Kodak X-Omat 5000 User manual
DIAGNOSTICS
for the
Publication No. 5B6342
January 1996
Supersedes October 1995
Kodak X-Omat
5000 RA PROCESSOR
© Eastman Kodak Company
H148_0004GA
PLEASE NOTE The information contained herein is based on the experience and knowledge relating to the
subject matter gained by Eastman Kodak Company prior to publication.
No patent license is granted by this information.
Eastman Kodak Company reserves the right to change this information without notice, and
makes no warranty, express or implied, with respect to this information. Kodak shall not be liable
for any loss or damage, including consequential or special damages, resulting from any use of
this information, even if loss or damage is caused by Kodak’s negligence or other fault.
This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.
Table of Contents
Description Page
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
All Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Non-Fatal Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mechanical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transport Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Artifacts and Wrong Film Densities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wet Films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Solution Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Internal Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Accessing the Internal Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
D1 Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
D2 Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
D3 Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Diagnostic Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
D1 Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
D2 Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
D3 Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Flowcharts for the Internal Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Printing Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SOLID STATE RELAYS (SSR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Possible Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking the LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking the SSR and the 5000 BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Publication History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 January 1996 – 5B6342
Error Codes
Section 1: Error Codes
Introduction
Overview The software on the 5000 MICROPROCESSOR BOARD controls and monitors the operation
of the PROCESSOR and continually checks for errors. Whenanerror occurs, a description of
the error is displayed on the DISPLAY PANEL.
When 2 or moreerrors occur together, allthe errors are displayed, butonly 1 error isvisible on
the DISPLAY PANEL at a time. The error with the highest priority is displayed first. You can
scroll through the list to view the other errors.
An error log on the 5000 BOARD records the last 100 errors that have occurred and the
number of times each error has occurred.
3 types of errors can occur:
• Fatal
• Non-Fatal
• Warning
Fatal and
Non-Fatal Errors
Only qualified service personnel should repair both fatal and non-fatal errors.
• Most fatal errors prevent optimum film processing.
• Most non-fatal errors do not prevent optimum film processing.
Important
When you service a PROCESSOR with a fatal or non-fatal error and you check an electrical
component or BOARD, also check all the:
• connections and CABLES for the component or BOARD
• voltages from the POWER SUPPLY for the component or BOARD
Warning Errors Operators can repair warning errors. Normally,you can feed filminto a PROCESSOR when a
warning error is displayed.
READY LED If any error prevents optimum film processing, the READY LED will de-energize. When the
LED de-energizes, you can feed film into the PROCESSOR but the image quality may not be
correct. Kodak recommends that you do not process film when the LED is de-energized.
5B6342 – January 1996 3
DIAGNOSTICS
All Errors
Important
When you check an electrical component or BOARD, also check all the:
• connections and CABLES for the component or BOARD
• voltages from the POWER SUPPLY for the component or BOARD
When you check a SOLID STATE RELAY, usethe tests inthe Appendix to determine the source of themalfunction.
ESD
Possible damage from electrostatic discharge.
Fatal Errors
Code Description Possible Malfunction Action
E001 Microcontroller error 5000 BOARD Install a new BOARD.
E002 Dryer over maximum
temperature
Note
The maximum temperature
is 79°C (175°F).
Normally, the DRYER AC
OVERTEMPERATURE
THERMOSTAT opens
before the DRYER reaches
this temperature.
E003 Loss of film accumulator
data link
E004 Inoperative transport See E041.
E007 Developer thermistor
failure
E008 Fixer thermistor failure The FIXER HEATER is disabled when this error occurs.
E009 Dryer thermistor failure The DRYER HEATER is disabled when this error occurs.
E010 Analog-to-digital converter
failure
DRYER BLOWER When the DRYER HEATER energizes,
the DRYER BLOWER should energize.
Check:
• RELAY K1
• DRYER BLOWER
DRYER THERMISTOR Check that the resistance at 25°C (77°F)
is approximately 10 KW.
SOLID STATE RELAY U1 that
controls the DRYER HEATER
5000 BOARD Install a new BOARD.
No communication withthe 6000
BOARD
BOOT PROM U6018 on the
6000 BOARD
6000 BOARD Install a new BOARD.
5000 BOARD Install a new BOARD.
The DEVELOPER HEATER is disabled when this error occurs.
DEVELOPER THERMISTOR Install a new THERMISTOR.
FIXER THERMISTOR Install a new THERMISTOR.
DRYER THERMISTOR Install a new THERMISTOR.
All 3 HEATERS are disabled when this error occurs.
5000 BOARD Install a new BOARD.
Check U1.
De-energize and energize the
PROCESSOR to automatically reset the:
• MICROPROCESSOR on the 5000
BOARD
• MICROPROCESSOR on the 6000
BOARD
Install a new U6018.
4 January 1996 – 5B6342
Error Codes
Code Description Possible Malfunction Action
E011 Developer heater failure This error occurs when the 8000 CURRENT SENSE BOARD detects no
current through the DEVELOPER HEATER.
When the temperature of the
developer solution is too high,
the DEVELOPER HEATER
Determine the cause for the high
developer temperature, and repair the
problem.
OVERTEMPERATURE
THERMOSTAT will open. The
THERMOSTAT will reset
automatically when the solution
cools.
No continuity for the
DEVELOPER HEATER
After the HEATER cools, check the
continuity. If necessary, install a new
HEATER.
The 5000 BOARD does not
energize the RELAY K5004 on
Check that the LED DS9 on the 5000
BOARD is energized.
the 5000 BOARD.
If necessary, install a new BOARD.
SOLID STATE RELAY U2 that
Check U2.
controls the DEVELOPER
HEATER
The 5000 BOARD does not
energize the SOLID STATE
Check that LED DS4 on the 5000
BOARD is energized.
RELAY U2.
If necessary, install a new BOARD.
8000 BOARD Install a new BOARD.
E012 Fixer heater failure This error occurs when the 8000 CURRENT SENSE BOARD detects no
current through the FIXER HEATER.
When the temperature of the
fixer solution is too high, the
Determine the cause for the high fixer
temperature, and repair the problem.
FIXER HEATER
OVERTEMPERATURE
THERMOSTAT will open. The
THERMOSTAT will reset
automatically when the solution
cools.
No continuity for the FIXER
HEATER
After the HEATER cools, check the
continuity. If necessary, install a new
HEATER.
SOLID STATE RELAY U5 that
Install a new U5.
controls the FIXER HEATER
The 5000 BOARD does not
energize the RELAY K5004 on
Check that the LED DS9 on the 5000
BOARD is energized.
the 5000 BOARD.
If necessary, install a new BOARD.
The 5000 BOARD does not
energize the SOLID STATE
Check that LED DS1 on the 5000
BOARD is energized.
RELAY U5.
If necessary, install a new BOARD.
8000 BOARD Install a new BOARD.
5B6342 – January 1996 5
DIAGNOSTICS
Code Description Possible Malfunction Action
E013 Level sensor circuit failure This error occurs when the level sensor circuit on the 5000 BOARD
malfunctions. The following parts are disabled:
• DEVELOPER and FIXER REPLENISHMENT PUMPS
• RECIRCULATION PUMP
The temperature control for the fixer and developer is disabled.
5000 BOARD Install a new BOARD.
E014 Invalid program software E014 is displayed on the DEVELOPER TEMPERATURE DISPLAY. This
error disables all subsystems, except communications.
The main program software in
Download new software.
the EEPROM on the 5000
BOARD
E015 Invalid bootstrap software The bootstrap software for the
Install a new U5006.
PROM U5006 on the 5000
BOARD
E016 Invalid film accumulator
software
This error does not disable any subsystems. The PROCESSOR will remain
in the standby modeuntil the FILM DETECTOR SWITCHESactuate. These
SWITCHES provide information about the length of the film. Because the
6000 BOARD does not operate correctly, the PROCESSOR uses the
information from the SWITCHES to determine the replenishment rate.
The main program software in
Download new software.
the EEPROM on the 6000
BOARD
6 January 1996 – 5B6342
Non-Fatal Errors
Code Description Possible Malfunction Action
E032 Developer tank fill
error
This error will occur if the:
• DEVELOPER TANK:
– does not fill in 2 minutes in normal operation
– does not fill in 10 minutes in the Tank Fill Mode
– is empty and the operator does not select the Tank Fill Mode
• REPLENISHER TANK is empty.
• REPLENISHMENT HOSE has:
– an obstruction
– a kink
– an air bubble
• TANKS of thePROCESSOR are filledwith water during the initial installation
.
The following parts will be disabled:
• DEVELOPER REPLENISHMENT PUMP
• RECIRCULATION PUMP
• temperature control for the fixer and developer
To prevent the error from occurring during the initial installation:
• Add 240 mL (8 fl oz) of developer to the DEVELOPER TANK before you fill
the PROCESSOR with water.
• Energize the RECIRCULATION PUMP to move the developer and remove
any air bubbles. Use the diagnostics to energize the PUMP.
LEVEL PROBES Clean and check the PROBES.
The solution level in the
REPLENISHER TANK is low.
Solution does not flow through the
HOSES between the
REPLENISHMENT TANK and the
REPLENISHMENT PUMP.
The DEVELOPER DRAIN VALVE
is opened.
SOLID STATE RELAY U3 that
controls the DEVELOPER
REPLENISHMENT PUMP
POPPET VALVES in the
DEVELOPER REPLENISHMENT
PUMP
DEVELOPER REPLENISHMENT
PUMP
The 5000 BOARD does not
energize the SOLID STATE
RELAY U3.
Mix new developer solution.
Check that the:
• HOSE CLAMPS are tight.
• HOSES:
– are round and opened
– have no obstructions or air bubbles
Close the VALVE.
Check U3.
Clean and check the VALVES.
Check the REPLENISHMENT PUMP
MOTOR B3.
Check that LED DS3 on the 5000 BOARD
is energized.
If necessary, install a new BOARD.
Error Codes
5B6342 – January 1996 7
DIAGNOSTICS
Code Description Possible Malfunction Action
E033 Fixer tank fill error This error will occur if the:
• FIXER TANK
– does not fill in 2 minutes in normal operation
– does not fill in 10 minutes in the Tank Fill Mode
– is empty and the operator does not select the Tank Fill Mode
• REPLENISHMENT TANK is empty.
• REPLENISHMENT HOSE has:
– an obstruction
– a kink
– an air bubble
• TANKS of the PROCESSOR are filled with water during the initial installation
.
The following parts will be disabled:
• FIXER REPLENISHMENT PUMP
• RECIRCULATION PUMP
• temperature control for the fixer and developer
To prevent the error from occuring during the initial installation:
• Add 240 mL (8 fl oz) of fixer to the FIXER TANK before you fill the
PROCESSOR with water.
• Energize the RECIRCULATIONPUMP to movethe fixer andremove any air
bubbles. Use the diagnostics to energize the PUMP.
LEVEL PROBES Clean and check the PROBES.
The solution level in the
Mix new fixer solution.
REPLENISHER TANK is low.
Solution does not flow through the
HOSES between the
REPLENISHMENT TANK and the
Check that the:
• HOSE CLAMPS are tight.
• HOSES:
REPLENISHMENT PUMP.
– are round and opened
– have no obstructions or air bubbles
The FIXER DRAIN VALVE is
Close the VALVE.
opened.
SOLID STATE RELAY U4 that
Check U4.
controls the FIXER
REPLENISHMENT PUMP
POPPET VALVES in the FIXER
Clean and check the VALVES.
REPLENISHMENT PUMP
FIXER REPLENISHMENT PUMP Check the REPLENISHMENT PUMP
MOTOR B4.
The 5000 BOARD does not
energize the SOLID STATE
Check that LED DS2 on the 5000 BOARD
is energized.
RELAY U4.
If necessary, install a new BOARD.
8 January 1996 – 5B6342
Code Description Possible Malfunction Action
E038 Loss of developer
cooling ability
Water does not enter the WASH
TANK.
Check:
• that water is supplied to the
PROCESSOR
– The water supply is turned on.
– The FILTER is clean.
• WASH WATER SOLENOID L1
– The operation is correct.
– The SCREEN has no obstructions.
• COOLING/DRAIN SOLENOID L2
The temperature of the water
entering the WASH TANK is too
hot.
Decrease the temperature of the water
supply. The wash water must be a
minimum of 5.5°C (10°F) below the setpoint
of the developer.
HEAT EXCHANGER in the
DEVELOPER TANK
The 5000 BOARD does not
energize the SOLENOID L1 or
Remove any obstructions from the
EXCHANGER.
Check for 24 V DC at TERMINALS1 and 2
on the WASH WATER SOLENOID L1.
de-energize the SOLENOID L2.
Check that 24 V DC is not present at
TERMINALS 1 and 2 for the
COOLING/DRAIN SOLENOID L2.
Error Codes
E040 Loss of dryer heating
ability
If necessary, install a new BOARD.
RECIRCULATION PUMP Check the RECIRCULATION PUMP
MOTOR B5. If necessary, install a new
PUMP.
A PANEL is not installed. Install the PANEL.
DRYER OVERTEMPERATURE
THERMOSTAT
Reset the THERMOSTAT. If the
THERMOSTATopensagain,determinethe
cause of the high temperature. If you
cannot determine the cause of theproblem,
install a new THERMOSTAT.
SOLID STATE RELAY U1 that
Check U1.
controls the DRYER HEATER
No continuity for the DRYER
HEATER
The 5000 BOARD does not
energize the SOLID STATE
Check that the resistance at 25°C (77°F) is
approximately 18 W.
Check that LED DS5 on the 5000 BOARD
is energized.
RELAY U1.
If necessary, install a new BOARD.
5B6342 – January 1996 9
DIAGNOSTICS
Code Description Possible Malfunction Action
E041 Loss of transport speed control
When the PROCESSOR operates normally:
• The supply voltage from the +24 V POWER SUPPLY PS3 to the
PCOM and +24 V TERMINALS of the DRIVE MOTOR
Note
This error occurs when the
transport speed is adjusted for
10 seconds and the speed is
not within 7.6 cm/min (3 in./min)
of the setpoint.
CONTROLLER A4 is 24 V DC.
• The control voltage to TERMINALS 4 and 6 on the DRIVE MOTOR
CONTROLLER A4 is approximately:
– 0.85 V DC for the Extended Speed
– 1.55 V DC for the Standard Speed
– 2.25 V DC for the Rapid Speed
– 3.00 V DC for the K/RA Speed
• Feedback pulses from the DRIVE MOTOR CONTROLLER A4 at
Test Point MOTFB on the 5000 BOARD indicate the speed of the
DRIVE MOTOR.
If the transport operates slower than the set speed, the
MICROPROCESSOR increases the control voltage approximately
25 mV every second at TERMINALS 4 and 6 on the DRIVE MOTOR
CONTROLLER A4. If the voltage reaches 5 V DC, the
MICROPROCESSOR stops increasing the voltage. When you check
the voltage, if it is:
• 5 V DC, check for mechanical malfunctions.
• 0, check the wiring and the CONNECTOR.
5000 BOARD If the control voltage is not correct at
TERMINALS 4 and 6of the DRIVE MOTOR
CONTROLLER A4, install a new BOARD.
DC DRIVE MOTOR B6 or
DRIVE MOTOR
CONTROLLER A4
If B6 operates, but no pulses occur at Test
Point MOTFB on the 5000 BOARD or if the
supply voltage and the control voltagetothe
CONTROLLER are not correct, check:
• B6
•A4
E042 Loss of accessory data link Loose connections Check all connections between any
accessory and the PROCESSOR.
5000 BOARD Install a new BOARD.
2000 BOARD Install a new BOARD.
E045 Display data link error CABLES between the
Check the CABLES.
3000 and 5000 BOARD
10 January 1996 – 5B6342
Warnings
Error Codes
Error
Code
E128 Top cover not in
place
E129 Tanks currentlybeing
filled
E130 Replenish pumps
disabled
E132 Developer under set
temperature
E133 Developer over set
temperature
E134 Dryer under set
temperature
E137 Film accumulator
LED error
Error
Description
Possible
Malfunction Action
When this error occurs, the following functions are disabled:
• film transport
• film accumulation
The TOP COVER is opened. Close the TOP COVER.
INTERLOCKSWITCHESS3
and S4
• MAGNETS
7000 BOARD Install a new BOARD.
When this error occurs,
• the following functions are disabled:
– film transport
– film accumulation
• the following parts are disabled:
– RECIRCULATION PUMP
– 3 HEATERS
None None. This message will clear automatically.
None Use the KEYPAD to select either Automatic or
None None. This message will clear automatically when
None None. This message will clear automatically when
None None. This message will clear automatically when
6000 BOARD Check that no chemical deposits are on the
Check S3 and S4. If necessary, install a new
SWITCH or MAGNET.
Flooded Replenishment to enable the PUMPS.
the developer reaches the setpoint temperature.
the developer reaches the setpoint temperature.
the DRYER reaches the setpoint temperature.
PROTECTIVE COVER for the BOARD.
De-energize and energize the PROCESSOR to
reset the:
• MICROPROCESSOR on the 5000 BOARD
• MICROPROCESSOR on the 6000 BOARD
Check the BOARD. Use the internaldiagnostics. If
necessary, install a new BOARD.
E141 Low developer tank
level
E142 Low fixer tank level When this error occurs, the:
5B6342 – January 1996 11
When this error occurs, the:
• RECIRCULATION PUMP is disabled
• temperature control for the fixer and developer is disabled
None None. This error will clear automatically when the
developer solution reaches the correct level.
• RECIRCULATION PUMP is disabled
• temperature control for the fixer and developer is disabled
None None. This error will clear automatically when the
fixer solution reaches the correct level.
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