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CAWOMAT 2000 IR
Cawomat 2000 IR
Reference manual
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© CAWO Photochemische Fabrik GmbH 1999.
No parts of this document may be reproduced, copied, adapted or transmitted in any form or by any means
without the written permission of CAWO Photochemische Fabrik GmbH.
CAWO Photochemische Fabrik GmbH makes no warranties or representation, expressed or implied, with re-
spect to the accuracy, completeness or usefulness of the information contained in this document and specifically disclaims warranties of suitability for any particular purpose. CAWO Photochemische Fabrik GmbH
shall under no circumstances be liable for any damage arising from the use or inability to use any information, apparatus, method or process disclosed in this document.
CAWO Photochemische Fabrik GmbH reserves the right to make changes to this document without prior notice.
CAWO Photochemische Fabrik GmbH, P.O. Box 1129, D-86521 Schrobenhausen, Germany.
Cawomat 2000 IR is a trademark of CAWO Photochemische Fabrik GmbH.
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Table of contents
Preface: Introducing the Cawomat 2000 IR 1
Welcome to the Cawomat 2000 IR 3
About this manual 4
Safety precautions 5
Chapter 1: Installation of the Cawomat 2000 IR 7
Basic installation requirements 9
Installation 11
Chapter 2: Getting started with the Cawomat 2000 IR 19
Main components 21
Control panel 24
Preparing the chemicals 25
Checking the replenishment rates 27
Replenishment rate adjustment 29
Using the Cawomat 2000 IR 31
Chapter 3: Cleaning the Cawomat 2000 IR 33
Cleaning frequency 35
General cleaning directions 36
Removal of the tanks 37
Cleaning the tanks 39
Cleaning the processor chassis 41
Cleaning the dryer 42
Reinstalling all parts 44
1220C GB 19991004
Chapter 4: Troubleshooting 45
Troubleshooting checklist 47
Processor fails to operate 48
Appearance of processed films 49
Film transport problems 54
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Chapter 5: Advanced service: instructions for skilled service personnel 55
Important safety notice 57
Resetting the thermal cutouts 58
Film drying problems 59
Maintenance of the main drive assembly 64
Adjustment of replenishment pump gears 79
Replacement of roller springs 81
Appendix A: Equipment information sheet 83
Specifications 85
Safety standards 88
Appendix B: Parts list and exploded views 89
Spare parts list 91
Parts list (sorted on part code) 122
Standardized parts list 130
Appendix C: Index 131
1220C GB 19991004
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Preface
Introducing the
Cawomat 2000 IR
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0
Preface
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1220C GB 19991004
Page 7
Welcome to the Cawomat 2000 IR
The Cawomat 2000 IR is a most up-to-date table-top processor designed to
handle all types of medical X-Ray film suitable for rapid processing. All operations are programmed and each step takes place automatically.
The complete throughput, drying included, takes only 125 seconds.
The Cawomat 2000 IR offers the following features:
■ Automatic film processing.
The Cawomat 2000 IR handles film from 100 x 100 mm (4” x 4”) up to 350 mm (14”) wide
and 1200 mm (51”) long.
Easy to handle, compact in size, light in weight.
■
■ No installation cost:
– Just plug it in.
– No extra plumbing: no fixed water supply or water-drainage system required.
Low operation cost:
■
– Economical standby mode.
– No waste of water.
– Precise and automatic control of developer temperature.
– Precise and automatic control of chemical replenishment. The film scanner registers
exactly the amount of solutions needed to process a specific film size.
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Preface
1220C GB 19991004
Easy maintenance and cleaning:
■
The simple construction of the Cawomat 2000 IR allows easy access to all parts needing
cleaning or replacement.
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0
Preface
About this manual
This manual is your reference guide to the Cawomat 2000 IR.
It has a task-oriented, modular structure and describes in detail all instructions
for setup, operation and maintenance.
The reference manual consists of the following chapters:
■ Chapter 1, ‘Installation of the Cawomat 2000 IR’, offers a step by step descrip-
tion of the unpacking and installation procedure for the Cawomat 2000 IR.
■ Chapter 2, ‘Getting started with the Cawomat 2000 IR’, introduces the Cawomat
2000 IR to the user and explains some key concepts.
■ Chapter 3, ‘Cleaning the Cawomat 2000 IR’, guides you through cleaning tasks
which require no special skills, tools or training.
■ Chapter 4, ‘Troubleshooting’, serves as a guide to recognize, identify and solve
possible errors and problems.
■ Chapter 5, ‘Advanced service: instructions for skilled personnel’, describes
maintenance and repair procedures which may be carried out by skilled service
personnel only.
■ Appendix A, ‘Equipment information sheet’.
■ Appendix B, ‘Exploded views and parts list’.
■ Appendix C, ‘Index’, lists the main topics in alphabetical order to help you find
the appropriate procedure for any task.
❖ The present instruction manual is focussed on the installation, use and maintenance
procedures of the Cawomat 2000 IR processor, with a minimum of technical assistance. If you encounter difficulties with the installation or operation instructions, or if
the processor fails to operate as specified, call your local service organization.
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1220C GB 19991004
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Safety precautions
General safety instructions
0
■ The Cawomat 2000 IR was designed for processing medical X-ray films and
should only be used for this purpose.
■ The processor may only be operated by qualified staff.
■ Make sure that only authorized personnel has access to the processor.
■ Only trained and authorized service personnel can make repairs or changes to
the processor.
■ If there is visible damage to the machine casing, the processor should not be
started or used.
■ Do not override or disconnect the integrated safety features.
■ Disconnect the processor from the mains before performing any maintenance
activities.
■ Like all technical devices, the processor must be operated, cared for and ser-
viced correctly, as described in the documentation provided with the machine.
■ If the processor is not operated correctly or if you do not have it serviced cor-
rectly, CAWO is not liable for resulting disturbances, damages or injuries.
■ When installing the processor, care must be taken to ensure that there is either
a mains plug or an all-cable disconnecting device in the internal installation fitted near the processor and that it is easily accessible.
■ If connections with other components or assemblies are made, CAWO can
guarantee safety only for combinations which are approved by CAWO.
Preface
1220C GB 19991004
■ If you notice conspicuous smoke or noise, disconnect the processor immediate-
ly.
■ An earth leakage circuit breaker (I = < 30 mA) must be built into the electric
circuit.
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Special instructions for the handling of chemicals
■ When handling chemicals, you must observe safety and environmental regula-
tions as well as the operating and warning instructions accompanying the
chemicals.
Preface
■ Wear stipulated protective clothing and safety goggles.
■ When disposing of chemicals and waste water, you must comply with the local
regulations concerning waste water and environmental protection.
■ If chemicals get into your eyes, immediately rinse your eyes with cold water and
consult a physician.
■ Do not inhale vapor from chemicals. Make sure that there is sufficient ventilation
where the processor is installed, i.e. air exchange that is at least ten times the
space volume per hour.
■ Always comply with the installation instructions.
■ Regularly check all connections to the processor for tightness.
■ If liquid gets into the inside of the processor (due to spills), disconnect the
processor from the mains immediately and have the device cleaned thoroughly
by service personnel.
Collect spent chemicals in separate containers and suspend hose pipes at a sloping
angle without any kinks.
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Chapter
Installation of the
Cawomat 2000 IR
1
This chapter offers a step by step description of
the installation and unpacking procedure for the
Cawomat 2000 IR.
Basic installation requirements
Installation
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1
Installation
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1220C GB 19991004
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Basic installation requirements
Before unpacking the unit, make sure you have a darkroom with an adequate
working area and the basic installation requirements, as listed below. Complete
specifications are provided in Appendix A.
Installation requirements
■ Power requirement
Prior to connecting the processor to the mains, check whether the specifications on the data plate match your local power supply (120V / 230V). The
processor must not be run without earth protection. An earthed power outlet
protected by a fuse (15A / 16A) is required. An earth leakage breaker
(IN = < 30 mA) must be built into the electric circuit.
■ Water requirement
The Cawomat 2000 IR processor does not need a separate water connection.
Water is supplied by a water replenishment bottle, and should be at normal
room temperature (15°C to 25°C / 59°F to 77°F). A convenient sink and water
hose is recommended for filling the water replenishing bottle, for mixing the
chemicals and for cleaning the processor.
An optional fixed water connection can be ordered though, if continuous water
supply is wanted. Refer to page 87 for the appropriate order code.
■ Disposal of waste chemicals and waste water
It is the purchaser’s responsibility to conform to local rules and regulations regarding the disposal of waste chemicals. Care should be taken when handling
chemicals at all times. Please observe the hazard instructions provided on the
chemical labels.
■ Ventilation requirement
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1220C GB 19991004
The Cawomat 2000 IR processor does not require a separate exhaust system
and does not produce excessive external heat. The processor will operate properly at a room temperature between 15°C and 30°C / 59°F and 86°F, and at a
relative humidity between 30% and 80%.
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Light-tight cover
550 mm
(22")
370 mm
(14.8")
650 mm
(26")
560 mm
(22.4")
Minimum
counter size
660 mm x 660 mm
(26.4" x 26.4")
940 mm
(37.6")
CAWOMAT 2000 IR
1
Installation
Working area requirements
The Cawomat 2000 IR is designed to be installed in a darkroom. Consult the
medical imaging film company for recommended darkroom lighting conditions.
The counter or support upon which the processor is to be set up must have a
minimum surface of 660 x 660 mm. A larger working surface is recommended
for safety purposes. The processor should be accessible from all sides if possible, but a minimum clearance must be provided. Consult the diagram:
10
The Cawomat 2000 IR Support Table
is an option meeting exactly all requirements: it features appropriate
support leg holders and a hole to
lead through the drain hoses to the
waste bottles which can be placed in
a safe location underneath the table.
❖ Refer to Appendix A for order codes
and specifications.
1220C GB 19991004
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Installation
❖ Refer to page 21 for a diagram of the main components.
Arranging the drain hoses
1 Remove the rubber bands.
Lift the processor and set it down on its rear end with two people. Do not use the legs as
a pivot point. The drain hoses are held in place by rubber bands.
2 Withdraw and unroll the three drain hoses.
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1220C GB 19991004
If the processor has been placed as shown above, you see from the left to the right: the
developer hose, the fixer hose and the wash-water hose.
3 Lower the processor back into operating position with two people.
Do not use the legs as a pivot point.
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4 Arrange the hoses into their appropriate waste bottles.
CAWOMAT 2000 IR
1
Waste solutions must be drained preferably into three separate waste bottles. The developer hose and the waste-water hose can be put together into one bottle. However, the
fixer hose should be put into a second waste bottle.
Installation
5 Correct the hose length.
If the processor is to be installed on a counter with the waste bottles stored beneath,
holes should be cut into the counter top for the drain hoses to pass through.
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Levelling the processor
The processor must be exactly level for a reliable operation and a proper replenishment of the chemicals. Levelling screws in the legs are provided to enable a
proper adjustment. Use a levelling instrument to achieve satisfactory results.
1 Level the machine by means of the adjustable legs.
Level the machine front-to-back and left-to-right, preferably on the tank rollers as shown
in the figures above.
– Turn the levelling screws clockwise to raise the processor and counter-clockwise to
lower the processor.
– Turning the screws is made easier by lifting slightly the appropriate corner.
2 Now you can replace the processor cover.
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Installation
1220C GB 19991004
Make sure that the interlock pin, marked on the processor cover with a white dot, is properly engaged with the interlock switch. If not, the processor will fail to work.
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1
Installation
Fitting the exit tray
1 If not done already, remove the exit tray from its polyfoam wrapping.
2 Engage the left hook of the exit tray in the slot on the left of the dryer cover.
3 Engage the right hook of the exit tray in the leftmost ventilation slot on the right
side of the dryer cover.
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Inserting the replenishment bottles
A set of replenishment bottles was packaged in the accessories box that also
contained this manual. Supplementary sets of 5 l or 2.5 l replenishment bottles
can be ordered to assure quick changing of the chemicals. Refer to the
Appendix A ‘Equipment information sheet’ for the appropriate order codes.
1 Make sure the replenishment bottles have the correct valves attached.
The valves are color coded to match them to their corresponding bottles to avoid contamination of the chemicals. Refer to the table on page 36 for the appropriate color codes.
❖ Never interchange the valves!
2 Insert the empty replenishment bottles into the corresponding receptacles.
❖ The replenishment bottles should be inserted emptily at this time. The mixing and filling
procedure for chemicals can be found in chapter 2, ‘Getting started with the Cawomat
2000 IR’.
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Installation
1220C GB 19991004
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Installing the light-tight cover
CAWOMAT 200
The light-tight cover is an optional accessory making it possible to leave the darkroom safely once processing of films has started.
❖ Refer to Appendix A for order codes and specifications.
1 Remove the light-tight cover accessory from its packing.
1
Installation
2 Slide the light-tight cover onto the feed tray and press it firmly into position.
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Installing a fixed water connection
150 mm (5.9")
Outer thread
10 mm (3.8")
200-500 mm (7.8"-10.7")
200 mm (7.8")
Pressure:
max 0.8 bar
Set the flow to
0.2 - 0.25 l/min
Length 5000 mm (107")
For normal operation the Cawomat 2000 IR processor does not need a separate
water connection. However, it is possible to install a fixed water connection if
continuous water supply is wanted. The fixed water connection accessory can be
ordered as an option.
❖ Refer to Appendix A for order codes and specifications.
1 Remove the fixed water connection accessory from its packing.
2 Install the fixed water connection accessory as shown in the diagram below.
The pressure reducing valve is connected to the water source (1.805 cm / 3/4” pipe with
shut-off valve). The connection is a male union with a 0.953 / 3/8” O.D. thread. Set the
pressure reducing valve to the values as indicated in the diagram.
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Installation
1220C GB 19991004
3 Remove the water replenishment bottle and insert the hose connector into the
water receptacle, marked by a white ring.
Water temperature should be between 5°C and 25°C (40°F and 70°F).
❖ The water line valve should be shut off at the end of a work period. You must have a
fixed floor drain for waste water when using the fixed water connection accessory.
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1
Installation
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1220C GB 19991004
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Chapter
Getting Started with
the Cawomat 2000 IR
2
This chapter introduces the Cawomat 2000 IR to
the user and explains some key concepts.
Main components
Control panel
Preparing the chemicals
Checking the replenishment rates
Replenishment rate adjustment
Using the Cawomat 2000 IR
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2
Getting started
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Page 25
Main components
123 4 5 6 789101112 131415
16 17 18 19 20 21 22 2423 25 18 26
2
Getting started
1. Developer bottle receptacle 14. Exit tray
2. Developer ring (red) 15. Dryer transport roller cover
3. Developer bottle valve (red) 16. Feed tray
4. Developer replenishment bottle 17. Developer tank cover
5. Processor cover 18. Adjustable leg
6. Fixer replenishment bottle 19. Developer heater
7. Fixer tank guide plate 20. Developer thermal cutout
8. Water replenishment bottle 21. Fixer heater
9. Wash-water tank guide plate 22. Fixer thermal cutout
10. Control panel 23. Heater cables
11. Film transport roller 24. Wash-water tank
12. Dryer assembly cover 25. Squeegee roller assembly
13. Dryer fan & heater compartment 26. Dryer transport roller assembly
1220C GB 19991004
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Functional Diagram
213456
Exposed film is inserted directly into the feed slot at the left side of the processor. The film passes the film scanner regulating the replenishment and dryer
systems, and then passes through the developer, the fixer and the wash-water
tanks. After drying, the film leaves the dryer section and is deposited into the
exit tray.
2
Getting started
22
1. Feed section
2. Developer section
3. Fixer section
4. Wash-water section
5. Dryer section
6. Exit section
1220C GB 19991004
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Operation
When the power switch is turned ON, the drive motor, the pump motor, the tank
heaters and the dryer fans start to operate.
After about 7 minutes, the chemical solutions are heated up sufficiently for the
Cawomat 2000 IR to become operational.
When a film is fed into the processor, it is detected by the film scanner, a pair of
magnetic rollers. The film scanner also measures the length of the film to determine the replenishment rate, being different for each separate tank. At the same
time, the replenishment system, the dryer heaters and the fan are activated.
As long as film feed is detected, the replenishment pumps operate at double
speed. This increased circulation causes the contents of the developer tank, fixer tank and wash-water tank to rise in their pump tubes and flow into the drains.
An appropriate amount of fresh solution and wash water is replenished automatically from the supply.
When the end of the film is detected and the film scanner rollers are no longer
turning, the following occurs:
▼ The indicator light remains on for about 15 seconds. When it turns off, another film
can be fed into the processor.
▼ Provided that no additional film is inserted, the circulation rate is slowed down again.
40 seconds after the last film exits the dryer, the infrared dryer heaters turn off, and
after an additional 40 seconds, the lower fan turns off. The upper fan works continuously.
As long as the machine is left on, it remains in standby mode but uses neither
chemicals nor water.
2
Getting started
1220C GB 19991004
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Page 28
Control panel
3
4
5
6
1
2
0
°C
0
3
4
5
6
1
2
2
Getting started
The control panel contains the power switch, the manual replenishment key with
the film feed light, and the dryer temperature step-switch.
Position ‘I’ of the red power switch turns the processor ON.
Depending on the room temperature, solutions reach their proper
operating temperature within 7 minutes.
Position ‘0’ switches the processor OFF.
❖ Caution: the processor should only be switched on with full tanks.
❖ Caution: the processor should never be switched off during film trans-
port.
The manual replenishment key allows the user to initiate an additional replenishment cycle, during which a red indicator light is illuminated.
The manual replenishment key should be pressed if the processor
has been idle for more than a day. Film may be inserted into the
processor when the additional replenishment cycle is completed,
which is indicated by the red light going OFF.
The light is also illuminated during film feed.
The 6 step-switch controls the dryer temperature. This enables
the dryer temperature to be adjusted to particular environment
conditions (humidity and ambient temperature). The normal setting is ‘3’.
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1220C GB 19991004
Page 29
Preparing the chemicals
If the replenishment bottles are to be filled with chemicals for the first time, be
sure to read the following instructions:
■ Prior to filling the tanks for the first time, it is recommended that they be re-
moved from the processor and rinsed with tap water. The standard cleaning
procedure as described in chapter 3, ‘Cleaning the Cawomat 2000 IR’ can be
followed, except that there are no chemicals yet to be drained.
■ To save chemicals, check and adjust the replenishment rates using water in
three spare replenishment bottles (which can be ordered as an option). If the replenishment rates are satisfactory, you can fill the genuine set of replenishment
bottles with chemicals. The procedures for checking and adjusting the replenishment rates can be found further on in this chapter.
❖ The chemical products can cause skin irritations with people who are sensitive to them.
It is therefore advisable to wear rubber gloves and to wash your hands thoroughly afterwards.
❖ Always prepare the solutions in accordance with the directions from your supplier.
Read the accompanying leaflet and/or the instructions on the bottle, to check for congruity with the procedures below.
Preparing the developer solution Agfa G153
Agfa G153 should be used to prepare the developer solution. A unit package
contains 12 sets of 2 concentrated solutions (parts A and B), each set being
used for making up 2.5 litres of working solution (if you want to make up 5 litres
of working solution, double the values for water and chemicals):
– part A contains 1000 ml of concentrated developer.
– part B contains 250 ml of concentrated hardener.
2
Getting started
1220C GB 19991004
1 Fill up the red marked replenishment bottle with 1.25 litres of water
(15°C - 40°C).
2 Add part A and mix by stirring the bottle a few moments.
❖ Never mix the concentrated solutions A and B. Part A is first to be thoroughly mixed
with the water before part B can be added.
3 Add part B, screw the red valve on the bottle and thoroughly mix once more.
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Preparing fixer solution Agfa G353
A unit package of Agfa G353 contains 18 sets of 2 concentrated solutions (parts
A and B), each set being used for making up 2.5 litres of fixer solution (if you
want to make up 5 litres of working solution, double the values for water and
chemicals in the procedure below):
– part A contains 500 ml of concentrated fixer,
– part B contains 250 ml of concentrated hardener.
1 Fill up the blue marked replenishment bottle with 1.75 litres of water (10°C-30°C).
2 Add part A and mix by stirring the bottle a few moments.
❖ Never mix the concentrated solutions A and B. Part A is first to be thoroughly mixed
with the water before part B may be added.
2
Getting started
1 Fill up the blue marked replenishment bottle with 1.5 litres of water (10°C-30°C).
2 Add the chemical and mix by stirring the bottle a few moments.
Preparing fixer solution Agfa G354
A unit package of Agfa G354 contains 18 units of 1000 ml chemical, each for
making up 2.5 litres of fixer solution (if you want to make up 5 litres of working
solution, double the values for water and chemicals in the procedure below):
Inserting the replenishment bottles
❖ A full replenishment bottle of each solution should always be kept in readiness to en-
sure quick replacement. The solutions can be preserved for about one week in a full
and closed replenishment bottle. Always keep in mind the preservation instructions indicated on the bottles.
Place the replenishment bottles in the receptacles, taking the color codes into account (red for developer, blue for fixer, white for water). When the replenishment bottles are inserted into the processor, the tanks will automatically be filled to the bottom edge of the bottle valves.
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1220C GB 19991004
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Checking the replenishment rates
The Cawomat 2000 IR processor features an automatic replenishment system,
in which the replenishment cycle is controlled by the length of the film.
However, the width of the film will affect the replenishment rates. By watching
the liquid levels in the replenishment bottles you can easily check and - if necessary - adjust the replenishment rates.
❖ Each of the three replenishment bottles has its own replenishment rate.
Checking the replenishment rate is required in the following circumstances:
■ After installation of the machine.
■ After replacement of the pumps.
■ If the standard film size is altered. The replenishment pumps have been factory-
set for average replenishment rates based on processing 240 x 300 mm films. If
you will be processing either mainly larger or smaller sizes, it will be necessary
to adjust the pumps.
1 Insert full replenishment bottles.
2 Switch the processor on and wait several minutes until the tanks have com-
pletely filled.
2
Getting started
1220C GB 19991004
3 Carefully indicate the liquid level on each bottle, using a marker.
4 Depress the manual replenishment key to start an additional replenishment cy-
cle of about 3 minutes.
The indicator light turns on.
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Page 32
5 After completion, mark the new liquid level on each bottle and measure the level
6 Compare the rates with those in the table below. If you have an incorrect replen-
2
Getting started
difference from the first mark to the second.
ishment value for one of the replenishment bottles, the rate should be adjusted,
as described on the next pages.
The table indicates the amount of liquids (± 15% tolerance) flowing into the tanks during a
replenishment period of approximately 3 minutes.
Film sizes Developer Fixer Rinsing water
average mix 8 mm (5/16”) 11 mm (7/16”) 13 mm (1/2”)
larger than 240x300 mm 11 mm (7/16”) 13 mm (1/2”) 13 mm (3/4”)
smaller than 240x300 mm 5 mm (3/16”) 8 mm (5/16”) 11 mm (7/16”)
❖ The above values are based on a daily throughput of at least 10 films. If fewer films are
being processed, you ought to increase the replenishment rate of the developer and
change all tanks more frequently.
28
1220C GB 19991004
Page 33
Replenishment rate adjustment
❖ Adjustment of the replenishment pumps involves removing the processor cover and
handling the tanks. If the adjustment is done with chemicals in the tanks, it is recommended that you wear protective gloves, glasses and an apron for your safety.
1 Remove the replenishment bottles and the processor cover.
2 Carefully free the tank heater cables from their retaining clips.
3 Lift the tank slightly and pull it forward enough to gain access to the drain valves
and pumps.
2
Getting started
1220C GB 19991004
The tank covers do not have to be removed.
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Page 34
4 Loosen the locknut by turning it counter-clockwise.
5 Adjust the screw on top of the vertical pipe, using a screwdriver.
2
Getting started
Carefully turn the screw clockwise to decrease the replenishment rate, or counter-clockwise to increase the rate.
6 Retighten the locknut by turning it clockwise, while holding the adjustment
screw in place with the screwdriver to prevent it from turning.
7 Slide the tank back into position, making sure that the drive gears are properly
engaged.
8 Replace the processor cover and the replenishment bottles.
9 Depress the manual replenishment key to initiate an additional replenishment
cycle of 3 minutes.
10 Check the replenishment rate by following the procedure described earlier in
this chapter. If necessary, repeat the adjustment procedure to match as much
as possible the rates in the table on page 28.
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1220C GB 19991004
Page 35
Using the Cawomat 2000 IR
Switching on
1 Plug the power cord into the wall outlet.
2 Check whether the replenishment bottles are full enough and examine the level
in the waste bottles.
❖ Only switch on the processor with full tanks.
3 Turn off all lights but the darkroom safelight.
4 Switch the processor on by pressing the power switch (to position ‘I’).
❖ The processor will automatically be switched off if the dryer assembly cover or the
processor cover is not properly closed.
5 Wait for about 7 minutes to achieve the appropriate operating temperature.
Additional replenishment
If the processor has been idle for more than 24 hours, press the manual replenishment key to initiate an additional replenishment period of 3 minutes.
Film feed
❖ Caution: Do not put films on or near the dryer! Films can get fogged when placed on
the dryer.
You should first run a test film if, for example, the machine has been standing
idle for some time.
1 Push the film into the feed slot until the LED above the replenishment key shows
a red light. When the LED turns off, you can feed the next film.
The largest film width is 350 mm, the smallest sizes processable are 100 x 100 mm and
2
Getting started
1220C GB 19991004
31
Page 36
2 Check to see if processing and drying are satisfactory. If so, you can start regu-
1 Switch off the processor and disconnect the power cord from the outlet.
2 Remove the developer replenishment bottle (marked by a red dot) to stop un-
2
3 Remove the water replenishment bottle (marked by a white dot) and pour out
4 Slightly raise the processor cover to prevent condensation of chemicals.
Getting started
90 x 120 mm. Films of these sizes have to be fed diagonally.
Films are processed for about two minutes and then discharged on the output tray.
lar processing.
If you detect a problem, refer to chapter 4, ‘Troubleshooting’. But first, try switching the
processor OFF and ON again. This can often solve the problem.
Switching off
After work, or at the end of the day, switch off the Cawomat 2000 IR as follows:
necessary oxidation.
the water to prevent the forming of algae.
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1220C GB 19991004
Page 37
Chapter
Cleaning the Cawomat
2000 IR
3
This chapter guides the user through cleaning
tasks which require no special skills, tools nor
training.
Cleaning frequency
General cleaning directions
Removal of the tanks
Cleaning the tanks
Cleaning the processor chassis
Cleaning the dryer
Reinstalling all parts
Page 38
3
Cleaning
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1220C GB 19991004
Page 39
Cleaning frequency
Regular cleaning of the processor is essential to maintain optimal image quality.
Therefore, the processor should be cleaned carefully at least once a fortnight.
Cleaning becomes absolutely essential when a crystalline deposit is observed
on the rollers. If dry residues of chemicals stick to the rubber rollers it may happen that these stick to each other. It is therefore recommended to clean the
rollers regularly with lukewarm water.
The following cleaning activities should be done on a regular basis:
Each day
■ Replace the water in the water replenishment bottle daily to prevent the forming
of algae.
■ Follow the switching off procedure as described in the paragraph ‘Using the
Cawomat 2000 IR’ which can be found in chapter 2, ‘Getting started with the
Cawomat 2000 IR’.
Each week
1220C GB 19991004
■ Drain and clean the wash-water tank.
■ If you are processing less than 80 films per week, or if the processor is inter-
rupted for more than one week:
– Drain the developer and fixer tanks and replenishment bottles. Replace exhausted
chemicals.
– Clean the tank covers and rollers, the transport rollers, the guide plates, the tanks and
replenishment pumps, the valves on the replenishment bottles and the feed tray.
■ If you are processing more than 80 films per week:
– Perform the above tasks every two weeks.
Each month
■ Clean the squeegee rollers (dryer assembly).
3
Cleaning
35
Page 40
3
Cleaning
General cleaning directions
When cleaning the processor, always keep in mind the following directions:
■ Always disconnect the power cord from the outlet.
■ Never use hot water. The highest temperature allowed is 40°C.
■ The electric cables to the heaters are permanent and should never be discon-
nected.
■ Never clean the chassis or the plastic parts of the heaters in running water.
Wipe with a damp cloth or sponge.
■ Roller sets are numbered for proper replacement after cleaning.
– The developer roller sets are numbered 1 & 2.
– The fixer roller sets are numbered 3 & 4.
– The wash-water roller sets are numbered 5 & 6.
The replenishment bottles, bottle valves, bottle receptacles, tank covers, pumps
■
and tanks are color-coded to prevent contamination of the chemicals and for
ease of assembly after cleaning. They must be returned to their proper location
after cleaning. Consult the table below.
Developer Fixer Water
Replenishment bottle Red dot Blue dot White dot
Bottle valve Red color Blue color Beige color
Bottle receptacle Red color Blue color White color
Tank cover Red dot Blue dot White dot
Tank Red dot Blue dot White dot
Pump Red color White color Black color
Rollers N°. 1 & 2 N°. 3 & 4 N°. 5 & 6
36
❖ You are reminded to handle all chemicals with care, to wear protective gloves and an
apron to protect your clothing, and to wear protective glasses for your safety. Always
conform to local regulations regarding the disposal of chemicals.
1220C GB 19991004
Page 41
Removal of the tanks
3
3
❖ Always keep in mind the general cleaning directions (refer to the previous page).
1 Remove the replenishment bottles and processor cover.
2 Carefully free the tank heater cables from their retaining clips.
3 Slightly lift the tank to be cleaned and pull it forward enough to give free access
to the drain valve.
1220C GB 19991004
4 Remove the tank cover.
3
Cleaning
37
Page 42
5 Remove the guide plate.
4
3
3
6 Remove the tank heater by lifting it straight up.
3
Cleaning
38
3
3
4
The electrical connections are fitted firmly and must never be disconnected.
7 Drain the tank by releasing the drain valve clamp.
It may be necessary to gently pull the end of the drain tube to facilitate proper draining.
Allow liquids to run out. For easy flow, the drain tube should not be kinked.
8 Remove the tank from the processor.
Repeat steps 3 to 8 for all tanks having to be cleaned.
1220C GB 19991004
Page 43
Cleaning the tanks
1 Take the tank, the tank cover and the guide plate to a sink for cleaning.
2 Remove the transport rollers from the tank.
Wash the rollers with a sponge and running water.
3 Unfasten the replenishment pump by loosening the two wing nuts, and then pull
the pump out.
1220C GB 19991004
3
Cleaning
39
Page 44
4 Clean the replenishment pump in running water, paying special attention to the
impeller.
5 After cleaning, reinstall the pumps, observing the color codes on the pumps and
the tanks, in order to avoid contamination.
Consult the table on page 36.
6 With the drain valve open, wash the tank under running water, allowing water to
drain through the valve. After draining, close the drain valve.
3
Cleaning
40
7 Clean the guide plate, the tank covers and the rollers in running water.
1220C GB 19991004
Page 45
Cleaning the processor chassis
1 Remove the light-tight cover accessory (if present).
2 Clean the feed tray and the feed slot with a sponge and lukewarm water.
3 Disengage and clean the film scanner.
If necessary, take the film scanner to a sink for cleaning.
4 Clean the heaters.
Never hold the plastic part of the heaters in running water, or immerse it in a liquid.
1220C GB 19991004
5 Clean the drainage troughs using a sponge and lukewarm water.
3
Cleaning
6 Clean any chemical residue around the replenishment receptacles and on the
exterior surface of the processor chassis.
7 Replace the film scanner and the light-tight cover accessory.
41
Page 46
Cleaning the dryer
1 Remove the dryer assembly cover.
2
1
Lift the cover slightly to disengage the interlock pin [1], and then slide the cover forward
to remove it from its rear holding lip [2].
2 Remove and clean the squeegee roller assembly.
3
Cleaning
42
Do not dismantle the squeegee roller assembly. Clean the rollers with lukewarm water.
1220C GB 19991004
Page 47
3 With a socket wrench, loosen the fastener that secures the dryer transport cover
and remove the cover. Lift the dryer transport roller assembly out of the processor.
Clean the rollers if necessary. Do not dismantle the dryer transport roller assembly.
4 Wipe clean the dryer heater and the fan compartment, with a damp cloth.
1220C GB 19991004
Make sure no water gets into the dryer.
5 Reinstall the transport roller assembly.
Make sure that the dryer transport drive gear is properly engaged.
6 Replace the dryer transport cover.
7 Reinstall the squeegee roller assembly.
Make sure that the squeegee roller drive gear is properly engaged.
8 Securely close the dryer assembly cover.
Make sure that the interlock pin is properly engaging the interlock switch.
3
Cleaning
43
Page 48
Reinstalling all parts
❖ Follow the color codes carefully. Consult the table on page 36.
1 Put the rollers, the guide plates and the tank covers back into the appropriate
tanks.
Make sure that the bent edges of the guide plates are inserted into the grooves on the
side of the even numbered rollers of the tanks.
2 Install the tank units into the processor.
– Make sure that the roller gears are properly engaged with their drive gears.
– Make sure that the drain valves are fastened in the upright/closed position.
– Make sure that the heaters are engaged in their retaining slots.
– Make sure that the heater cables are put back in their clips.
3 Replace the processor cover.
3
Cleaning
44
Make sure that the interlock pin, which is marked on the processor cover with a white
dot, is properly engaged with the interlock switch (together with the pin on the dryer assembly cover). If not, the processor will fail to work.
4 Chemical and water replenishment bottles may now be reinserted.
The tanks will be filled automatically.
1220C GB 19991004
Page 49
Chapter
Troubleshooting
4
This chapter provides solutions to some
problems you may encounter while working with
the Cawomat 2000 IR.
Troubleshooting checklist
Processor fails to operate
Appearance of processed films
Film transport problems
Page 50
4
Troubleshooting
46
1220C GB 19991004
Page 51
Troubleshooting checklist
The Cawomat 2000 IR is designed for trouble-free operation. Nevertheless, if
you encounter some problems resulting from improper operating procedures,
processing techniques or equipment malfunction, this section will help you analyze the problem, determine its cause, and solve it if it can be remedied without
the intervention of a service technician.
Most problems related to processed films can be traced back to improper operating, replenishment or cleaning procedures. If you have followed all installation,
operating and cleaning instructions as described in chapters 1, 2 and 3, the
problem can be caused by an electrical or mechanical malfunction.
The troubleshooting procedures in this chapter should help you to identify and
correct most common problems.
❖ Some problems can be corrected simply by turning the power switch off and then on
again.
❖ Always wear rubber gloves, protective glasses and an apron when working with chemi-
cals. It is also recommended that the tanks be drained before handling parts submerged in chemicals.
1220C GB 19991004
4
Troubleshooting
47
Page 52
Processor fails to operate
1 Check that the power cord is plugged in and that the power switch is on.
2 Check that both the dryer assembly cover and the processor cover are firmly in
place.
3 Check that the interlock pins in the dryer and processor covers are engaging the
interlock switch.
The processor cannot work if the interlock switch is not engaged as shown on the figure
above.
4 If none of the above provides a solution, the problem can be caused by a defec-
tive power switch or an electrical circuit malfunction.
Call your local service organization.
4
Troubleshooting
48
1220C GB 19991004
Page 53
Appearance of processed films
Scratches (lengthwise)
1 Check the condition of the feed table.
If required, clean it with a sponge and lukewarm water. Dry the feed table prior to processing a film.
2 Remove the processor cover and the tank covers and check the tank guide
plates.
4
3
3
If required, remove and clean the guide plates with a sponge and lukewarm water.
1220C GB 19991004
Roller marks (crosswise)
1 Check the condition of the tank transport rollers and the dryer squeegee rollers.
– Remove the processor cover, the tank covers and the dryer assembly cover to access
the rollers.
– Remove the rollers and clean them in a sink with a sponge and lukewarm water.
Follow the instructions as described in chapter 3, ‘Cleaning the Cawomat 2000 IR’.
4
Troubleshooting
49
Page 54
2 Check the roller springs for proper tension.
If they are loose, replace them: refer to chapter 5 ‘Advanced service: instructions for
skilled service personnel’, for the appropriate instructions.
3 Check the upper and lower transport roller drive gears for damage.
If they need to be replaced, refer to chapter 5 ‘Advanced service: instructions for skilled
service personnel’.
4 Check the squeegee roller drive gear for damage (dryer assembly).
If it needs replacement, refer to chapter 5 ‘Advanced service: instructions for skilled service personnel’.
5 Check that the developer is not exhausted.
– Drain and clean the developer tank and the replenishment bottle by following the in-
structions in chapter 3, ‘Cleaning the Cawomat 2000 IR’.
– Mix new developer in the replenishment bottle and refill the developer tank: refer to
chapter 2, ‘Getting started with the Cawomat 2000 IR’.
6 Check and, if necessary, adjust the developer replenishment rate.
4
Troubleshooting
50
The procedures for checking and adjusting the developer replenishment rate can be
found in chapter 2, ‘Getting started with the Cawomat 2000 IR’.
1220C GB 19991004
Page 55
Water spots
1 Check the squeegee rollers in the dryer assembly for dirt deposits.
– Remove the processor cover and the dryer assembly cover.
– Remove the squeegee roller assembly and clean it with lukewarm water. Do not dis-
mantle the squeegee roller assembly.
2 Check the squeegee rollers for stretched retaining springs.
The retaining springs hold the rollers tightly together. Inspect the springs on each end,
without disassembling the rollers. If the rollers are loose, the spring has to be replaced.
Call your local service organization.
1220C GB 19991004
4
Troubleshooting
51
Page 56
Irregular drying patterns
1 Check that the dryer temperature is not too high.
2 Check that the room temperature is not too low.
Ambient room temperature should be between 15°C and 30°C / 59°F and 86°F.
Insufficient or excessive contrast, insufficient density
1 If the processor has been idle for more than one day, the developer may have to
be replenished.
– Press the manual replenishment key to initiate a 3-minutes replenishment cycle.
– Run an exposed test sheet to check results.
2 Remove the developer replenishment bottle and place a thermometer in the re-
ceptacle to check the developer temperature.
If the temperature is not in the range of 33°C and 35°C / 92°F and 94°F, call your local
service organization.
3 The developer can be improperly mixed or exhausted.
– Drain and clean the developer tank and the replenishment bottle by following the in-
structions in chapter 3, ‘Cleaning the Cawomat 2000 IR’.
– Mix new developer in the replenishment bottle and refill the developer tank: refer to
chapter 2, ‘Getting started with the Cawomat 2000 IR’.
4 Check, and if required, adjust the developer replenishment rate.
4
Troubleshooting
5 Check the replenishment system.
52
Refer to chapter 2, ‘Getting started with the Cawomat 2000 IR’ for checking and adjusting
the developer replenishment rate.
Follow the troubleshooting procedures for film drying problems, as discussed in
chapter 5, ‘Advanced service: instructions for skilled service personnel’.
1220C GB 19991004
Page 57
Dense fogging
1 The developer can be contaminated by fixer.
– Drain and clean the developer tank and the replenishment bottle by following the in-
structions in chapter 3, ‘Cleaning the Cawomat 2000 IR’.
– Mix new solutions in the developer replenishment bottle: refer to chapter 2, ‘Getting
started with the Cawomat 2000 IR’.
– After insertion of the replenishment bottle, the tank will be refilled automatically.
2 Make the same checks as in the procedure to solve contrast problems (see
above).
3 Check that the processor is level.
Incorrect levelling can result in excessive drainage. If you want to level the processor, refer to chapter 1, ‘Installation of the Cawomat 2000 IR’.
❖ Caution: Do not put films on or near the dryer! Films can get fogged when placed on
the dryer.
1220C GB 19991004
Film not completely dry
Most film drying problems are caused by insufficient hardening of the film due
to inadequate fixer replenishment or to fixer exhaustion. However, the problem
can also be caused by a mechanical or electrical failure in the control circuits,
the dryer or the replenishment system, or by adverse temperature or humidity
problems. Refer to ‘Film drying problems’ in chapter 5, ‘Advanced service: instructions for skilled service personnel’.
4
Troubleshooting
53
Page 58
Film transport problems
If the film is not transported through any of the rollers, the source of the problem
could be the transport drive gears in one of the tanks or the dryer. Alternatively,
the problem can be caused by one of the components that drive the gears: the
gears in the main drive system, the drive motor itself or the drive belt. Refer to
chapter 5, ‘Advanced service: instructions for skilled service personnel’.
❖ If the drive motor is defective, call your local service organization.
4
Troubleshooting
54
1220C GB 19991004
Page 59
Chapter
Advanced service:
instructions for
skilled service personnel
5
This chapter deals with troubleshooting and
maintenance work for the Cawomat 2000 IR
during which live electrical or hot components
may become exposed.
Important safety notice
Resetting the thermal cutouts
Film drying problems
Maintenance of the main drive assembly
Adjustment of replenishment pump gears
Replacement of roller springs
Page 60
5
Advanced service
56
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 61
Important safety notice
Warning
This chapter deals with repairs and preventive maintenance work for the
Cawomat 2000 IR during which live electrical or hot components may become exposed.
The procedures described hereafter can imply hazardous situations and are
therefore to be carried out by skilled service personnel only.
5
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
57
Page 62
5
Resetting the thermal cutouts
Thermal cutouts are provided to protect the developer and the fixer tank
heaters. If the heaters do not get warm, it is possible that the cutouts have been
activated.
Advanced service
1 Remove the processor cover.
2 Check the developer and/or fixer tanks to make sure that they are properly
filled.
Replenish the tanks if required. Refer to chapter 2, ‘Getting started with the Cawomat
2000 IR’.
3 With tanks properly filled, press the reset switch on the appropriate heater.
Press in the direction of the arrow to reset the thermal cutout.
4 If several attempts to reset the cutouts fail to remedy the problem, call your lo-
cal service organization.
58
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 63
Film drying problems
Most film drying problems are caused by insufficient hardening of the film due
to inadequate fixer replenishment or to fixer exhaustion. However, the problem
can also be caused by a mechanical or electrical failure in the control circuits,
the dryer or the replenishment system, or by adverse temperature or humidity
problems. You may have to check one or more of the following:
Mechanical / Electrical
1 Check for excess temperature or humidity.
Ambient temperature should be less than 30°C / 86°F and humidity should be less than
80%.
2 Check that the dryer fans are operating.
– Turn the power switch OFF, and then ON again to activate a fan sequence.
5
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
59
Page 64
5
3 Check that the infrared tubes in the dryer assembly light during the dryer fan cy-
cle.
– This can be viewed by removing the processor cover and dryer assembly cover.
– To momentarily check the infrared tubes, depress the interlock switch with a pencil or
Advanced service
Chemical / Fixer replenishment
1 Check that the fixer is not exhausted.
– If the tanks have not been cleaned according to the weekly cleaning schedule (refer to
– Replace the fixer tank, mix a new solution in the replenishment bottle and reinsert it in
– Check for proper film drying by running an exposed test film.
a screwdriver.
chapter 3, ‘Cleaning the Cawomat 2000 IR’), drain and clean the fixer tank and the replenishment bottle.
the processor. The tank will be filled automatically.
2 If the processor has been idle for more than one day, the fixer may have to be
replenished.
Depress the manual replenishment key to initiate a replenishment cycle of 3 minutes. The
indicator light should remain illuminated and the replenishment pump motor should operate at double speed.
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
60
1220C GB 19991004
Page 65
3 If, after pressing the replenishment key, the indicator does not light, refer to the
next procedure, ‘Mechanical / Replenishment’.
4 If the indicator does light, but the pump motor does not increase in speed, the
problem can be a blown fuse, a defective pump motor, or an electrical malfunction. Refer to the next procedure, ‘Mechanical / Replenishment’.
5
5 Since the problem could also be caused by insufficient fixer replenishment, the
replenishment rate can be checked.
– Check and, if necessary, adjust the fixer replenishment rate following the procedures
in chapter 2, ‘Getting started with the Cawomat 2000 IR’.
– When the replenishment rate is corrected, check for proper film drying by running an
exposed test film.
Mechanical / Replenishment
1 Listen to the sound of the replenishment pump motor.
If the motor speed does not increase to two times its normal rate when the manual replenishment key is depressed, either a fuse could be blown or the motor could be defective.
– Call a service technician.
2 If the pump motor seems to be working properly, check that the fixer replenish-
ment pump is operating.
– The trouble can be caused by a defective pump gear, pump drive gear, replenishment
pump drive belt or motor drive belt. Refer to ‘Maintenance of the main drive assembly’.
– Check to see whether chemicals pass through the drain hoses into the waste bottles
when the replenishment key is depressed.
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
61
Page 66
5
3 Check if any gears are binding or making unusual noises.
To inspect the pump gears and pump drive gears, the processor cover and the tank covers need to be removed. Depress the interlock switch, using a pencil or a screwdriver, in
order to keep the processor turning while the cover is removed.
Advanced service
The pump gears must be properly engaged with their associated drive gear. If either or
both gears are defective or worn, replenishment will be affected.
62
The height of the pump gear is critical to gear engagement and may require adjustment.
The instructions to adjust or replace pump gears can be found in ‘Maintenance of the
main drive assembly’ and ‘Adjustment of replenishment pump gears’ respectively.
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 67
4 If none of the pump gears is turning but the pump motor sound is OK, check for
a broken or slipping motor drive belt.
This belt connects the pump drive motor to the larger of two transfer gears. For a location
diagram and replacement instructions, refer to ‘Maintenance of the main drive assembly’.
5 The problem can also be a broken or slipping replenishment pump drive belt.
This belt simultaneously drives the three pumps. For a location diagram, refer to
‘Maintenance of the main drive assembly’. If this belt is defective, call your local service
organization.
5
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
63
Page 68
1 12 4 63 3 5 5 7 8
5
Maintenance of the main drive assembly
Several replaceable parts are located in the main drive assembly at the rear of
the processor, under the rear cover. It is not likely that you will have to replace
parts in the main drive assembly, but if any part should become defective, it can
easily be replaced.
Advanced service
❖ When maintenance procedures require the handling of parts that are in contact with
chemicals, rubber gloves and suitable protection should be worn. Remove the replenishment bottles, drain the tanks and then rinse the parts in water, in order to remove all
chemicals. The parts can now safely be handled without rubber gloves.
Location of gears
1. Developer transport roller drive gear 5. Water transport roller drive gear
2. Developer pump drive gear 6. Water pump drive gear
3. Fixer transport roller drive gear 7. Squeegee roller drive gear (red)
4. Fixer pump gear 8. Dryer transport roller drive gear
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INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 69
Gear components
12 2 2 3 45
6791010 1111101213899999
111
The diagram below gives the location of the different transport drive gears.
1. Transport roller drive gear 8. Dryer transport roller drive gear
2. Replenishment pump drive gear 9. Worm drive
3. Replenishment pump drive belt 10. Transport roller transfer gear
4. Motor drive belt 11. Belt guide roller
5. Motor drive gear 12. Dryer squeegee roller drive gear
6. Larger transfer gear 13. Main worm drive shaft
7. Smaller transfer gear
5
Advanced service
1220C GB 19991004
The diagram below gives an overview of the main components of a drive gear
shaft. However, individual drive gears can be assembled differently. Always take
care to use the same number of components in the same order when reassembling gears.
1
1. Snap ring
2. Spacer
3. Gear
4. Cylinder pin
5. Bearing
6. Drive shaft
7. Drive shaft holder
364 7
1524321
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
65
Page 70
5
Accessing the main drive assembly
1 Turn the power switch off and disconnect the power cord.
2 Remove the replenishment bottles, the processor cover and tank covers.
Advanced service
3 Pull the tanks out partially and drain them.
Refer to chapter 3, ‘Cleaning the Cawomat 2000 IR’.
4 Remove the two screws securing the rear cover using a screwdriver, and re-
move the rear cover.
66
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 71
Replacement of defective gears: general procedure
❖ Prevent small parts such as snap rings, cylinder pins, washers and spacers from falling
into drain holes or into the processor sink. Use tape to cover exposed holes.
After locating a defective gear, removal and replacement follow this general procedure:
5
1 Remove the snap ring by prying it off.
2 Withdraw the gear slowly from its shaft, so as not to lose any spacers or wash-
ers (e.g. there may be several above and below a pump gear), or cylinder pins
holding the gear to the shaft.
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
67
Page 72
5
3 Replace all spacers and washers and slide a new gear on the shaft.
Use the same number of spacers and washers in the same position.
4 Replace the snap ring.
If a snap ring has been lost or damaged, replace it with a new one.
Advanced service
5 Check the assembly by turning the drive gear with your finger.
If the drive roller turns smoothly, all parts can be replaced and the operation resumed.
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INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 73
Replacement of a cover drive gear
1 Remove the snap ring by prying it off.
2 Remove the fastener and the upper rack drive gear.
5
Advanced service
1220C GB 19991004
3 Replace all spacers and washers and slide a new gear on the shaft.
Use the same number of spacers and washers in the same position.
4 Replace the snap ring.
If a snap ring has been lost or damaged, replace it with a new one.
5 Check the assembly by turning the drive gear with your finger.
If the drive roller turns smoothly, the tank cover can be replaced and the operation resumed.
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
69
Page 74
5
Replacement of a replenishment pump gear
❖ Refer to chapter 3, ‘Cleaning’, to know how to locate and access a replenishment
1 Unfasten the replenishment pump by loosening the two wing nuts, and then pull
the pump out.
Advanced service
2 By prying it off, remove the snap ring that holds the pump gear onto the pump
shaft.
pump.
70
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 75
3 Withdraw the gear slowly from its shaft, so as not to lose any spacers or wash-
ers (e.g. there may be several above and below the pump gear), or cylinder pins
holding the gear to the shaft.
The “D” shape of the shaft matches the shape of the hole in the pump gear to prevent it
from turning independently.
4 Replace all spacers and washers and slide a new gear on the shaft.
Use the same number of spacers and washers in the same position.
❖ Refer to ‘Adjustment of replenishment pump gears’ if the pump is not properly en-
gaged with its associate drive gear.
5 Replace the snap ring.
If a snap ring has been lost or damaged, replace it with a new one.
5
Advanced service
1220C GB 19991004
6 Check the assembly by turning the drive gear with your finger.
If the pump drive gear turns smoothly, all parts can be replaced and the operation resumed.
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
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Page 76
5
Replacement of the red squeegee roller drive gear
❖ Refer to the diagram on page 64 for the location of the red squeegee roller drive gear.
The squeegee roller assembly can be cleaned by the user, but may never be
dismantled. If servicing is necessary, call your local service organization. The
red drive gear, however, can be replaced if it is damaged.
Advanced service
1 Remove the snap ring by prying it off.
2 Withdraw the damaged gear slowly from its shaft.
3 Slide a new red drive gear on the shaft.
4 Replace the snap ring.
If a snap ring has been lost or damaged, replace it with a new one.
5 Replace the squeegee roller assembly, being certain to engage the red drive
gear.
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1220C GB 19991004
Page 77
Replacement of the dryer transport roller drive gear
❖ Refer to the diagram on page 64 for the location of the dryer transport roller drive gear.
The dryer transport roller assembly can be cleaned by the user, but may never
be dismantled. If servicing is necessary, call your local service organization. The
drive gear, however, can be replaced if it is damaged.
5
1 Remove the snap ring by prying it off.
2 Withdraw the damaged gear slowly from its shaft.
3 Slide a new drive gear on the shaft.
4 Replace the snap ring.
If a snap ring has been lost or damaged, replace it with a new one.
5 Replace the transport roller assembly, being certain to engage the drive gear.
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
73
Page 78
5
Replacement of a worm drive gear
A worm drive gear is driven by a worm drive on the main drive shaft. Consult the
diagram on page 65.
After accessing the main drive assembly, do the following:
Advanced service
1 Remove the snap ring and the spacer on the worm drive shaft side of the
processor.
2 Slide the drive gear off its shaft.
❖ The cylinder pin is removable, so be careful not to drop it.
3 Slide the new gear on the shaft and replace the snap ring.
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INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
1220C GB 19991004
Page 79
Replacement of a drive shaft bearing
Excessive wear on certain bearings may cause gear misalignment. The replacement procedure for all shaft bearings is essentially the same. Consult the diagram on page 65.
After accessing the main drive assembly, proceed as follows:
5
1 Remove the snap ring and the spacer on the worm drive shaft side of the
processor.
2 Slide the drive gear off its shaft.
3 Remove the cylinder pin and spacer(s).
Be careful not to drop any components.
4 On the opposite side, pull the shaft out.
Transport drive gear shafts are pulled out at the chemical tanks side.
5 Replace the defective shaft bearing(s) from the front and/or the rear sides of the
shaft channel.
Advanced service
1220C GB 19991004
6 Reinsert the gear shaft through the bearings and replace the spacer.
7 Put the cylinder pin back, as well as the worm drive gear, and secure the gear
with a snap ring.
Carefully align the worm drive gear with the worm drive on the main shaft.
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
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Page 80
2
1
5
Replacement of the motor drive belt
The motor drive belt is a toothed belt that engages sprockets in the motor drive
gear and the larger of two transfer gears. Before replacing the motor drive belt
however, the longer replenishment pump drive belt must be removed. Consult
the diagram on page 65.
Advanced service
1 Remove the keeper [1] from the smaller transfer gear [2] shaft and remove the
plastic retaining disc.
2 Disengage the replenishment pump drive belt [1] from the sprockets of the
smaller transfer gear.
2
1
3 Disengage the motor drive belt [2] from the sprockets of the larger transfer gear
and then from the motor drive gear.
4 Slide the spare motor drive belt first onto the motor drive gear and then on to
the larger transfer gear.
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
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5 Slide the replenishment pump drive belt onto the smaller transfer gear.
Make certain it is properly engaged with the three pump drives.
6 Replace the plastic retaining disc and the keeper on the transfer gear shaft.
5
Replacement of the replenishment pump drive belt
The replacement of the replenishment pump drive belt is not user serviceable.
Call your local service organization.
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
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5
Reassembling the main drive assembly
1 Put the rear cover back into its place and secure it with the two screws.
2 Make sure that the tanks are installed and that all gears are properly engaged.
Advanced service
3 Replace the tank covers and the processor cover.
Make sure that the interlock switch, indicated on the processor cover with a white dot, is
properly engaging the interlock switch. If not, the processor will fail to operate.
4 Insert the replenishment bottles.
The tanks will be filled automatically.
78
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
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Adjustment of replenishment pump gears
If a pump gear is not properly engaged with its associated drive gear, the position of the gear on the shaft can be lowered or raised by adjusting the number
of spacers below the pump gear. Spacers may be reused, as they are not subject to wear.
5
❖ Refer to chapter 3, ‘Cleaning’, to know how to locate and access the replenishment
pumps.
1 Unfasten the replenishment pump by loosening the two wing nuts, and then pull
the pump out.
2 By prying it off, remove the snap ring that holds the pump gear onto the pump
shaft.
Advanced service
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INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
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Page 84
5
3 Withdraw the gear slowly from its shaft, so as not to lose any spacers or wash-
ers (there may be several above and below a pump gear), or cylinder pins holding the gear to the shaft.
Advanced service
4 Replace the gear, the spacers and the washers.
Increase or decrease the number of washers to adjust the position of the pump gear.
.
5 Replace the snap ring.
If a snap ring has been lost or damaged, replace it with a new one.
6 Check the assembly by turning the drive gear with your finger.
If the drive roller turns smoothly, the tank cover can be replaced and the operation resumed.
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
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1220C GB 19991004
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Replacement of roller springs
Replacing a transport roller spring
Refer to chapter 3, ‘Cleaning the Cawomat 2000 IR’, for the location and the removal
of transport rollers.
5
1 Remove the roller spring by sliding it over the end of the bearing on the trans-
port roller assembly.
2 Slide a new roller spring over the bearing, taking care not to stretch out the
spring while fitting it in place.
Make sure that the spring is properly relocated in the bearing grooves.
Replacing a squeegee roller spring
The squeegee roller assembly can be removed easily for cleaning purposes, but
it can not be dismantled. Call your local service organization if a squeegee roller
spring needs replacement.
Advanced service
1220C GB 19991004
INSTRUCTIONS FOR SKILLED SERVICE PERSONNEL ONLY
81
Page 86
5
Advanced service
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1220C GB 19991004
Page 87
Appendix
Equipment information sheet
A
Page 88
A
Specifications
84
1220C GB 19991004
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Specifications
General
Product description
Type of product Medical film processor
Commercial name Cawomat 2000 IR
Model number 9462/305/345
Type Table-top model
Original seller/manufacturer Agfa-Gevaert NV-Mortsel
Labelling
CE (Type 305) 93/42 EEC ‘Medical Devices’ (Europe)
TÜV (Type 305) EN 60950; DIN 1988 (Germany)
ULc (Type 345) UL 1950, CSA 22.2 No.950 (US)
Dimensions
Length, feed table and receiving tray
excluded 940 mm
Length, feed table and
receiving tray included 1090 mm
Width 650 mm
Height 370 mm
Height, receiving tray included 400 mm
Weight
Unpacked and empty 49 kg
Packed (with accessories) 81.5 kg
Materials
(refer to the recycling instructions manual for a complete overview of materials)
Equipment does not contain as a constituent element: CFC or HCFC, Asbestos,
PCB or PCT, Mercury, Cadmium, Lead as additive to plastics parts.
Plastic parts > 50 g are marked in accordance with ISO 11469.
Electrical connections
ABC: 342XN (Type 9462/305) 230-240 V, 50 Hz, 8 A (CE & TÜV)
ABC: 342ZR (Type 9462/345) 120 V, 60 Hz, 9 A (UL)
Power consumption
Standby 180 W
During film processing 500 W (max. 1700 W)
Environmental conditions
Relative humidity 10% - 80% (non-condensing)
Room temperature 15 °C - 30 °C
A
Specifications
1220C GB 19991004
85
Page 90
A
Specifications
Recommended consumables
1
Developer Agfa G153 X-ray developer
Fixer Agfa G 353 and G 354 X-ray fixer
Film All general X-ray films
Water tap water
Tank volumes
Developer tank 0.9 l
Fixer tank 0.9 l
Water tank 0.9 l
Replenishment bottles 5 l each (optional 2.5 l)
Developer temperature
(default value upon installation)
Developer tank 34 °C
Fixer temperature
(default value upon installation)
Fixer tank 34 °C
Replenishment rates
(default values upon installation)
Developer 600 ml/m
Fixer 750 ml/m
Water 900 ml/m
2
2
2
Film characteristics
Smallest film size 100 x 100 mm or 90 x 120 mm
Max. film width 360 mm (max format 350 x 430 mm)
Physical emissions
Noise emission (sound power level according to ISO 7779)
- During film processing 55 dB(A)
- Standby 46 dB(A)
Magnetic field 1.5 mT max.
Radio frequency emission according to CE requirements
Heat emission
- During film processing total: 1800 kJ/h; into the room: 1800 kJ/h
- Standby total: 650 kJ/h; into the room: 650 kJ/h
Chemical emissions (equipment & consumables)
depending on processing conditions, and type of chemicals; in direct surroundings
of equipment, when using recommended chemicals, and if installed according to
instructions.
SO2(sulfur dioxide) below TLV values
CH3COOH (acetic acid) below TLV values
2
2
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1220C GB 19991004
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Process data
Output 60 films per hour (240 x 300 mm format)
Processing time 137 seconds from dry to dry
Film transport speed 280 mm/min.
Drying system
Infrared drying (6 levels) air throughput about 80 m3/h
End of life
Estimated product life (if regularly
serviced and maintained according to
CAWO instructions) 7 yrs
For re-use, recycling or disposal of used apparatus and for recycling instructions,
please contact your local service organization.
Options Function ABC code
Light-tight cover Darkroom protection 2T7ZG
Fixed water connection For continuous water supply HV49W
Support table Sturdy and easy to clean 25JMK
Replenishment system 230-240 V / 50/60 Hz 34UZW
Replenishment system 120 V / 60 Hz 3XN83
A
1220C GB 19991004
Consumables Order volume ABC code
Agfa G153 X-ray developer Set 12 x 2.5 l of developer chemical HT536
Agfa G353 X-ray fixer Set 18 x 2.5 l of fixer chemical 2TRXG
Agfa G354 X-ray fixer Set 18 x 2.5 l of fixer chemical 2828Q
Replenishment bottles Set 3 x 2.5 l 3N5PN
Replenishment bottles Set 3 x 5 l 3N5OL
1 Take note of the relevant Material Safety Data Sheets
2 Threshold limit value for chemical substances in the work environment as adopted by the ACGIH
(American Conference of Governmental Hygienists).
Specifications
87
Page 92
Safety standards
A
Specifications
The Cawomat 2000 IR complies with the VDE 0805/EN 60950/IEC 950 safety
regulations and with the European regulations on radio interference suppression
EN 55022, Class B and CISPR Publication 22 (1990) Level B.
The non-return water connection system complies with the DIN 1988 standards.
The Cawomat 2000 IR carries the CE label.
Only applicable to North America:
The Cawomat 2000 IR has been constructed in accordance with the safety regulations UL Standard 1950 and UL 775, with CSA 22,2 N° 950 and with the regulations on radio interference suppression USA Standard FCC 47, Part 15,
Class A.
Only applicable to North America: The Cawomat 2000 IR is UL and cUL certified.
Warning
The Cawomat 2000 IR generates, uses and can radiate radiofrequency energy
and if not installed and used in accordance with the user manual, may cause interference with radio communications. The Cawomat 2000 IR has been tested
and found to comply with the limits for a class A computing device pursuant to
Subpart B of Part 15 of the FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case the user will be required to take at his own expense
whatever measures may be required to correct the interference.
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1220C GB 19991004
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Appendix
Parts list and
exploded views
B
Page 94
B
Parts list
90
1220C GB 19991004
Page 95
Spare parts list
Notes
❖
Electrical connections and repairs should only be made by authorised electricians. Mechanical connections and repairs should only be made by authorised
technicians.
❖
D = Standardized part. For orders please refer to the separate spare parts list
for standardised parts on page 130.
❖
Grey colored table cells indicate an assembly of p art s, which are also indi cated
by dotted lines on the diagrams.
❖
Data and characteristics may be changed without notice.
Location diagram
Assembly name Pages N°
Mounting rack
Electronic rack
Drive plate
Roller mounting diagram
Developer tank
Fixer tank
Water tank
Squeegee roller assembly
Cross-flow blower
Dryer section
Exit unit
92-93
94-95
96-99
100-101
102-105
106-109
110-113
114-115
116-117
118-119
120-121
1
2
3
4
5
6
7
8
9
10
11
9
B
9
11
1220C GB 19991004
3
6
5
7
2
8
Parts List
4
4
10
4
1
91
Page 96
Mounting rack
D95
D82
D2412
13
D218
14
D247
26
15
D247
B
34
21
23
25
24
04
33
D247
D800
28
38
D2211
06
12
05
30
03
27
39
29
31
35
36
02
42
01
18
Parts List
08
11
19
10
09
22
20
40
41
16
41
07
92 1220C GB 19991004
Page 97
Mounting rack
Item Nr Part Code Description
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
38
39
40
41
42
CM+0.0000.07.025 HOSE TRANS
CM+0.0000.64.055 HOSE TRANS
CM+7.0205.016.00 SREW LOCKING
CM+7.0426.6311.0 COVER SWITCH
CM+7.0471.7170.0 FLAT PLUG
CM+9.5220.1680.1 SCANNING ROLL ER
CM+9.8896.2952.1 ELBOW
CM+9.9432.1070.5 RED VALVE (DEVELOPER REPLENISHMENT BOTTLE)
CM+9.9432.1075.1 GASKET
CM+9.9432.1090.5 WHITE VALVE (WATER REPLENISHMENT BOTTLE)
CM+9.9432.1110.5 BL U E VALVE (FIXER REPLENISHMENT BOTTLE)
CM+9.9432.3025.0 SNAP RING
CM+9.9462.1017.3 TABLE PLATE
CM+9.9462.1019.1 MEASURING PIN
CM+9.9462.1034.2 SNAP SPRING
CM+9.9462.1035.0 REDUCING PART
CM+9.9462.1043.0 RED BOTTLE RECEPTACLE (DEVELOPER)
CM+9.9462.1044.0 BLUE BOTTLE RECEPTACLE (FIXER)
CM+9.9462.1045.0 WHITE BOTTLE RECEPTACLE (WATER)
CM+9.9462.1052.2 PIN
CM+9.9462.6082.0 BOTTLE
CM+9.9462.1105.0 PROTECTING CAP
CM+9.9462.1106.0 HOLDER
CM+9.9462.1107.0 HOLDER
CM+9.9462.1111.1 SNAP CASE
CM+9.9463.1090.0 FEED TABLE
CM+9.9462.1520.0 FILM SCANNER
CM+9.9462.2566.0 CABLE UL
CM+9.9463.2950.0 SCANNING ROLL ER
CM+9.9462.4566.0 CABLE UL
CM+9.9463.1062.0 DRYER COVER
CM+9.9463.1400 .0 EXIT TRAY
CM+9.9462.6101.0 LEG
CM+9.9463.1120.0 CHASSIS
CM+9.9463.1042.0 PROCESSOR COVER
CM+9.9463.1072.0 GEAR COVER
CM+9.9462.1175.0 COVER
CM+7.0372.0040.0 HOSE CLAMP
CM+7.0371.7011.0 HOSE CLAMP
B
Parts List
1220C GB 19991004
93
Page 98
Electronic rack
ST5
ST1
01
ST21
SI1
04
06
09
SI5
ST18
ST16
B
ST12
ST22
ST7
SI3
Parts List
08
07
01
05
03
ST8
XK1
SI4
SI8
ST10
ST6
SI6 SI7
ST3
ST4
SI2
ST17
02
94 1220C GB 19991004
Page 99
Electronic rack
Item Nr Part Code Description
01
01
02
02
03
03
04
05
05
06
07
08
09
09
CM+7.0451.9608.0 FUSE
CM+7.0451.9604.0 FUSE
CM+7.0451.9630.0 FUSE
CM+7.0451.9707.0 FUSE
CM+7.0451.9706.0 FUSE
CM+7.0451.9727.0 FUSE
CM+7.0451.9716.0 FUSE
CM+7.0451.9720.0 FUSE
CM+7.0451.9705.0 FUSE
CM+9.9463.1460.0 COVER WELDED
CM+9.9463.9010.2 BOTTOM PART PREASS
CM+9.9463.1451.0 BOTTOM PART
CM+9.9463.2567.0 EPROM V 1102 for type 205/845
CM+9.9463.2817.0 EPROM V 1101 for type 285 (230 V 60 Hz)
1220C GB 19991004
B
Parts List
95
Page 100
Drive plate 1/2
02
D2321
D195
21
22
06
17
03
30
11
04
17
09
23
01
29
08
16
24
11
D195
24
D82
01
D134
D2388
07
11
01
07
01
24
18
B
25
12
28
Parts List
D244
05
13
14
06
26
15
27
24
11
96 1220C GB 19991004
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