate. While the heater panels and developer solution are heating up the Control Panel will display “Waiting for temp”

Check the Operating Parameters

When processing plates, periodically check the Status Window to make sure that the processor is operating correctly.

Regular maintenance is required for optimal processing

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daily, weekly, and monthly schedules.

As processor maintenance is essential to good performance, it is recommended that a log be kept of user maintenance, processor readings, and service. A Maintenance Logbook is provided with the processor.

Following Periodic Maintenance are more detailed procedures for maintaining the rollers, fi lters, changing developer fl uid, and replacing a fuse.

Daily Maintenance

1. Turn on the water supply and empty the waste buckets. Check that the drain hose is properly positioned and the drain is clear.

2. Turn the processor on by turning the red power switch clockwise to the “1:” position and wait for READY to appear on the display.

3. Verify that temperature and speed settings on the machine are set correctly.

4. Raise the Top Cover of the processor. Turn the Main Cover Switch in Service Mode.

and printing results. Be sure to perform the daily, weekly, and monthly maintenance procedures. Modify these schedules at the manufacturers directions, or as your experience dictates.

Check the water levels in the Pre-wash and Rinse Sections during operation to make sure that they are draining properly and the water fl ow and pressure are not excessive.

To reduce power and developer usage, we recommend turning the processor off when it will not be used for an extended time. However, allow 10 minutes for the processor to come to temperature before processing the fi rst plate. Check the developer level. When the processor is ready the control panel will indicate Ready.

The water supply should be turned off when the processor is left unattended. Be sure to turn it on when restarting the processor.

Maintenance

Routine maintenance of the processor is necessary to assure optimal processing. Below are the recommended

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5. Initiate a processing cycle by covering the Input Detector for at least fi ve seconds. Verify that spray tube nozzles are not plugged with dried fl uid or debris. If so, clean the jet tubes thoroughly.

6. Wipe the rollers as they rotate using a damp sponge.

7. Looking at the two slots on the developer tank, refi ll with developer until it starts to run over equally from both slots.

It is very important for optimal results that the developer tank remains fi lled and developer trickles over the drain slots.

To assure optimal processing it is recommended that the developer solution pH be measured. If it does not meet specifi cations, take the recommended corrective measures.

Some developers will leave chemical deposits on tanks, fi ttings and rollers that are not soluble in water and can be diffi cult to remove. These deposits can normally be removed by soaking them with the developer and wiping with a sponge. Before turning the processor off, move the gum roller to a “parked” position to clean.

Weekly Maintenance

Check the developer fl uid to make sure that it has not become too thick due to evaporation, plate emulsion saturation and needs replacement. Measure the pH and compare it to the manufacturer’s recommendations. Correct if necessary.

When the developer fl uid is changed, as described under Monthly Maintenance, change the fi lter as well.

Turn the processor off by turning the red power switch clockwise to the “0:” position.

Wear protective eyewear and gloves.

1. To change the fi lter, place a large bucket beneath the fi lter housing.

2. Unscrew the fi lter housing and drain the fi lter canister. Remove the fi lter from the housing and discard it and the developer fl uid. (See developer manufacturer’s MSDS and consult with local agencies for any special instructions.) Rinse the housing thoroughly with water.

28

3. Insert a new fi lter and replace the fi lter housing. Check that the “O” ring is undamaged and in place. If necessary, replace it. Do not over tighten.

4. Turn the processor on and check for leaks. If developer fl uid or plate coating has dried anywhere on the rollers, brush, platens, or covers, use a damp sponge to clean them.

Monthly Maintenance

It is recommended that in addition to cleaning the processor, the developer solution should be replaced once a month. However, depending on processor usage, the manufacturer may recommend a more frequent schedule.

1. Drain and rinse developer section and wash the tanks with fresh water until they run clean. Wipe away any residue. Inspect the brushes and check for leaks in the tanks.

2. Remove and wash “wet” rollers and splashguards.

3. Replace all fl uids and fi lters.

4. Check transmission gears and lubricate if necessary.

5. Check chiller fl uid level if used.

6. Inspect motor belts for wear.

Periodic Maintenance

Wear protective eyewear and gloves.

1. Open the top and remove the side covers from the processor.

2. With the processor off, place a 20 liters container (2 fi ve gallon buckets) under the Developer Drain Valve and empty the used developer fl uid into the waste bucket. After the processor has drained, turn on the system for ten seconds to pump out the remaining fl uid.

DO NOT allow the processor to run more than ten seconds as this will burn out the pumps. DO NOT turn the processor on until you have replaced the developer fl uid.

3. Replace the fi lter as described in this manual.

4. Remove the three spray tubes and rinse them clean with warm water. Remove any residue with a sponge.

29

5. Remove all of the accessible roller sets sequentially, three through nine, from the processor by pulling equally up on both supports in the directions shown in Figure , below. Note their location, as they must be returned to the same place.

6. Keep the roller pairs assembled. After lifting them out, do not let the support bushing separate from the roller end.

7. Clean the rollers under warm, running water and use a wet sponge to remove any debris.

8. Using a sponge with warm water, clean all tanks thoroughly. Remove all loose debris in the tanks, and scrub any accessible residue adhering to the walls and fl oor of each tank.

9. Inspect the brush for residue and uniformity. Remove any debris or residue.

10. Put 15 liters of recommended developer solution into the developer tank.

11. Replace each roller pair to its assigned location in the processor.

12. Replace the spray bars with the spray directed down.

13. Turn the processor on.

14. Activate a processing cycle by placing a plate over the Input Detector for more than fi ve seconds. Direct the fl ow of the pre-rinse down and the two wash bars onto their respective rollers. Make sure that the water does not fl ow over the top of the roller.

15. Top off the developer solution using the drain slots as your guide.

16. Make sure that there are no leaks.

17. Replace the top and side covers.

It is suggested that the fl oor, and waste receptacles, beneath the PlateRunner be cleaned.

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Cleaning the Rollers

The rollers in the PlateRunner should be wiped down daily. They also require periodic, thorough cleaning.

Follow this procedure to clean the rollers:

1. Turn off the PlateRunner and unplug it.

2. Open the top and remove the side covers from the processor.

3. Note the location of each roller set and remove them from the processor by pulling up on both supports.

4. Keep the roller pairs assembled. Do not remove the rollers from the end supports.

5. Clean the rollers under warm, running water and use a sponge to remove any residue.

6. Re-insert the roller assemblies into their assigned slots.

7. Plug the PlateRunner in.

Removing the Brushes

Lifting the Brushes Assembly straight up removes them or their location as seen below.

You need to be cautious when lifting as you should apply the strength in the same direction and have the set levelled all the time to avoid any damage.

Replacing the FilterThe developer fi lter is at the rear underside of the PlateRunner.

31

Periodically the fi lter needs to be replaced. This is best done when changing the fl uid. We recommend changing fi lters every time the developer fl uid is changed. The fi lter cartridges are 25.4 cm long (10”) and are available from Xante.

Wear protective eyewear and gloves.

1. Place a large bucket beneath the fi lter housing.

2. Drain the fi lter canister.

3. Unscrew the fi lter housing and empty the developer fl uid into the bucket. Remove the fi lter from the housing.

4. Dispose of the used fi lter cartridge and developer fl uid. (See developer manufacturers MSDS and consult with local agencies for any special instructions.) Rinse the housing thoroughly with water.

5. Insert a new 10” long fi lter into the housing.

6. Check that the “O” ring is undamaged and in place. If necessary, replace it.

7. Replace the fi lter housing in the support, tightening it by hand. Do not over tighten. Close the drain valve.

8. Raise the Top Cover and turn on the processor.

9. Check that the fi lter housing does not leak.

10. Observing the developer tank drain slots, top off the developer solution from the control panel using the manual replenishment function.

Changing Developer

Recharging of the developer fl uid should be done on the

32

schedule recommended by the plate manufacturer. To replace the developer:

Wear protective eyewear and gloves.

1. Raise the Top Cover and place a 20 litres container (fi ve-gallon waste bucket) under the developer tank drain valve.

2. With the processor off, drain the developer fl uid into the waste bucket. After the processor has drained, turn on the system for ten seconds.

DO NOT allow the processor to run more than ten seconds as this may burn out the pumps. DO NOT turn the processor on until you have replaced the developer fl uid.

3. Clean the developer rollers.

4. Replace the developer fi lter.

5. Add 15 liters of the recommended developer solution.

6. When fi lling the tank, use a container, siphon

hose, or funnel that allows you to pour the chemicals in the correct tank. Avoid splashing developer on the mechanical and electrical components. As some developing fl uids foam easily, pour carefully to avoid excessive foaming.

7. Turn the processor on.

8. Observing the two drain slots, top off the developer, as the level will drop due to the fi lling of hoses and fi lter. Use the manual replenishment system from the front panel.

9. Measure the pH for future reference when the processor shows ‘Ready’.

10. Dispose of the waste fl uids properly. See developer manufacturer’s MSDS and consult with local agencies for any special instructions.

Replacing a Fuse

Prior to checking a fuse, turn the PlateRunner off and unplug it from the power source. The fuses are located at the front of the PlateRunner under the Input Tray.

33

Access the Fuse Panel by removing the two thumbscrews and lowering the Electronics Cover.

CAUTION: Check that the PlateRunner is unplugged.

You will see the Fuse Panel to the left of the circuit breakers.

There are fuses for the PlateRunner motors, pumps, and heaters. The location of each is shown. To replace a fuse pull the top the fuse holder forward and remove the spent fuse. Replace it with the value specifi ed in Fuse Values.

34

Replace the fuse with one of the same rating. The values are summarized below.

A sample Logbook entry:Date Time pH

LevelPlateSize

PlateCount

RoomTemp/Humidity

OutsideTemp/Humidity

Comments:

◊◊◊

Chapter 6TroubleshootingPlateRunner Specifi cations

Use ONLY plate manufacturer specifi ed processing fl uids.

35

the number of plates processed and the amount of time that the developer is exposed to the environment.

If you are processing a lot of plates, the replenishment rate may be too low. Raise it. If the pH falls while the system is idle, raise the standby replenisher volume and frequency.

“Why is the developer level falling below the drain slots?”If the developer level falls below that waste slots and is not reaching the waste bucket, adjust replenishment rates. If the level falls while you are processing a lot of plates, raise the replenishment rate. If falls while the PlateRunner is idle, raise the standby replenisher volume and/or frequency.

“Why are the plates underdeveloped?”Check the developer solution, temperature, and the processing time. If the system is at the right temperature, and the developer is fresh, increase the development time. If it is still underdeveloped, raise the developer temperature.

If there are any jet tubes that are not jetting properly, fi rst wipe the openings with a sponge before removing the jet tube for cleaning. This will often clear the obstruction and allow the jet tube nozzle to function normally.

Developer fl uid replacement will be dependent on usage, and may need to occur more often than once per month. A tint of emulsion observed over the non-imaged area of the plate is an indicator that the developer fl uid needs replacement.

Keeping the rollers clean is very important. Be sure to maintain the developer fl uid at the correct level.

Temperature issues can also arise occasionaly. Attaching temperature strips to the back of a plate before processing can also help detect some processing issues.

“Why isn’t the processor brush turning?”If after introducing a plate in the processor the brushes are not turning, check the fuse. Prior to checking the fuse, turn the PlateRunner off and unplug it from the power source. Replace the fuse as described on Replacing a Fuse.

“Why is the developer pH too low?”Basically, two major factors in maintaining pH level are

36

“Why is there no image?”Check that the developer is fresh and the processor setting are correct. Expose a plate to room light for one minute and process it. If it develops, check the imaging system.

“Why is there emulsion on the unimaged areas?”If there is emulsion in the unimaged areas, and the developer is fresh, lower the developer brush ½ turn. Check the activity of the developer and its temperature. Try turning the brush speed up.

“Why do the dots appear scrubbed?”If the dots appear over scrubbed, raise the developer brush ½ turn.

“Why aren’t the plates cleaned in the pre-wash section?”Check the pre-wash brush setting and rinse water fl ow rate. If the protective coating is stuck to the plate, increase the brush pressure. If there is loose residue, increase the water fl ow. Check the drainage after adjusting the fl ow rate.

“Why isn’t the gum drying after processing?”Increase the dryer temperature. Do not increase it so that the plates are too hot to handle.

“Why isn’t the gum evenly applied?”If there is too much gum, reduce the fl ow. If there is too little, increase the fl ow. If it is not uniformly spread, adjust the gum delay. Check that the gum is thinned to the manufacturers recommended ration. If it is still too thick, increase the ratio of the water.

“Why does the wastewater level rise in the tanks?”Check that there are no obstructions in the Pre-wash and Rinse waste lines, drain, or tanks. Decrease the water fl ow. The drain must be located within 1.2 m (four feet) and 61 cm (24 inches) below the processor for correct operation.

“Why isn’t my plate coming out?”Check that the plate fed into the processor and the power is on. Open the Top Cover and look for it. When found, determine why it didn’t complete processing.

37

“Why aren’t the plates going through in a straight line?”If the plates do not pass through the processor in a straight line, open the Top Cover and watch a plate traverse. See if there is any impediment or debris on the rollers. If it changes direction at a roller set, remove them and make sure that the springs are in good working order.

“Why doesn’t “Ready” replace “Waiting for Temp” on the Status Display?”Check that the Pre-heat and Developer heaters are turned on. Check the temperatures entered. Wait for the temperatures to reach their set points. Determine which heater is not operating by opening the Top Cover and measuring the developer temperature and placing your hand above the Pre-heat Section to determine if it is on. Check the fuses for the heaters.

“Why are the plates light struck?”Check that the safelight used conforms to the plate manufacturer’s specifi cation. Check for light leaks by placing a plate emulsion on the Entrance Tray for two minutes before processing.

“Why can’t I get the developer residue off?”The developer residue is not soluble in water. Use developer as a cleaning agent. Be sure to wear protective gloves and eyewear.

If you have issues or concerns that are not specifi cally addressed in this chapter, please contact Xante Technical Support or your local Xante Authorized Retailer.

◊◊◊

38

Service and Support• Tech Support

1-800-926-8393 (US and Canada) 1-251-473-4920 (Local) +31-(0)26-319-32-10 (Europe) Other areas, contact your Xante vendor.

• Fax1-251-473-6503 (US and Canada)

+31-(0)26-319-32-11 (Europe)

• Hours of Operation7 a.m. - 6 p.m. Mon. - Fri. CST (US and Canada)

• Email europesupport@xante.com

For more information about Xante products,please visit our website:

www.xante.com/support

PlateRunner Users Guide Rev1. 11/28/07

Record your Serial Number:

______________________________

Date of Purchase:

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