Service Manual for FNDX 5
Model: FNDX 5
Type: NDT FILM PROCESSOR
Version: MF800 V2.8r09a
Date: 08/2009 FR
Produced for FUJIFILM by COLENTA Labortechnik GmbH & Co. KG, Austria.
ATTENTION !!! TAKE CARE TO FOLLOW THE SAFETY INSTRUCTIONS IN CAPTURE 1 OF THE INSTRUCTION MANUAL FNDX 5!
ACHTUNG !!! BEFOLGEN SIE GENAU DIE SICHERHEITSHINWEISE IN KAPITEL 1 VON DER BEDIENUNGSANLEITUNG FNDX 5!
OBSERVANCE: THIS SERVICE MANUAL CAN ONLY BE USED IN COMBINATION WITH THE CORRESPONDING INSTRUCTION MANUAL FOR THE FNDX 5! THE INDICES IN THIS SERVICE MANUAL ARE AN ADDITION OF THE CHAPTERS IN THE INSTRUCTION MANUAL !
ZUR BEACHTUNG: DAS SERVICE MANUAL KANN NUR IN VERBINDUNG MIT DER BEDIENUNGSANLEITUNG FNDX 5 VERWENDET WERDEN! DIE INHALTE IN DIESEM SERVICE MANUAL SIND EINE ERWEITERUNG VON DEN KAPITELN IN DER BEDIENUNGANLEITUNG !
THIS SERVICE MANUAL IS ONLY INFORMATION FOR QUALIFIED TECHNICIANS! EACH POINT MAY USE ONLY BY AN AUTHORIZED COLENTA TECHNICIAN!
Index
- Before installation: 1
- Location: 1
- Electrical supply: 1
- Internal Water circuit: 2
- Water drain: 2
- Internal chemistry circuit: 3
- Chemestry drains: 3
- Chemical replenishment system: 4
- Transportation on site and assembling: 5
- Assembly the fix rack with spraybar: 6
- Mounting of rollers fix rack 1: 6
- Mounting of spraybar: 6
- Adjustment of spraybar: 7
- Mounting of rollers fix rack 2: 7
- Additional to the fix rack: 8
- Additional to installation of the racks: 8
- Additional to installation of the dryer rack: 8
- The first steps: 9
- Additional to the first steps: 9
- Using the chemistries: 9
- Processor functions: 10
- Additional safety devices: 10
- Filter system of developer: 11
- How to replace the filter insert: 11
- System of chiller assy: 13
- How to fill the cooling liquid: 13
- Setup jumper: 15
- Setup of the processor: 16
- The before mentioned values are defined as following: 17
- Flowchart: 18
- I2C Bus overview: 19
- Test instruction for I2C Bus system: 20
- Trouble shooting: 23
- Service report: 27
- Notes: last sites
1.1.1 BEFORE INSTALLATION
Site preparation, e.g., water supply, drainage electrical supply must be completed prior installation.
1.1.2 LOCATION
Processor can be installed "through-the-wall" or completely in the darkroom. Required measurements can be taken from the processor specification sheet. For "through-the-wall", a purpose built panel is required (optional accessory).
1.1.3 ELECTRICAL SUPPLY
All electrical connections must meet national safety requirements. Correct fuses and electrical requirement can be taken from the processor specification sheet.
Power cord with plug: CEE 3P+N+PE 16-6h 415V 16A
Main switch
1.1.4 WATER SUPPLY
- The processor must be connected to the local water supply by using a DVGW-approved system separating device or pipe separating device.
- The cold water supply pipe must have a stopcock fitted connection to the processor and should be done by using the 3/4" hose connector, supplied. Easy access to the stopcock should be provided as it has to be opened and closed daily.
- A built in magnetic valve reduces water consumption to a maximum of 2.0 ltr./minute using pressure and quantity control.
- It is recommended to run a second cold water supply with 2.5 meters of hosing to facilitate easy cleaning of the racks and tanks (water supply kit - optional accessory).
Diagram: Water connection and drains in front of the processor (see page 3)
1.1.5 INTERNAL WATER CIRCUIT
Diagram showing the internal water circuit: water tank, stop-cock, 1-way-water-solenoid (watersupply) connected to the processor. An arrow indicates "...to set the flow trough, which depends on the pressure of the water supply line".
2.1.1 WATER DRAIN
- The wash water should be drained separately according to local environmental regulations. The Processor comes with the suitable hose connections.
- The level of the water drain should be as low as possible with a minimum drainpipe diameter of Ø40 mm.
Diagram illustrating water drain: fresh water inlet, level indicator, overflow tube, and sewage collector, with an arrow indicating "CIRCULATION".
2.1.2 INTERNAL CHEMISTRY CIRCUIT
Diagram showing the internal chemistry circuit: circulation inlet tube, overflow tube, DEV/FIX tank, Circulation, heat exchanger 350W with cooling, circulation pump, and drain DEV/FIX.
NOTE: for the DEV there is additional a filter installed. See more in chapter 5.1.3 "Filter System for Developer".
2.1.3 CHEMISTRY DRAINS
Diagram showing the front panel with connection points labeled: Drain WASH, WATER, FIX, DEV, Water Supply. Also shows valve diagrams labeled CLOSED and OPEN.
3.1.1 Chemical Replenishment System
When operating a processor which uses chemicals for the continuous production of plate/film it is very important that the chemicals within the machine are keep in good working order so as to provide consistent processing quality. To achieve this consistency, replenishment solutions are used, formulated by the chemical manufacturer and injected into the processor precisely for the area of material being produced. Replenishment of chemical tanks is done automatically using infra-red sensors at the processor entrance. These sensors monitor the width of material entering the processor, and this information is used by the microprocessor (CPU) control software to calculate the surface area for each plate. Each sensor, when covered, generates a pulse, recorded on a decoder and counted. When the count reaches the programmed value, it triggers a replenishment cycle. During each cycle, replenishment pumps inject fresh solution from small storage bottles/tanks into the corresponding "working" tank solutions for a pre-set time.
Diagrams showing DEV and FIX replenishment systems. DEV shows a canister with a standpipe and filter, with a lid labeled "USE FLOADING LID TO PROTECT DEVELOPER AGAINST OXYDATION". FIX shows a standpipe and filter. Both connect to a "Replenishment Pump".
NOTE: A Level control device for replenisher tank is optional available on request.
WARNING:
- Do not use brass or copper in the drainage system.
- Chemistry disposal must be in accordance with local environmental regulations.
- To avoid back pressure in the drain, the hoses should be free of bends and with a constant downward gradient.
4.1.1 TRANSPORTATION ON SITE AND ASSEMBLING
The transport to the installation area can be done easily by two men.
WARNING: DURING TRANSPORT ALL RACKS AND DRYER MUST BE TAKEN OUT OF PROCESSOR!!
Diagram showing the processor with dimensions for installation, indicating it fits between walls.
IMPORTANT: The Processor must be installed leveled for optimum performance.
Photos showing internal racks.
5.1.1 ASSEMBLY THE FIX TANK WITH SPRAYBAR
CAUTION: Pay attention to the Roller configuration about the FIX Rack!
Diagram showing the fix tank assembly with numbered components (16, 22, 23).
| Position | Teile Nr. (part no.) | Beschreibung | Description |
|---|---|---|---|
| 16 | 90 16 606 | Einzugswalze gerillt, PE 32 schwer | Input roller fluted, PE 32 heavy |
| 22 | 90 17 425 | Einzugswalze PE 25 schwer | Input roller, PE 25 heavy |
| 23 | 90 15 179 | Eingangswalze Fix, Stahl 19 | Input roller Fix, Steel 19 |
5.1.2 MOUNTING OF THE ROLLERS 16 AND 22 IN THE CORRECT ORDER
Diagram showing rollers 16 and 22 being mounted in order.
5.1.3 MOUNTING OF THE SPRAYBAR
Diagram showing the spraybar being mounted.
5.1.4 ADJUSTMENT OF THE SPRAYBAR
Diagram showing the spraybar adjustment with labels: "adjustable flowrate regulator", "fixing nut", "hose connector for spray-bar".
5.1.5 MOUNTING OF THE ROLLER 23 IN THE CORRECT ORDER
Diagram showing roller 23 mounting.
Be sure, that the spray-bar sheet not contact the steel roller - not to shear of.
5.1.6 ADDITIONAL TO THE FIX RACK
Diagram showing a "valve to switch the fixer for the spray-bar" and "hose connector for spray bar". Also shows a simplified diagram of circulation within the fix rack with "fix inlet pipe", "level", "circulation", "fix", "heat exchanger", and "circulation pump".
6.1.1 ADDITIONAL TO INSTALLATION OF THE RACKS
- The processor is delivered complete assembled, except the transport racks, dryer and film catch tray.
- Transport fixings must be removed before use.
- Insert each rack at the location indicated by reference number or label.
- Rinse the tanks with water and then fill it to the red marker on the tank wall.
- Insert the racks according the reference number or label
- Turn on the transport motor and check rotation
- Insert racks carefully and slowly, avoiding chemistry splashes.
Rack assignments:
- RACK 1: in the developer tank
- RACK 2: in the fixer tank
- RACK 3: in the water tank
Photos showing hands inserting racks into tanks and a separate dryer rack unit.
6.1.2 ADDITIONAL TO INSTALLATION OF THE DRYER-RACK
Dryer Rack in the dryer
Sample photos of the dryer rack installation.
7.1.1 THE FIRST STEPS
WARNING: Separate the Film Processor from mains. To do so, switch the main power switch of the Filmprocessor to "0" position. Wear safety goggles, protection gloves and clothing!
7.1.2 ADDITIONAL TO THE FIRST STEPS
We recommend that the machine is fully water tested on installation before filling with chemistry – this is just a safety procedure in case of transport damage.
- Thoroughly clean processor ensuring no packing materials restricts the free running of the processor. Pay special attention to the racks and inside of the tanks.
- Close the drain taps for the developer, fixer and wash.
- Fill the tanks (Dev, Fix and Wash) with water to the markers on the tank wall.
- Switch on the processor
- Check for signs of leakage.
7.1.3 USING THE CHEMISTRIES
- Only use chemistry suitable for roller transport systems.
- Follow instructions of chemistry manufacturers.
FIXER BATH:
- Empty fixer tank by opening the fix drain tap.
- Remove the Fixer-rack.
- Check fixer tank is free of alien material.
- Close fix drain tap.
- Fill fixer tank with ready-to-use-fixer solution to the red marker on the tank wall.
- Insert the Fixer-rack very carefully and slowly, add hardener solution if advised by the chemistry manufacturer.
DEVELOPER BATH:
- Empty developer tank by opening dev drain tap.
- Remove the Developer-rack.
- Check developer tank is free of alien material.
- Close dev drain tap.
- Fill developer tank with ready-to-use-developer solution to the red marker on the tank wall.
- Insert the developer-rack very carefully and slowly. Replenishment tanks may be used to mix the chemistry. Any remaining can be used for replenishment.
CAUTION: Even the smallest quantity of fixer could contaminate the developer solution. Therefore, always fill with fixer first. When removing the fixer rack, always cover the developer tank. For removing the fixer rack use rack carrier tray (optional accessory).
8.1.1 PROCESSOR FUNCTIONS
Programming:
Automatic processing parameters, e.g., temperature, speed and replenishment rates, can be stored in 9 different programmes.
Warm-Up Time:
Once programmed, temperature settings are accurately controlled. Constant solution temperatures are maintained in the processing tanks. Temperatures tolerances +/- 0.2 °C are achieved by the microprocessor control unit while the solutions are circulated by circulation pumps. When temperature has reached PRE-SET levels, the processor enters STANDBY mode and is ready for use.
Standby:
In case no film is in process - after a fixed period of time and when, after the last plate leaves the dryer, the processor transport, dryer and water supply is switched off automatically. The processor goes to standby mode. During standby, the processor activates two important features: ANTI-OXIDATION and ANTI-CRYSTALIZATION programmes.
Anti-Oxidation:
During STANDBY mode - and in long periods of no production, a preprogrammable ANTI-OXIDATION cycle (replenishment cycle) is initiated. The additional replenishment compensates the impact of air oxidation of the chemistry during standby mode and maintain chemistry levels in the tanks, in order to compensate evaporation of the water in the solutions.
Anti-Crystalization:
During STANDBY mode - within a programmable cycle period - the transport rollers and the gum pump are activated - this helps to prevent crystalization build-up on the rollers.
Automatic Replenishment:
The processor is equipped with a film area measuring system. Infrared sensors scan the incomming plate area and when the preprogrammed amount of plate (area) enters the processor, a replenishment cycle will be activated.
Automatic (Start-Stop):
Infrared sensors also automatically control the start cycle of the film processor. The film processor changes from STANDBY to RUN once a film has interrupted the light barrier. As the rollers turn, water is supplied to the wash tank and to the intermediate rinse bath system. Once the last film has passed through, the film processor reverts to STANDBY. The film can be taken out of the receiving basket or top cover lid.
9.1.1 ADDITIONAL SAFETY DEVICES
- Thermostatically controlled solution heater with overheating CUT-OUT and AUTO-RESET.
- Thermostatically controlled dryer heater with overheating CUT-OUT and MANUAL-RESET.
- All electric motors are equipped with thermal CUT-OUT and AUTO-RESET.
- Each electrical component is protected by a fuse on the power distribution board (PDB).
10.1.1 FILTER SYSTEM FOR DEVELOPER
During working, the filter has to be installed inside the processor. If you want to change/replace the filter insert, mount the filter on the frame like in the pictures.
CAUTION: To change the filter cartridge it is necessary that the filter system is fixed on the main frame.
NOTE: Mount the side panel to the processor and fix it with the mounting screws.
10.1.2 HOW TO REPLACE THE FILTER INSERT
- Switch off the processor using the Main power switch.
- Open the closing sheet.
- Remove the Filter Cover.
- Take out the used filter cartridge.
- Check position of the O-ring inside filter housing.
- Put in the new filter cartridge slowly and carefully.
- Close the filter system in the reversed sequence as described before (step 2).
CAUTION: After the insert has been replaced, place the filter inside the processor again.
IMPORTANT: After the filter has been replaced, reset the filter log. Go to programming mode menu Options/Filter/Log and clear the processed area to 0000.
11.1.1 SYSTEM OF THE CHILLER ASSY
If you want to change/add the Cooling liquid, follow the steps below:
11.1.2 HOW TO FILL THE COOLING LIQUID
- Switch off the processor using the Main power switch.
- Open the marked Stop cock to the Chiller Assy.
- Press the red button all the time during the filling!
- Fill in Cooling Liquid carefully up to 3/4 of the Filter using a funnel, while pressing the red button!
CAUTION: Do not fill in more than up to 3/4 of the Cooling Liquid Tank!
Indicator showing "Fill in up to 3/4 (about 2 litres)".
- Close the marked Stop cock to the Chiller Assy.
IMPORTANT: After the first cooling cycle, control the level of the cooling liquid. Contingently fill up the cooling liquid to the right level. Inspection glass should filled 3/4.
12.1.1 SETUP JUMPER
ADDITION FOR AUTHORIZED TECHNICIANS
It is possible to see data and to change working data in the SETUP menu but to save any new data entered into the SETUP menu then it will be necessary to insert a jumper on the main board of the processor:
Diagram of PDB MF800 showing jumper positions ST17 and ST14.
When selecting Save in the setup menu, the program will refuse to save the data unless this wire jumper is present.
DO NOT forget to remove the Jumper after service! Otherwise the cooling is switched continuously!!!
CAUTION: The shaft of the main drive motor has a tachometer installed. When the drive motor starts, the tacho will rotate to generate a speed counter which sends pulses to the Processor CPU. By using these pulses the CPU is able to accurately control the transport speed/timing sequences after entering the Setup-Menue:
Diagram of "Main drive motor with tachometer".
12.1.2 SETUP OF THE PROCESSOR
Switch on the processor, use 1-time and you will see:
Values see: Testwerte_xx.pdf
Interface elements shown: Program, Setup, Options, RS232. Navigation with arrow keys and confirm button.
Use ➔ to move to Setup and confirm with ➔. There are about 10 pages, which depend on the mechanical construction and must be entered during the factory setup.
| Parameter | Value/Setting | Description |
|---|---|---|
| Gear | 137 pls/m | Number of motor pulses per meter of material advance. Used for calculating processed film area and processing speed. |
| Pump | 06.7 ml/s | Milliliters per second of the replenishment pump. |
| Sensor distance | 072 mm | Distance between two sensors of the sensorbar, used for film area calculation. |
| Power save | 1 (1-yes, 0-no) | If set to 1 (yes), tank2 heater switches off when tank1 and dryer heaters are on, to manage power consumption. |
| Replenish after | each 0.125 sq.m. | Area after which a replenishment cycle is activated. |
| Pause between sw heaters | 1000 ms | Prevents disturbances to the power line/supply. Dryer heater power is split/switched time-delayed. |
| T1 Str | 0012 pls | Startpoint of the DEV-rack. |
| T1 End | 0091 pls | Endpoint of the DEV-rack. |
| T2 End | 0180 pls | Startpoint of the Fix-rack. |
| T3 End | 0269 pls | Endpoint of the WASH-rack. |
| DR End | 0344 pls | Endpoint after the dryer. |
| Wat.ref t_out | 20 | Timeout for automatic water refill. If water level sensor is not reached within this time, an error message "Can't fill water" is displayed. |
| Wat Str | 0135 pls | Startpoint when the wash valve is on. |
| Wat End | 0274 pls | Endpoint when the wash valve is off. |
| Film checking | 0 (1-yes, 0-no) | 0 = Normal mode. 1 = Feeder mode (for machines with Auto Feeder). Film is checked from input to feeder until input to processor. |
Use Save to store your adjustments (requires setup jumper). Use Cancel to leave.
DO NOT forget to remove the setup jumper! Otherwise the cooling is switched continuously!!!
12.1.3 THE BEFORE MENTIONED VALUES ARE DEFINED AS FOLLOWING
Diagram showing the processor's racks (DRYER, WASH, FIXER, DEVELOPER) with sensor points and levels indicated.
EEPROM CRC CHECK
The setup, standby options, and the three programs are stored in EEPROM on the PDB. A CRC is used to ensure data validity. The software is designed to recognize valid EEPROM data.
The program startup follows this sequence:
- Checks the setup data CRC. If not valid, "Setup Invalid" error appears, and the user is taken to the programming menu. If CRC is OK, the program continues.
- Next, the Standby options CRC is checked. If invalid, "Options invalid" is displayed, proceeding to programming mode.
- Next, Program 1 CRC is checked. If invalid, "Program1" is displayed, proceeding to programming mode.
- Only if all checks are OK, the processor will run in work mode.
Note that P2...P9 are not required to be valid, only P1. However, if P2...P9 have invalid CRC, an error message "Program invalid" will appear when attempting to switch to that program.
12.1.4 FLOWCHART
Flowchart illustrating the processor's operational states and menu navigation, including Program, Setup, Options, and Monitor functions. Key parameters like Gear, Pump, Sensor distance, Power save, Replenish after, Pause between heaters, rack start/end points (T1, T2, T3, DR), water settings (Wat.ref t_out, Wat Str, Wat End), and Film checking are detailed. It also shows the sequence for modifying programs (P1 Modify, etc.) and saving/canceling settings.
13.1.1 I2C-BUS - OVERVIEW
Probes positioned under solution levels precisely monitor all solution tank temperatures. These temperature probes continuously supply information to the microprocessor on actual solution temperatures within the tanks. The microprocessor compares these actual temperatures to the required programmed "set" temperatures and controls the relevant heaters/cooling systems accordingly. A i2C-Bus System is installed to transfer this information.
Block diagram showing PDB MF 800 (CPU MF 800, ST12, ST10, ST-3) connected to a Control panel/Display. Temperature probes (DRYER, FIX, DEV) are connected via an I2C-Distribution Board (ST-7 to ST-1) to the PDB. Sensorbar is also shown connected to the I2C-Distribution Board. Color coding for probes is indicated: DRYER...RED, FIX...BLUE, DEV...YELLOW.
14.1.1 TEST INSTRUCTION FOR THE I2C-BUS SYSTEM
Testing of the I2C-Bus is easy!
Prior to the test, disconnect all elements of the I2C-Bus System and follow the necessary working steps:
- Connect the Display to the Main Board PDB (ST3).
- Install the Cable between Main Board PDB (ST12) and the Distribution Board (ST-6).
- Connect the Temperature sensor DRYER to the Distribution Board (ST-5).
- Connect the Temperature sensor FIX to the Distribution Board (ST-4).
- Connect the Temperature sensor DEV to the Distribution Board (ST-3).
- Install the Sensorbar to the Distribution Board (ST-2).
14.1.2 CONNECT THE DISPLAY TO THE PDB (ST3)
If it's O.K., it will show the Software identification and the electronic will go in operation mode.
Diagram showing PDB MF 800 and Control panel/Display connection.
14.1.3 INSTALL A CABLE BETWEEN PDB (ST12) AND THE I2C-BOARD (ST-6)
If no trouble is shown, the connection Cable + the Distribution Board will be O.K.
Diagram showing PDB MF 800 and I2C-Distribution Board connection.
14.1.4 CONNECT THE SENSOR DRYER TO THE I2C-BOARD (ST-5)
Press ➔ to see T2 (FIX) and T3 (DRYER) also. If no trouble is shown, then the sensor will be O.K. On the Display will be shown the actual measured temperature +/- 1 °C. If "???" or some other indefinable signs are shown, the temperature sensor is defective!
Diagram showing connection of DRYER temperature probe to the I2C-Distribution Board.
14.1.5 CONNECT THE SENSOR FIX TO THE I2C-BOARD (ST-4)
If no trouble is shown, then the sensor will be O.K. On the Display will be shown the actual measured temperature +/- 1 °C. If "???" or some other indefinable signs are shown, the temperature sensor is defective!
Diagram showing connection of FIX temperature probe to the I2C-Distribution Board.
14.1.6 CONNECT THE SENSOR DEV TO THE I2C-BOARD (ST-3)
Press ➔ to see T2 (FIX) and T3 (DRYER). If no trouble is shown, then the sensor will be O.K. On the Display will be shown the actual measured temperature +/- 1 °C. If "???" or some other indefinable signs are shown, the temperature sensor is defective!
Diagram showing connection of DEV temperature probe to the I2C-Distribution Board.
14.1.7 INSTALL THE SENSORBAR TO THE I2C-BOARD (ST-2)
If no trouble is shown, then the sensor will be O.K. If all sensors are O.K., you can see in the monitor program.
Diagram showing Sensorbar connection to the I2C-Distribution Board.
15.1.1 TROUBLE SHOOTING
| Problem | Possible Cause | Correction |
|---|---|---|
| 1. Tank1 too cold The Developer temperature is more than 1 °C below the programmed value | a) Developer bath temperature is too low b) Heater problem c) No circulation in the bath | a) Check the Heat up time, check Developer temperature in 2-3 Minutes, 1°C temperature increase b) Check in the Monitor mode H1, check the LD3 on main board and check the Fuse F3 c) Check the Circulation pump, check the LD7 on Main board and check the Fuse F7 |
| 2. Tank 1 too warm The Developer temperature is more than 1 °C above the programmed value | a) Chiller doesn't work b) Cooling Pump c) too less Cooling Fluid | a) Check the Cooling assembly, check the LD9 on Main board and check the Fuse F9 b) Check the Cooling Circulation Pump c) Check the fill level of the Cooling Fluid using the inspection glass |
| 3. Tank2 too cold The Fixer temperature is more than 1 °C below the programmed value | see point 1 | see point 1, check the Fuse F4 / LD4 check the Fuse F7 / LD7 |
| 4. Tank2 too warm The Fixer temperature is more than 1 °C above the programmed value | see point 2 | see point 2, check the Fuse F9 / LD9 |
| 5. Dryer too warm The Dryer temperature is more than 5°C above the programmed value | a) Set temperature is too low (lower than room temperature) b) main board defective c) Solid State | a) Change the Set temperature b) Change main board c) Solid State Relais defective |
| 6. Motor overload The Drive motor did not reach, it's Set-speed | a) Main Drive assembly blocked b) Main drive chain to much tension c) Film jam in the racks | a) Check the main drive for easy running b) Check the chain c) Check the racks |
| 7. Cover opened The cover of the machine is not closed | a) The cover of the machine is not closed correctly b) the cover switch is damaged | a) Check the machine cover b) Check function of the cover switch |
| 8. Main Drive and Dryer run continuously | a) Main Drive was started in "manual mode" b) Material always under the sensorbar. Material not transported/pulled into the processor c) Sensor/s at the sensorbar is/are wet or dirty d) Main board defective | a) Check in the manual program if "STOP" is shown; stop the transport with the button. CAUTION: If also an automatic cycle is started by the sensor bar this cycle will end first. b) Check the Input rubber roller, check if a film is on the film table under the sensorbar. c) Clean the sensor/s d) Change the Main board |
| 9. Material wet when exiting processor | a) Dryer temperature is too low b) Transport speed to high c) Unusable or wrong Developer or Fixer d) Dryer blows only cold air | a) Increase the Dryer temperature (max. 60 °C) b) Lower the Transport speed c) Increase the Replenishment rate or change the chemicals d) Fuse F4 of the Heater Dry defective or solid state relais defective, or dryer heating elements defective, or thermoswich from heating element is open |
| 10. Temperature problems Temperature is shown incorrect. | The Temperature probes has to be positioned according their code. | The Temperature probes are colour coded: Developer ... Yellow Fixer ... Blue Dryer ... Red |
| 11. No fresh water supply | a) Water tap is closed b) Water valve is blocked or faulty c) Main board defective | a) Open the Water tap b) Clean the small Filter in the valve, or exchange it c) Check the Fuse F8 / LD8 |
| 12. Circulation pump don't work | a) Pump wheel is blocked by dirt b) no electrical power | a) Clean the Pump wheel and make sure easy running b) Check the Fuse F7 / LD7 |
| 13. Level in water tank to high, Water tank Overflows | a) Water drain/overflow blocked b) Worse water drain installation | a) Clean the Water tank and clean the Overflow and the Water drain b) Modify the Water drain installation |
| 14. Level in Developer- or Fixer tank to low. | a) Tank leaks b) Too low Replenishment rate or too long Anti-Oxid.cycle c) Replenishment container empty d) no electrical power on the Replenishment pumps | a) Seal the Tank leak b) Increase the Replenishment rate or decrease the Anti-Oxid.cycle time c) Fill up the Replenishment containers d) Check the Fuse F5 / F6, check the Fuse LD5 / LD6 and clean the Replenishment pump or exchange it |
| 15. Chemical temperature can't be reached | a) Incorrect temperature b) Temperature sensor is faulty c) The processor was started without liquid in tanks. The safety fuses at the heating element have interrupted the current supply d) PDB is faulty | a) Program the temperature correctly b) Replace the temperature sensor c) Reset the safety Fuse. d) Replace PDB |
| 16. Scratches or pressure marks | a) Unsuitable handling of the processing materials b) Cross over rollers are dirty. c) Bent guide bars | a) Handle material carefully b) Clean all rollers above the fluid level c) Clean and check guide bars. If nesessary, replace it |
| 17. Material remains in the Processor | a) Material fed incorrectly b) Material has excessive curl c) Material is too thin d) Rollers are not rotating | a) The material must be fed in straight b) Fold leading edges and feed in the processor c) Use a leader to process d) Check gears and the position of the loose rollers |
| 18. Processor could not be switched on | a) Main cable isn't plugged b) Main Fuse is faulty | a) Plug in main cable correctly b) Check the Main Fuse F1 |
| 19. Paper of Film too dark | a) Developer temperature is too high b) Processing time is too slow. c) Exposure time is too long d) After new chemistry: starteris missing | a) Decrease developer temperature b) Increase processing time c) Reduce exposure time d) Add starter according to instructions |
| 20. Paper of Film too light | a) Bath temp is too low b) Transport speed is too high c) Exposure time is too short d) Bath level ist too deep (no heating and circulation) e) Developer exhausted f) Fixer getting into developer (Dev becomes cloudy) g) Exposure settings are incorrect or machine is faulty | a) Adapt the bath temperature to the recommended process or change chemistry b) Decrease transport speed c) Increase exposure time d) Fill bath to the right level and check Replenish-tanks e) Replenish or change chemistry f) Carefully clean the tank and replace chemistry g) Adjust setting or repair faults |
| 21. Paper or Film is fogged | a) Light leak in darkroom or cassette b) Incorrect darkroom light c) Material is outdated | a) Seal off light leak b) Check the Filter, wattage and distance from the dark room lamp to the processor c) Check the date of maturity |
| 22. Paper or Film has yellow-green surface | a) Unsuitable hand processing material is used b) Fixer is exhausted c) Level of fixer bath has dropped (Temperature safety fuse has been activated) d) Circulation pumps have failed | a) Only use material suitable for roller processing b) Replenish or change chemistry c) Check level of the Replenishment containers and fill up the bath to the required level d) Check the pump motor and eventually replace it |
16.1.1 SERVICE REPORT
This Service-Report may use only by a qualified COLENTA Service-Technician!
CAUTION: All listed points in this Service-Report must be conducted professionally! The listed points must be tested in a specified sequence as below. If there are any deficiencies found, the qualified Service-Technician must repair the defects accordingly! After the trouble shooting and remedy of all deficiencies a new Service-Report must be created. All listed points in this Service-Report must be conducted again till the Processor is working correctly! The Safety Inspector must record each Testing-Step on the Service-Report! The measured test values and the general information about the test equipment must be recorded also in the Service-Report. The Safety Inspector confirms with the notes "Location, Date and Signature" the data of each Testing-Step.
WARNING: Prior to all actions, the Power Supply of the Processor must be disconnected!
# Direct Connection: Turn the Main Switch of the Processor (installation side) to the position "0". Secure the Main switch against switching on and check the voltage-free parts.
# Plug Connection: Disconnect the Power Plug of the Processor.
PROCESSOR: FNDX 5
SERIAL NUMBER: ......................................................
SOFTWARE-REVISION: ......................................................
16.1.2 TESTING THE GROUNDING CONDUCTOR
The voltage resistor value between all grounded components of the Processor and the Power Plug must be less than 300 mV (mOhm).
| Processor Component | Measurement (mV) | Result |
|---|---|---|
| Terminal clamp of the grounding in the processor | ............... | F c O.K. F c not O.K. |
| Main switch - mounting plate | ............... | F c O.K. F c not O.K. |
| E-Box-Cover | ............... | F c O.K. F c not O.K. |
| Mounting plate of the Solid-State-Relais | ............... | F c O.K. F c not O.K. |
| Main filter Corcom 20VB6 F7354 | ............... | F c O.K. F c not O.K. |
| E-Box-Housing | ............... | F c O.K. F c not O.K. |
| Printed circuit board track (ST21) | ............... | F c O.K. F c not O.K. |
| Exhaust Fan (Plug ST34) | ............... | F c O.K. F c not O.K. |
| Heating Tank 1 (Housing) | ............... | F c O.K. F c not O.K. |
| Heating Tank 2 (Housing) | ............... | F c O.K. F c not O.K. |
| Replenishment pump Tank 1 (ST15/1) | ............... | F c O.K. F c not O.K. |
| Replenishment pump Tank 2 (ST16/1) | ............... | F c O.K. F c not O.K. |
| Dryer Fan | ............... | F c O.K. F c not O.K. |
| Dryer-Housing (Heating) | ............... | F c O.K. F c not O.K. |
| Magnet valve Spraybar Fixer (ST8/1) | ............... | F c O.K. F c not O.K. |
| Processor-Frame | ............... | F c O.K. F c not O.K. |
| Processor-Mounting Plate | ............... | F c O.K. F c not O.K. |
| Feeder: Grounding Screw Power Supply Side panel | ............... | F c O.K. F c not O.K. |
| Fan | ............... | F c O.K. F c not O.K. |
| Power Supply-Mounting flange | ............... | F c O.K. F c not O.K. |
| Feeder-Construction | ............... | F c O.K. F c not O.K. |
| Feeder-Cover | ............... | F c O.K. F c not O.K. |
| Film Infeed Giude | ............... | F c O.K. F c not O.K. |
Safety Tester: ...............................................
ID-No. Tester: ...............................................
Calibration Date: ...............................................
Safety Inspector: ...............................................
Location, Date: ...............................................
16.1.3 ISOLATION RESISTOR
The Isolation voltage resistor value between the grounding conductor of the Processor and all electrical components (L/N) must be less than 2 mV (mOhm)!
| Processor Component | Measurement (mV) | Result |
|---|---|---|
| Main Switch to the position "1" | ............... | F c O.K. F c not O.K. |
Safety Tester: ...............................................
ID-No. Tester: ...............................................
Calibration Date: ...............................................
Safety Inspector: ...............................................
Location, Date: ...............................................
16.1.4 LEAKAGE CURRENT (ERSATZ-ABLEITSTROM)
Only the measure of the "Backup-Leakage Current" value is possible with the Safety Tester! The Leakage Current must be less than 4 mA (mAmpere)!
| Processor Component | Measurement (mA) | Result |
|---|---|---|
| Main Switch to the position "1" | ............... | F c O.K. F c not O.K. |
Safety Tester: ...............................................
ID-No. Tester: ...............................................
Calibration Date: ...............................................
Safety Inspector: ...............................................
Location, Date: ...............................................
16.1.5 VISUAL INSPECTION
The Safety Inspector must make a visual check of all surfaces and assembled components!
- Are the electrical conduction/cables installed in the E-Box accordingly? ...... F c O.K. F c not O.K.
- It is not allowed that Primary lines are in touch with the blanc Secondary Parts.
- It is not allowed that Secondary lines are in touch with the blanc Primary Parts.
- Are the ground conductor connections installed professionally and safe? ....... F c O.K. F c not O.K.
- Is the Strain/Pull Relief of the Power Cord correct? (Hand test) ...................... F c O.K. F c not O.K.
- Strain/Pull Relief of the Processor
- Strain/Pull Relief of the Power Plug
- Check the Power Cable and the Power Plug for damages! ............................ F c O.K. F c not O.K.
- Exist the Nameplate/Typelabel on the Processor and is it completely? ......... F c O.K. F c not O.K.
- Are all Covers mounted in the right position checkt the surfaces? ................... F c O.K. F c not O.K.
- Are all protective conductor connections connected and installed safety? ...... F c O.K. F c not O.K.
- Are all Processor Side Panels fix and screwed on correctly? ........................ F c O.K. F c not O.K.
- Are all Feeder Side Panels and the Top Cover fix and screwed on correctly?.... F c O.K. F c not O.K.
- The Processor Dryer Rack with the Support Bracket on the left side, must be secured against mechanical extraction! .................................. F c O.K. F c not O.K.
Safety Inspector: ...............................................
Location, Date: ...............................................
16.1.6 CHECK OF THE INTERLOCK SWITCH
The Safety Inspector must make sure that the Covers are mounted correctly!
Processor:
- Interlock Switch is fix and safety F c O.K. F c not O.K.
Safety Inspector: ...............................................
Location, Date: ...............................................
16.1.7 ACCEPTANCE TESTRUN OF THE PROCESSOR
The Safety Inspector must make a Testrun as described in the Instruction Manual and have to check the full function!
Processor:
- minimum 1 Heat-up phase of the Heating components checked F c O.K. F c not O.K.
- Testrun like in the Instruction Manual described done and completed F c O.K. F c not O.K.
Safety Inspector: ...............................................
Location, Date: ...............................................
16.1.8 TEST FOR LEAKS
The Safety Inspector must check the whole Hose-System and must test the Processor for leaks!
Processor:
- Internal and external Piping and Hose-System F c O.K. F c not O.K.
Safety Inspector: ...............................................
Location, Date: ...............................................
ACCEPTANCE BILL: A complete technical inspection has been carried out and specific problems has been discussed with the customer.
NOTES
(Content from pages 35-37, which are blank except for the word NOTES)
