Protec Ecomax User Manual

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Page 1

Film Processor

Operation Manual

English

PROTEC GmbH & Co. KG

In den Dorfwiesen 14, D-71720 Oberstenfeld, Germany Telephone: +49-7062-9255-0 e-mail: [email protected]

Machine No.: Type: Installation Date: Status: 08-2009/1.3 Subject to change

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EU-Declaration of Conformity

PROTEC® declares, that the product Description: Machine type: Model no.

conforms to the following harmonized standards:

ECOMAX X-Ray-Film Processor

1 186-x-0000 x is a number between 1 and 9

Safety: EMC:

according to the regulations of:

IEC 61010-1:2001; DIN 1988 T4:12/1988; UL 3101-1; CSA 22.2-1010-1 EN 61326:1997 + A1:1998; EN 61000-3-2:1995 + A1/A2:1998 + A14:2000;

EN 61000-3-3:1995

• the Medical Device Directive 93/42/EEC “Class 1”,

• the Low Voltage Directive 73/23/EEC and the

• EMC Directive 89/336/EG

Supplementary guidelines:

• DIMDI: DE / 0000042967

• WEEE: DE 55471807

PROTEC GmbH & Co. KG, Lichtenberger Strasse 35, D-71720 Oberstenfeld, Germany

Place and date of issue: Oberstenfeld, 02. July 2007 Jochen Krupp (Technical Manager Analogue Systems)

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Table of Contents

Introduction.......................................................................................................... 3

Intended Use.........................................................................................................4

Technical Specifications..................................................................................... 6

Safety Instructions............................................................................................... 7

Installation............................................................................................................8

Initial Operation.................................................................................................. 11

Operation

Short Overview and Front Panel Pad..........................................................12

Stand-by mode................................................. .. .........................................13

Switching on the machine............................................................................14

Display “Infeeding film”................................................................................ 14

Anti-Chrystalisation Function / Anti-Oxidisation Function............................ 14

Automatic replenishment............................................................................. 15

Care

Daily Care.................................................................................................... 16

Weekly Care................................................................................................ 16

Thorough Cleaning......................................................................................17

Maintenance / Disposal ..................................................................................... 18

Problems and Solutions

Advice on Film Defects................................................................................21

Advice on Machine Errors ...........................................................................22

Accessories........................................................................................................ 23

Service Manual as appendix, see page page 25

English

Information on Liability

This manual has been checked for correctness. The instructions and specifications were correct at the time it was published. Future models may have modificati ons without prior notice. PROTEC® does not take responsibility for damage caused directly or indirectly by error, omission or non-conformity of the manual.

Introduction

The ECOMAXTM processor is a compact, automatic table-top processor. Due to the precision roller transport system, sheet films can be processed. The film materials are developed, fixed, rinsed and dried. The ECOMAX tomatic film-registration and a Stand-by mode. The developing solutions a re temperature-regulated, circulated and automatically replenished.

These Operating Instructions contain important instructions for installation, o peration and servicing of the machine. Please read the provided information carefully to ensure reliable and satisfactory operation of your ECOMAX

has been fitted with an au-

ECOMAX

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Intended Use

The X-ray film processor ECOMAXTM is intended exclusively for the p urpose describe in the introduction above.

X-ray film processorss (MDD class I) are employed in “medical” applications (medical products directive) and “non-medical” applications (electri cal appliances and EMC directives).

Intended use includes observing the operating instructions, the installation instructions and adherence to the safety notes.

Any application differing from intended use voids the guarantee by PROTEC The owner of the machine will be liable for damages resulting from unintended use

or faulty application. Intended use includes adherence to all statutory re gulations concerning occupa-

tional safety and radiation protection applicable at the operating site.

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English

ECOMAX

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Technical Specifications

Film transport:

Film formats:

Processing capactiy:

Process time:

Linear speed:

Developer time:

Tank capacities:

Circulation system:

Replenishment:

Developer temperature:

Fixer temperature:

Continuous roller transport system

In general: sheet films up to max. 35.8 cm (14.1’’) width; Smallest film format 10x10 cm (4x4 ’’).

74 films 24x30 cm (10x12 “) per hour (standard model, feed film crosswise)

Standard 105 s

Standard 37 cm/min. (14.5 in/min)

Standard 29 s

Developer, fixer 2.3 litres each (0.51 gal) and water tank 2.1 litres (0.46 gal)

Developer and fixer are continiuously circulated by a circulation pump

Automatic replenishment by film detection, in relation to film length

Ex works set to 32 °C (89.6 °F) In exceptional cases can be set by a technician

Adjusted to developer temperature by heat exchanger.

Water connection:

Water consumption:

Drain capacity:

Noise level:

Heat emission:

Environmental cond itions:

Pollution degree:

System protection:

Permissible water pressure 2 - 10 bar (29 - 145 psi), permissible water temperature 5 - 30 °C (41 86 °F).

1.0 litres per minute (0.26 gal/min) when processing.

7 litres per minute (1.85 gal/min).

Less than 60 dB(A).

Operation: 0.1 kJ/s, Development: 1.1 kJ/s

1) Temperature 18 - 40 °C (51.6 - 104 °F), ventilated room, room temperature should be lower than set bath temperature.

2) Relative humidity lower than 80% up to 31 °C (80 °F), linearly decreasing to 50% at 40°C (104°F)

3) Height above sea level less than 2000 m (6666 ft.)

4) Indoor use 2

IP 20

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Technical Specifications

Electrical connections:

Power consumption:

Weight (unit):

Dimensions (LxWxH):

Floor space required:

Safety Instructions

Electrical specifications are indicated on the model nameplate. Type 1186-1-0000: 230 V±10%, 5.8 A, 50 Hz. Type 1186-2-0000: 230 V±10%, 5.8 A, 60 Hz. unit conforms to IEC 1010 (EN 61010, VDE 0411) overvoltate category II Type 1186-3-0000: 110 / 120 V~ ±10%, 12 A, 60 Hz, Type 1186-6-0000 110 / 120 V~ ±10%, 12 A, 50 Hz unit conforms to UL 3101 and CSA 22.21010 overvoltage category II

Operation: 0.12 kWh Development: 0.9 kWh

Empty 26.5kg (58.3 lbs) Filled 34 kg (74.8 lbs)

88x66x42 cm (34.7x26.4x17.0 ’’)

0.58 m2 (6.2 sqft)

English

To ensure the safe operation of this processor, installation and use should always conform to the instructions contained in this manual.

The developer and fixer chemicals used in the processor should be handled according to the manufacturers instructions. In general: Undiluted chemica ls are caustic. For this reason, chemicals should be handled very carefully. Avoid contact with skin, always wear protective clothing, gloves and glasses when handling the chemicals - for example, when mixing and refilling. Also when taking the racks out for cleaning or servicing. If chemicals have come in your eyes, rinse the eyes immediately with cold, running water for approximately 15 minutes and contact a medical doctor afterwards. Inhalation of chemicals can be dangerous to your health and should be avoided. For this reason, always ensure that the room in which the processor is installed is adequately ventilated.

Environmental regulations regarding the storage and disposal of waste chemicals should be obtained from the local water authorities and complied with.

Before opening the unit, switch off the unit and unplug it from the electrical socket. Service and repairs must be performed by trained service technicians only. Use only manufacturer´s replacement parts.

ECOMAX

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Installation

1. Requirements for installation

a. Fresh water connection: Shut-off tap, thread with 3/4" outside diameter

(washing machine connection), Water pressure 2 - 10 bar (29 - 145 psi).

b. Drainage connection: Plastic tube - inner diameter 50 mm (2”) or larger. A

ventilated syphon which serves as odour preventor should be included in the planning. The drainage tubes should be installed with a decline of minimum 5 %. Local Water Authorities regulations should be complied with.

c. Electrical connection: Fused wall socket with earth connection according to

electrical data (see technical specifications, page 7). It is also required to install an earth-leakage switch (with 25 A / 30 mA nominal error current).

Electrical connections should be carried out according to regulations by an electrician.

2. Transport

Due to the weight and dimensions of the film processor ECOMAXTM should always be carried by two persons. To do so, hold the machine on the sides of the bottom pan (see figure). While putting the machine down, watch the position of the levelling feet to prevent damaging these.

3. Set-Up

Unpack the Processor. Remove light protection cover and machine cover, remove roller racks, begin with the developer roller rack (red).

Remove the brackets for film output from the packaging and press them into the openings on the rear of the film output until they snap into place. Be sure the long side of the bracket points inward and touches the film output on top (see figure).

Table-top installation

In the event that the processor is to be installed on a work top or table, the four adjustable feet should be screwed on.

Attention! Machine should not be installed on table-top without adjustable feet. The ventilation openings under the machine must not be blocked, as this can cause overheating.

Unit with Worktable

If the unit is set up on a worktable (optional accessory), the unit should be screwed to the worktable. Mount the unit as outlined in the manual (included with the worktable).

Finally the processor needs to be levelled:

Place spirit level across the walls of the baths and adj ust the le ve lli ng feet accordingly (on the unit itself or on the worktable). Reinstall the roller racks in the unit and lock them; begin with the dryer roller rack.

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Installation

4. Connecting the processor

English

Water connection: Connect the water hose which comes out from the processor’s back to the fresh water supply.

All other hoses (see diagram page 10): First cut off the pre-installed hoses at the film processor so that the angle stubs protrude somewhat beyond the edge of the table (see figure). Connect the enclosed hoses at the front of the machine according to the colour system. Put hose clip (enclosed in accessory bag) over hose end, before attaching to connection. Warm up hose end (with hot water o r lighter) and push onto the respective connection. Finally push clip over hose and connection.

Cut hoses to required length. Then integrate the stop cocks into the three drainage hoses in such a position, that they are easy to reach.

Using the hose clips, connect the suction pipes to the ends of the hoses for the replenishment tanks. Feed the suction pipes through the cover opening into the respective replenishment tanks and snap them in to place.

The overflow and drainage hoses from the developer an d fixer should be guided into their respective collecting containers.

The overflow and the drainage of the water can either be guided into the drainage syphon or into respective collection containers.

ECOMAX

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Installation

Pay attention to the correct colour connections:

Developer: red; Fixer: blue; Water: clear

Replenishment Overflow Outlet

Hose Connections

Danger of Overflow! Use the included cable ties (accessory bag) to secure the hos-

es. Fix all hose ends which lead into the s yphon or c ollecting container, so that they do not drop into the liquid.

Very important: The hose piping should be straight (without the hoses going

up and down) with a constant decline. The hoses should be as short as possible and without bends and kinks. This is very important for the water overflow hose. Bad water overflow piping work may cause the machine to overflow!

Inform yourself of the local water board regulations regarding drainage. These regulations may differ from information in this manual, but they should be complied with.

If the machine is installed table-top, ensure that the table is stable enough and does not wobble.

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Initial Operation

1. Test run

Important! Processor should not be run dry!

a. Close the three drainage stop cocks and fill the tanks and replenishment con-

tainers with water. Open water inflow tap. Connect electrical socket and switch the machine on. Water now flows into water tank. The circulation pump activates, however the hosing of the machine must be ventilated.

b. Ventilation of the replenishment pump:

Switch the machine off again. Open the stop cocks of the developer and fixer for five seconds and switch machine on again. Repeat this procedure until no more air bubbles are visible in the developer and fixer baths and until the circulation pump runs quietly.

c. Ventilation of the circulation pump:

If air is in the circulation pump, a loud running noise can be heard. Switch the machine off again. Open the stop cocks of the developer and fixer for five seconds and switch machine on again. Repeat this procedure until no more air bubbles are visible in the developer and fixer baths and until the circulation pump runs quietly.

d. Check all hose connections for leakage. Switch machine off and drain water

out.

English

2. Filling the Processor with Chemicals

Prepare chemicals inside the replenishment containers according to manufacturers instructions.

Filling the processor manually

By using a suitable container, pour chemicals into the respective tanks. First the fixer and then the developer. Caution: when filling, be sure that chemicals do no splash from one bath into another. When fixer solution is mixed with developer solution, the developer chemical is destroyed.

Snap each suction pipe into the respective cover of it’s replenishment container and close it carefully. Place containers under processor.

Important! The machine should not be switched on in dry condition (no water/chemicals filled in), since the circulation pumps would otherwise run dry and be damaged.

Automatic filling of the unit / manual replenishment:

a. The chemicals containers need to be filled manually with at least 0.5 litres of

fresh chemicals, to ensure the pumps will not run dry. b. Switch the machine off. c. Keep the film detection switch pressed when switching the machine on again. d. Release the film detection switch. The replenishment pump will now run for 9

minutes or until the machine is switched off again. This function can also be

used for manual replenishment.

ECOMAX

Warning, hot surface!

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Operation

LED

Symbol for film feed released

Symbol for film feed locked

Operation

Short Overview and Front Panel Pad

Functions

• Feeding film Before feeding the next film wait until the LED stops flashing, but is continuously on. An acoustic signal additionally indicates that the next film can be inserted.

• Power (ready to operate) The LED is on as long as the unit is on.

• Warming up During warm-up the LED flashes; bef ore fe ed i ng th e next film wait until the LED stops flashing, but is continuously on. The end of the warm-up phase is indicated by an acoustic signal. If you try to insert a film during warm-up, an interval sound will occur permanently.

• Bath heating failure If the developer temperature is not reached within 30 minutes, the LED starts flashing rapidly and an interval sound occurs permanently.

Important! Safety function stops film transportation when cover is re-

moved. Therefore keep cover placed on the machine when processing films.

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Operation

Do not place any object on the processor.

Before use...

1. Close water-drainage stop cock.

2. Open water tap.

3. Switch processor on.

4. Check liquid level in replenishment and drainage collecting containers.

5. Wait until the developer temperature is reached. The LED stops flashing when the heat-up phase is completed.

6. Run cleaning films through processor.

Working procedure

7. Processing films: Open light protection cover. Important: Put film first on left side of infeed tray and then feed in. During processing films please watch the “Feeding film” LED. If it flashes, wait until it stops before feeding the next film; the LED must be continuously on and an acoustic signal must indicate that it is okay to feed a film.

After work...

8. Switch the unit off.

9. Close water tap.

10. Open water-drainage stop cock and drain water out of the machine.

Stand-by mode

When no film is being processed, the machine switches to Stand-by. The chemicals remain at a constant temperature. The film feed, the replenishment pumps and the water supply are switched on briefly at regular intervals, to prevent crystallisation of chemimals on the transport rollers and oxidisation of the chemicals. A film can be inserted at any time.

English

ECOMAX

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Operation

Switching on the machine

The processor is switched on at the main switch (front right). The developer bath will be heated up. The LED flashes during the warm-up phase and no X-ray film must be inserted into the machine during this time. When the ma chine is ready, a acoustic signal is heard and the LED is on continuously.

Display “Infeeding film”

If films are fed into the processor without gap one after another, then this may cause a film jam. The “Feeding film” LED flashes as long as a film is fed. Once the film has been fed completely the LED is on continusouly. Additionally an acoustic signal indicates that the next film can be inserted.

Both chemicals pumps - for fixer and developer - are driven in parallel by only one motor and therefore always run simultaneously. The regeneration volumes for developer and fixer thus are identical.

Anti-crystalisation function

During the stand-by mode, the film transport, the dryer ventilation, the dryer heating and the water inflow are activated every 20 minutes for a period of 20 seconds. This prevents the build-up of crystals on the rollers.

Anti-Oxidisation Function

Also during the stand-by, the developer chemicals are subject to change which causes their deterioration. By means of the time replenishment, a replenishment cycle is activated after 60 minutes without replenishment. The pump runs for 10 seconds. With this function, the qu ality of the developer chemicals are maintained even when standing idle for long periods.

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Operation

Automatic replenishment

Depending on the processed amount of films the chemical s are replenished automatically. This is done by pumping chemi cals from the replenishment containers. The surface area of the film processed is calcula ted on the basis of the film detection switch at the film feed. For every 40 seconds that the film detection switch is activated, a regeneration cycle of 13 seconds is started; thus a volume of fresh chemicals is introduced that is adequate for the film length processed. This corresponds to a regeneration rate of 600 ml pro m chart below shows the replenishment rate in ml per m2 film surface in relation to film width and setting of the pump.

REPLENISHMENT RATE

replenishment pump*

100 % (85 %)** 75 % (62 %)

Setting of the replenishment time

of film at a film width of 35 cm. The

Setting of the

by the controller

English

Film width 13 s 10 s 13 s 10 s

35 cm 24 cm 18 cm

600 ml/m 870 ml/m 1 150 ml/m

470 ml/m 690 ml/m 920 ml/m

450 ml/m 650 ml/m 875 ml/m

350 ml/m 520 ml/m 690 ml/m

*Setting at 50 Hz current resp. settings at 60 Hz current are in brackets **Standard setting

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Care

Daily Care

Before use...

• Remove dirt and dust from film-infeed with soft cloth.

• Run 2 - 3 cleaner films through the processor to remove all accumulated dirt and dust from the rollers.

• Check the liquid level in the replenishment containers and if necessary refill.

• Leave light protection cover open when no film is in the processor. This avoids condensation on infeed.

After use...

• When work has been completed at the end of the day, drain water out of the machine. This avoids the growth of algae in the water.

Attention: Do not allow liquids to enter the interior of the unit. Liquids may cause damage to the processor.

Weekly Care

The developer chemicals cause residue buildup in the machine. This residue has a negative effect on the developing process of the film material. For this reason the processor should be regularly cleaned. Proceed as follows:

1. Switch the machine off, lift of light protection cover and cover.

2. Loosen the securing latches of the roller racks (red, blue and beige) on the drive shaft.

3. Remove the roller-racks. First remove the developer rack (red). Then remove the fixer (blue) and dryer (black) racks one after the other. The roller racks of the developer and the water bath can be removed and inserted easier if you tilt them a little.

4. Rinse all racks thoroughly under warm running water and then leave to drain off. Use a soft sponge (do not use scouring-pad, as this would scratch the rollers!) and remove the pollution from the rollers.

5. Replace the racks: Red = Developer, Blue = Fixer. Black = rinsing/dryer. Begin with the dryer, proceed with the fixer and last insert the developer rack. Ensure that the racks are properly placed and do not forget to lock the drive shafts.

6. Re-install machine cover and light protection cover; be sure these are properly placed; check that the machine cover actuates the cover switch.

7. Clean processor outer shell with damp cloth. Do not use aggressive cleaners or solvents.

Important notes: When removing the rinsing / drying roller-rack, ensure that no

water gets into the film dryer air channel. For removal, the rinsing / drying roller-rack must first be

turned toward the film output, then it can be lifted out.

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Care

Thorough Cleaning

Every three months (maybe earlier) a thorough cleaning is necessary, depending on the quantity of films processed. Tank cleaners are available for developer and water baths. The fixer bath is cleaned with water. When preparing chemical tank cleaners, follow manufacturer's instructions explicitly.

How to proceed:

1. Switch the machine off and empty all tanks by opening the stop cocks.

2. Remove light protection cover and machine cover and wait until the tanks are drained completely; then close the stop cocks again. Now fill the fixer-tank with water. Prepare cleaner solutions for developer and water baths and fill into respective tanks.

3. Remove suction pipes from the replenishment containers and place them in a water filled bucket. Attention: Do not add chemical cleaners here!

4. Install the machine cover and switch the machine on.

5. Start film transportation and keep it running for 10 to 20minutes. After the heat-up phase, place a film in the feed so that it activates the film switch but will not be pulled into the processor. During the operation with water, the installed roller racks will be cleaned.

6. Important: After completion of tank cleaning, the tank should be rinsed thoroughly with clean water. To do this, fill the machine with fresh water twice and each time, let the machine run for a 10 minute period. Empty the tanks and reclose the stop cocks.

7. Remove the service cover. Take out the roller-racks and rinse them thoroughly with running water. Remove remaining dirt from the rollers by using a sponge and clean thoroughly. Doing this, the rollers can be turned by turning the drive shaft. Reinstall the roller-racks in the machine.

8. Refill the tanks with respective chemicals. Replace the suction pipes into the replenishment containers. In certain circumstances the circulation system must be ventilated: see page11, item 1c.

9. For quality check, process test films.

Before you go on holiday...

or if your processor will not be in use for longer than two weeks, all the chemicals have to be drained from the tanks. In case you don't want to do a complete tank cleaning at once, then fill the tanks after emptying, with water.

English

ECOMAX

Attention: Do not use alcohol containing solvents to clean the machine!

The colour changes in the baths is normal; it is caused by the properties of the chemicals!

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Maintenance / Disposal

Maintenance Protocol

Installation

Name: Machine type: Serial number: Technician: Training: by: Telephone: Date: Guarantee until:

Parameters Set

Developer temp.: Dryer temp.: Cycle time: Dev. reg. volume: Dev. reg. volume: Anti-oxidation: Developer: Fixer: Film type: Changed by: Date:

Maintenance work performed (see page 19)

Maintenance work performed

Date: Date: Date: Date: Date: Name: Name: Name: Name: Name: next maintenance: next maintenance: next maintenance: next maintenance: next maintenance:

Maintenance work performed

Date: Date: Date: Date: Date: Name: Name: Name: Name: Name: next maintenance: next maintenance: next maintenance: next maintenance: next maintenance:

Maintenance work performed

Date: Date: Date: Date: Date: Name: Name: Name: Name: Name: next maintenance: next maintenance: next maintenance: next maintenance: next maintenance:

Maintenance work performed

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Maintenance / Disposal

Attention: Never start the machine up unless it is filled with liquid!

Recommended Maintenance Work:

1. Functional check film intake / film transport / replenishment / bath heating / dryer heating / water supply

2. Cleaning

2.1. Switch off machine, remove cover

2.2. Empty all three tanks

2.3. Close drain cocks and fill tanks with water

2.4. Install cover, switch machine on

2.5. Fill two additional containers with water, place the suction pipes in these containers and activate the film intake

until the replenishing system is filled with water

2.6. Switch machine on for a few minutes

2.7. Switch machine off

2.8. Empty all tanks

2.9. Prepare tank cleaning agent for developer and water tank according to manufacturer´s instructions

English

Attention: Do not use chlorine containing cleaning agents!

2.10. Fill developer and water tank with tank cleaning agent (do not

2.11. Fill fixer tank with water

2.12. Place suction pipes into empty tanks

2.13. Install cover, switch machine on

2.14. Wait until the operating temperature is reached, (observe information concerning temperature, time, cleaning

procedure contained in the datasheet of the tank cleaning agent)

2.15. Activate the transport (activate film intake)

2.16. After approx. 15 minutes (observe information concerning temperature, time, cleaning procedure contained in

the datasheet of the tank cleaning agent) switch film transport off

2.17. Remove cover, neutralise developer tank (observe information concerning temperature, time, cleaning proce-

dure contained in the datasheet of the tank cleaning agent)

2.18. Switch machine off

2.19. Empty all three tanks

2.20. Fill machine with water and switch it on

2.21. Put suction pipes into vessels with water

2.22. Activate the film intake until the replenishing system is filled with water

2.23. Check all pumps for tightness

2.24. Switch machine off

2.25. Drain tanks

2.26. Fill tanks 3/4 with water

2.27. Switch machine on

2.28. Activate film transport for a few minutes

2.29. Switch machine off and drain all three tanks

2.30. Repeat item 2.20 to 2.29 if required (observe information e. g. regarding temperature, time and cleaning proce-

dure outlined in tank cleaner datasheet)

use the replenishment pumps to do so)

ECOMAX

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Maintenance / Disposal

2.31. Remove roller racks from the machine and remove dirt under flowing water using a soft rag or sponge

2.32. Remove risidual dirt particles from the tanks

2.33. Clean all toothed gear wheels, axles, bearings and rollers, check them for damage (replace if required)

2.34. Clean inlet plate using a soft rag

2.35. Align roller racks and re-insert them in machine

2.36. Fill machine with chemicals

2.37. Switch machine on

2.38. Feed cleaning film (approx. 4 pieces)

2.39. Check function as described under item 1.

2.40. Perform sensitometric test

Be sure to dipose properly of used machines.

Used machine contain valueable materials that should be recycled and turned over for proper treatment. Please be sure to turn used machines over to approved recycling centers.

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Problems and Solutions

Advice on Film Defects

Your processor has been constructed for long term use. Howe ver, if irregularities occur, you will find help to locate the problem below. Please check the listed points, before calling your service-technician.

Films do not have enough density

• Bath temperature is too low.

• Developing time too short.

• Exposure time is too short.

• Replenishment rate of developer too low.

• Developer chemicals are exhausted or too strong diluted: Renew.

• Fixer solution has been mixed into developer: Renew. Clean and rinse bath well before refilling.

• Circulation is broken down.

Too high a density

• Bath temperature too high.

• Developing time too long.

• Exposure time is too long.

• Replenishment rate of developer too high.

• Developer chemicals are too high diluted : Renew.

• After renewing chemicals: Starter is missing.

• Circulation is broken down.

English

Films will not dry

• If warm air comes out of the air channel in the dryer, chemicals and film type should be checked.

• Fixer solution is exhausted or diluted.

Film has a yellow-green surface

• Not fixed correctly. Check the film type and fixer chemistry.

• Fixer solution is exhausted or diluted. Replenishmen t rate of fixer is too low.

Scratches, pressure marks, dirt on film

• Prior to processing films, run cleaner films through the processor.

• Pressure marks caused by careless handling, finger nails etc.

• Rollers are polluted. Clean tanks and roller racks.

Cloudy film

• Level in developer is too low.

• First guide bar of fixer rack is dirty (condensate or crystals). Clean rollerracks.

• Developer is old or circulation not working.

• Try processing films by infeeding them with emulsion side up.

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Problems and Solutions

Advice on Machine Errors Unit does not switch on

• Ensure that electrical plug is firmly inserted into socket.

• Ensure that electrical socket has power supply by testing with an appliance (e.g. tablelight).

Film is not drawn in

• Place cover correctly on machine, ensuring that the cover switch on the right rear side is activated.

Machine does not start automatically

• Film switch left side at the infeed has not been pressed down. Feed in the film to activate the switch.

Developer temperature too low

• Developer heating is defective

• Capillary tube controller is defective or its adjustment is faulty - call service technician

Replenishment pump does not pump

• Check whether the replenishment containers are full and that the end of the suction pipe is positioned under the liquid level.

• Check whether there is air in the replenishment hoses. If this is the case, check the hose connections.

Rinsing water does not flow

• Open water inflow tap.

• The water pressure in the water supply system is too low: Minimum pressure 2bar (29psi).

Water tank overflows

• Water drainage hose (overflow) is bent. The hose end should be positioned above the drainage level in the syphon (see diagram on page 10).

• Check water drain opening in the tank and the hose for blockage and resi dues. The drainage hoses should have a constant fall.

The film does not transport correctly

• Film is fed in and gets caught in the machine: Check the positioning of the racks in the machine and make sure that the latches on the drive sha ft are closed.

Important notes: Ensure correct seating of roller racks; keep the lock closed at

all times. Don’t operate processor with empty replenishment tanks. After a long machine shut down check bath level and refill if

necessary.

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Accessories

For use of the film processor machine without permanent water supply connection

The water circulation system is a simple but effective accessory for installation sites that do not offer permanent water supply connection. It is comprised of a water reservoir with integrated circulation pump and hoses with stop cocks. Due to the separate power supply connection the water circulation system is immediately ready to operate. The proven circulation pump supplies the water from the reservoir to the water bath of the machine. From there the water flows back to the water reservoir via the overflow. A closed circuit results.

English

Technical Specifications

Tank volume:

Circulation system:

Noise level:

Pump volume:

Max. pumping height:

Water connection:

Environmental conditions:

Electrical connections:

Power consumption:

Weight:

Floor space required:

25 litres

Water is circualted by a rotary pump installed between water reservoir and water bath

Less than 58 dB(A)

60 l/h

1000 mm

No supply connection required

Room temperature, 18-40°C

220 V/50 Hz or 220 V/60 Hz 110-120 V/60 Hz

10 W

5 kg empty, 30 kg filled

0.03 m²

ECOMAX

Page 24

24 ECOMAX

Page 25

Service Manual

Table of Contents

Installation Data ...................................................... .. .........................................26

Trouble Shooting ...............................................................................................27

Spare Parts......................................................................................................... 33

............................................................................................................................. 40

English

ECOMAX

Page 26

Installation Data

59cm (23.3’‘)

66cm (26.0’‘)

64cm (25.2’‘)

Optional

processor stand

(accessory)

457

(

’

‘

)

50cm (20’‘)

60x40cm (24x16’‘)

1. Wall socket 220-240 V, 16 A or 1 10 V, 15 A (depending on machine model). Power supply should be equipped with earth-leakage breaker, 25 A / 30 mA nominal fault current. In addition, a power control switch can be installed.

2. Fresh water connection 3/ 4” with stop cock, permissible pressure 2-10 bar, water temperature 5-25 °C.

3. Drainage plastic pipe PVC ý

50 mm (2“) incl. syphon.

4. Drainage or collecting containers for used developer.

5. Drainage or collecting containers for used fixer.

6. Storage location for replenishment tanks: Below machine or externally.

7. Ventilation of darkroom is required.

8. Sink with freshwater and flexible hose. Inner dimensions minimum (LxWxH) 60x40x30 cm (24x16x12“).

Sink

Darkroom

Measures and positions are recommendations

46cm (18.2’‘)

88cm (34.7’‘)

Installation Data

88cm (34.7’‘)

37cm (14 .6’‘)

70cm (27.6’‘)

26 ECOMAX

)

‘

’

(

)

‘

’

( m

)

‘

’

Page 27

Trouble Shooting

Summary

1 Algae............................................................................................................ 27

1.1 Excessive algae growth in water tank ................................................... 27

2 General ........................................................................................................28

2.1 Unit does not switch on.........................................................................28

3 Drive............................................................................................................. 28

3.1 Film transport not running .....................................................................28

3.2 Machine does not start automatically.................................................... 28

3.3 Machine doesn't stop automatically....................................................... 28

3.4 Film transport does not function, fan runs............................................. 28

3.5 Machine stops before film comes out....................................................28

3.6 Relation between processing time and developer temperature ............ 29

3.7 Changing the transport speed............................................................... 29

4 Chemicals Baths......................................................................................... 29

4.1 No circulation in bath............................................................................. 29

4.2 Developer temperature too high............................................................30

4.3 Developer temperature too low .............................................................30

4.4 Developer temperature too low, fixer temperature too high .................. 30

4.5 Calibration of developer temperature.................................................... 30

5 Film defects.................................................................................................30

5.1 Films will not dry....................................................................................30

5.2 The film does not transport correctly..................................................... 30

5.3 Scratches, pressure marks, dirt on film................................................. 30

6 Replenishment............................................................................................31

6.1 Replenishment pump does not work or works insufficiently.................. 31

6.2 Replenishment volume too high or too low ...........................................31

6.3 Adjusting the replenishment pump........................................................ 31

7 Dryer ............................................................................................................31

7.1 Dryer fan does not run or runs with too slowly......................................31

8 Water............................................................................................................ 32

8.1 Rinsing water does not flow .............................................................. ... .32

8.2 Water tank overflows................................................................... .......... 32

English

1Algae

1.1 Excessive algae growth in water tank

• Algae growth inside the water tank is not only anoying, it causes increased cleaning work and leaves residues on the films. If algae growth becomes excessive, corrective measures must be taken:

• When work has been completed at the end of the day, drain water out of the machine.

• Clean dryer-water rack regularly. Use soft sponge and soap to remove residue from the rollers.

• Install a particle filter system in the fresh water supply for the processor.

• If water tank overflows due to algae growth blocking the overflow hose, then the overflow hose can directly be connected to the connection at the water tank inside the machine.

• If no other solutions can be found, use of anti-algae agents can result in improvement (automatic dispensers work the best). However, it is known that cleaning agents containing chlorine may corrode rubber rollers and high-grade steel in the tank area (check before use).

ECOMAX

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Trouble Shooting

2 General

2.1 Unit does not switch on

• Ensure that the power socket conducts power.

• Check machine fuse in main switch.

• While power switch is on, check the following components: Volt age on contact of main switch - if no voltage: - change main switch. Check input voltage at electronics. If the voltage is normal, exchange the electronics. if

no voltage: check the cable wiring harness.

Do only use original PROTEC ®' fuses with gilded caps as replacement part. They are optimzed for use with PROTEC proc-

essors.

3Drive

3.1 Film transport not running

• When placing processor cover on, the cover switch should be activated, re-adjust if necessary.

• Cover switch does not switch when activated: Replace.

• Check drive motor: If voltage can be detected on motor, then motor is defective.

• Check screwing of chain wheel on motor- and driveshaft.

3.2 Machine does not start automatically

• With the unit switched on, insert a film in the feed. If the LED begins to flash, the film detection switch is okay; if not, check the position of the actuator and replace the switch if required.

• Check the following parts: film detection switch, connecting cable for film detection switch, electronics module.

• Check the connecting cables between the electronics module and slots of the components (motor, dryer heating and solenoid valve). If the connections have no fault then the electronics module may be defective.

3.3 Machine doesn't stop automatically

• LED flashes continuously: Check positioning of the film switch actuator or replace the film detection switch.

• Check the following parts: connecting cable of film detection switch and electronics module.

3.4 Film transport does not function, fan runs

• Check screwing of chain wheels and run of chain.

3.5 Machine stops before film comes out

The follow-up time is the part of the processing time that follows passing of the film detection switch. Activate the switch in the feed tray with a film and remove the film. Measure the time until the processor stops automatically.

Change cycle time if necessary. The follow-up time can be set with a DIP switch on the controller. When the unit is restarted after a change of the setting, the new programming will be saved. The figure below illustrates the setting options:

28 ECOMAX

Page 29

Trouble Shooting

3.6 Relation between processing time and developer temperature

The following chart demonstrates guiding values for the relation between developer temperature and processing time. Variations are possible depending on the various films and chemicals. Changing the transport speed see 3.7.

Total processing time Developer temperature

105 s 32 °C - 34 °C 110 s 32 °C - 34 °C 117 s 32 °C - 34 °C 124 s 30 °C - 33 °C

3.7 Changing the transport speed

The processing speed can be changed by changing the gear wheels. The up per EPAC must be removed. First loosen the screw on the chain tensioner. After removing the drive motor and the drive shaft, the chain wheels can be replaced. Note that the follow-up time must be adjusted at the controller.

The following gear combinations are available:

English

220-240 V, 50 Hz versions

220-240 V, 60 Hz versions

tGmGs DIP

switch

positions

105 14 17 125 32,5 34,7 102 12 18 125 31,6 14,0

102 12 17 125 31,7 35,6 113 12 20 125 35,0 12,6 122 12 17 125 38,0 29,7 122 10 18 125 38,0 11,7 120 12 20 125 37,2 30,3 136 10 20 142 42,0 10,5 130 12 18 142 40,2 28,1 149 10 22 210 46,4 9,6 132 12 22 142 41 27,5

144 12 20 150 44,7 25,2 158 12 22 210 49,2 23,0

t = Processing time in seconds Gm = Chain gear on motor shaft Gs = Chain gear on drive shaft

Devel-

oper time

(s)

Feed

speed

(cm/min)

tGmGs DIP

110-120 V, 60 Hz versions

Devel-

switch

positions

oper time

(s)

speed

(in/min)

4 Chemicals Baths

4.1 No circulation in bath

• Circulation pump works but no circulation in bath: Air lock in heating and circulation system. Vent the pump (see page 11 item 1c).

• Particles in the pump chamber. The pump chamber can be opened easily by removing the four clips. When closing the pump, ensure that the rubber seal is positioned correctly and not damaged.

• Check connection of pump, circulation pump possibly defective.

Feed

ECOMAX

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Trouble Shooting

4.2 Developer temperature too high

• Check fastening of the temperature sensor of the temperature controller. It must be seated firmly on the tube, must have been installed with heat transfer grease, be covered by a silicone hose and be insulated with plastic foam.

• Temperature is set too high at the temperature controller: Set a lower temperature value by turning counterclockwise. (See “Calibration of developer temperature” on page30.)

• If no error can be detected in the temperature sensor, the temperature controller is defective.

4.3 Developer temperature too low

• Check circulation pump. Air lock in the circulation pump: vent pump (see page 11). If no circulation can be detected: check wiring of circulation pump, pump possibly defective.

• Bath is not heated: check temperature safety switch on heat-exchanger. Check heating element: impedance across the element should reach approx. 66 W.

• Check temperature sensor (see 4.2).

• If no other error can be detected, the temperature controller may be defective.

4.4 Developer temperature too low, fixer temperature too high

• Air lock in the circulation pump: vent circulation (see page 11).

4.5 Calibration of developer temperature

Temperature fluctuations can be compensated for by the temperature controller. The controller is accessible from top. Remove the cover plate above the pumps. Adjustment of the controller is expained on the drive shaft next to it (see figure)

5Film defects

5.1 Films will not dry

• No air comes out of air channel: check fastening of fan impeller, motor may be defective.

• Cold air comes out of air channel: check wiring of heating element in the air channel, heating element possibly defective.

• Hot air comes out of air channel, but the film is still not dried to satisfaction. Check chemicals and film type. If this leads to no solution then the transport speed of the machine can be reduced (see Changing the transport speed, page 29).

5.2 The film does not transport correctly

• Check the positioning of the racks in the machine and make sure that the latches are closed.

• Check the roller racks: rollers are correctly seated and do not have excessive clearance, rubber springs are correctly seated, all gear wheels are installed.

• Motor runs: the worm gear of the drive shaft should be secured with a split pin to avoid twisting. Check the screws and positioning of the chain and chain wheel.

5.3 Scratches, pressure marks, dirt on film

• Pressure marks caused due to polluted or damaged rollers. Check rollers for visible damage. Rubber rollers sometimes swell up. Replace defective rollers.

30 ECOMAX

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Trouble Shooting

• Clean valves inside connection tube of pump.

Install valve-insert correctly: pay attention to flow direction!

6Replenishment

6.1 Replenishment pump does not work or works insufficiently

• Check filter in the suction pipe (repl. container) and clean it if necessary.

• Replenishment pump sucks in air. Check hoses and connections.

• Check position of eccenter. Flow rate reads 240 ml/min at maximum eccenter position 100%.

• (60 Hz: 240 ml/min at 85 %)

• Measure the voltage between X3 and X4 directly after power-up of the unit or after the film detection switch has been actuated for 40 seconds. If no voltage can be measured, replace the power section.

6.2 Replenishment volume too high or too low

• The replenishment volume can be changed by altering the pump stroke or in the controller.

6.3 Adjusting the replenishment pump

• To do this, the eccenter on the replenishment pump must be adjusted. Maximum pump capacity is 240 ml/min (100 %). For adjustment of the eccenter first open the socket hex screw on the large eccenter with the red mark. If the screw is not accessible, switch the machine on briefly. Switch the machine off as soon as the screw becomes accessible.

• Turn the eccenter so that the red mark will be at the desired position, then fasten the socket hex screw.

English

Do not set the eccenter below 75 %.

6.4 Setting the replenishment volume in the controller

The replenishment volume can be changed by altering the pump run time per cycle. To do so, set the DIP switch on the cotroller to either 10 s or 13 s (Compare figure). When the machine is restarted the new programming becomes active.

7Dryer

7.1 Dryer fan does not run or runs with too slowly

• Check whether the threaded pin fastening the fan wheel to the rotor shaft of the motor has loosened.

• Check whether the motor is defective.

ECOMAX

Page 32

Trouble Shooting

OFF

8 Water

8.1 Rinsing water does not flow

• The water pressure in the water supply system is too low: Minimum pressure 2 bar (29 psi).

• The valve opens, but no water flows through: the coarse filter on the intake end is blocked.

• Check the water supply hose in the machine.

8.2 Water tank overflows

• The water drainage hose (overflow) should be laid out with constant descent. The hose end should be positioned above the drainage level in the syphon.

• Check water drain opening in the tank and the hose for blockage and residues.

• When extreme algae growth is registered, the overflow can be connected directly to the fitting of the water tank.

9 Shutting off time-controlled replenishment / anti-oxidation

The anti-oxidation function can be shut off at the controller. To do so, set the DIP switch on the controller as shown in the figu re .

Antioxi dation 5s / 20min

32 ECOMAX

Page 33

Spare Parts

English

Pos. Order No. Description:

1 1186-0-0200 Service cover, complete 2 1186-0-0201 Cover 3 1186-0-3100 Light protection cover, complete 4 2006-0-0005 Ball-type stop cock 10 mm 5 1170-0-2000 Replenishment tank, 12 l dev.

1170-0-2100 Replenishment tank, 12 l fix. 6 1170-0-1760 Suction pipe with filter for 12 l vessel, round 7 2004-0-0003 Electrical power cable 220-240 V

2004-0-0021 Electrical power cable 220-240 V 8 2018-0-0001 Water inlet tube 9 1286-0-0000 processor stand 10 1101-0-2000 Replenishment tank 25 l dev.

1101-0-2100 Replenishment tank 25 l fix. 1 1 1101-0-1700 Suction pipe with filter for 25 l vessel 12 1101-0-4100 Floating cover developer 13 1170-0-1400 Combination unit switch 14 2010-0-0010 Fusible, gold, T 10 A / 250 V UL 15 1186-0-0805 Bracket, film outlet

- 2018-0-0012 Hose 10 x 2 mm, celar, reinforced

- 2018-0-0009 Hose 10 x 2 mm, blue, reinforced

- 2018-0-0008 Hose 10 x 2 mm, red, reinforced

- 2018-0-0005 Hose 4 x 1 mm, green

- 2018-0-0021 Hose 9 x 2 mm, red, transparent

- 2018-0-0022 Hose 9 x 2 mm, blue, transparent

- 2022-0-0004 Tube clamp

- 2022-0-0019 Wire tube clamp

- 1101-0-4600 Floating balls, 300 pcs.

- 1101-0-4800 Floating balls, 200 pcs.

ECOMAX

Page 34

Spare Parts

20a

Fixer: Developer: Water

Pos. Order No. Description:

20 0202-1-0008 Replenishment pump 2KBA 220-240 V, 50/60 Hz

0202-6-0008 Replenishment pump 2KBA 115 V, 50/60 Hz 20a 0002-1-0008 Conical valve for pos. 20 21 2002-1-0013 Circulation pump 220-240 V, 50/60 Hz

22 1160-0-0702 Elbow fitting 23 1160-0-0710 Rubber hose stub 24 2006-5-0004 Solenoid valve 220-240 V, 50/60 Hz

25 0186-0-2200 Temperature controller set

- 1186-0-1250 Wiring harness 230 V

- 1186-0-1251 Wiring harness 115 V

2002-6-0013 Circulation pump 110 V, 50/60 Hz

2006-6-0003 Solenoid valve 110 V

34 ECOMAX

Page 35

Spare Parts

English

Pos. Order No. Description:

26 2001-0-0003 Main drive motor 220-240 V, 50 Hz

2001-6-0003 Main drive motor 120 V, 50/60 Hz 27 1186-0-1101 Motor plate 28 1186-0-1501 Drive shaft worm-gear 29 1170-0-1503 Worm-gear 30 1186-0-1502 Chain wheel t=10

1170-0-1506 Chain wheel t=12

1170-0-1504 Chain wheel t=14

1170-0-1505 Chain wheel t=16

1170-0-1102 Chain wheel t=17

31 2037-0-0003 Roller chain 32 3000-9-4013 Splint pin 2.0 x 20 mm, inox 33 2008-0-0001 Fan impeller TLR 85x52 34 1186-0-1302 Air channel 35 0186-5-1300 Heating element Ecomax 230 V, 900 W

36 1101-0-0146 Latch, red 37 1101-0-0141 Latch, blue 38 1101-0-0113 Latch, plain 39 2009-0-0019 Rivet

ECOMAX

1170-0-1507 Chain wheel t=18

1186-0-1503 Chain wheel t=20

1186-0-1504 Chain wheel t=22

0186-6-1300 Heating element Ecomax 110 V, 900 W

Page 36

Spare Parts

Pos. Order No. Description:

40 1186-0-1301 Controller cover plate 41 1186-5-1300

1186-6-1300 42 2007-0-0001 Micro switch 83.161-6 N/O W3 43 2007-0-0010 Actuator for micro-switch 44 1186-0-0502 Inlet cover 45 1186-0-0701 Chain tensioner 46 1186-0-0702 Bracket for chain tensioner 47 1186-0-0802 Film feed tray 48 2003-5-0010 Heating element 230 V, 300 W

2003-6-0002 Heating element 120 V, 400 W 49 1130-0-2101 Heat exchanger 50 2005-0-0005 Temperature limiter 51 2007-0-0005 Film detection switch

Controller 230 V Controller 110 V

36 ECOMAX

Page 37

Spare Parts

110

107

100

109

104 103

109

101

114

115

113

111

106

108

107

112

102

105

English

101

110

Standard roller racks

ECOMAX

Page 38

Spare Parts

Pos. Order No. Description:

Standard Processor

- 1186-0-0300 Roller rack, developer

- 1186-0-0400 Roller rack, fi xer

- 1186-0-0600 Roller rack, dryer

100 0186-0-0303 Roller support, dev. with axles

0186-0-0403 Roller support, fix. with axles 101 1186-0-0304 Rubber spring element, black 36.5 x 10 x 6 102 1186-0-0306 Rubber spring element, white 103 1186-0-0307 Rubber spring element, black 31 x 10 x 6 104 1140-0-0301 PU-roller 35 ground 105 1170-0-0310 Drive shaft rack 106 1101-0-0302 Gear t = 16, D-hole 107 1101-0-0304 Gear t = 32, round hole 108 1101-0-0303 Gear t = 32, D-hole 109 1170-0-0302 Worm wheel 110 1101-0-0305 Bearing bush 111 2014-0-0001 Circlip 112 2014-0-0003 Clamping ring 113 0186-0-0603 Roller support, dryer with axles 114 1140-0-0302 Rubber roller 35 115 1140-0-0605 Air jet (35)

38 ECOMAX

Page 39

Electric Diagrams Electric Diagrams

English

ECOMAX

Page 40

Electric Diagrams

40 ECOMAX

Page 41

Electric Diagrams

English

ECOMAX

Page 42

Electric Diagrams

42 ECOMAX