Protec Optimax User Manual

Film Processor

Operation Manual

English

PROTEC® Medizintechnik GmbH & Co. KG

Lichtenberger Straße 35, D-71720 Oberstenfeld, Germany Telephone: +49-7062-9255-0 e-mail: service@protec-med.com

Machine No.:

Type:

Date of Installation:

Issued: 05-2006/3.4

Subject to technical alterations

EU-Declaration of Conformity

PROTEC® Medizintechnik declares, that the product

Description:

OPTIMAX

Machine type:

Model no.

conforms to the following harmonized standards:

Safety:

EMC:

according to the regulations of:

X-Ray-Film Processor

117x-y-0000

x is a number between 0 and 9, y is a number between 1 and 9

IEC 61010-1:2001 + A1:92 + A2:95; DIN 1988 T4:12/1988; UL 3101-1; CSA 22.2-1010-1

EN 50081 Part 1, 03/1993; EN 50082 Part 1, 03/1993

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

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

• EMC Directive 89/336/EG

PROTEC® Medizintechnik GmbH & Co. KG, Lichtenberger Straße 35, D-71720 Oberstenfeld, Germany

Supplementary Guidelines:

Place and date of issue Oberstenfeld, 23. Mai 2006, Jochen Krupp (Technical Manager Analogue Systems)

• DIMDI: DE / 0000042967

• WEEE: DE 55471807

2 OPTIMAX

Table of Contents

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

Technical Specifications ..................................................................................... 4

Safety Instructions............................................................................................... 5

Installation ............................................................................................................ 6

Initial Operation.................................................................................................... 9

Operation

Short overview and control panel ................................................................ 10

Switching the machine on............................................................................ 12

Stand-by mode ............................................................................................ 12

Bath temperature......................................................................................... 12

Display “Film feed”....................................................................................... 12

Manual pumping .......................................................................................... 12

Anti-crystallisation function / Time replenishment ....................................... 12

Automatic replenishment ............................................................................. 13

Rollfilms and paper films ............................................................................. 13

Care

Daily Care.................................................................................................... 14

Weekly Care ................................................................................................ 14

Thorough Cleaning ...................................................................................... 15

Maintenance / Disposal ..................................................................................... 16

Problems and Solutions

Troubleshooting Film Defects...................................................................... 19

Troubleshooting Machine Errors ................................................................. 20

Accessories ........................................................................................................ 21

Service Manual as appendix, see page 23

English

intechnik.

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 modifications without prior notice. PROTEC age caused direct or indirect by error, omission or non-conformity of the manual.

Caution (U.S.)

Federal Law restricts this device to sale by or on the order of a medical professional.

Medizintechnik does not take responsibility for dam-

Introduction

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

This Operation Manual contains the most important instructions for installation, operation and servicing of this machine. Please read the provided information carefully to ensure reliable and satisfactory operation of your OPTIMAX

incorporates

OPTIMAX

Technical Specifications

Film transport:

Film formats:

Processing capactiy:

Process time:

Linear speed:

Developer time:

Tank capacities:

Continuous roller transport system

In general: Sheet and roll films up to 35.8 cm (14.1’’) width; roll films with leader from 70 mm (2.8’’) width; smallest film format 10x10 cm (4x4’’). Mammography Type 1171: For processing Mammography Films. Graphic-Arts Type 1172: With cassette box (LxWxH) 35x13x12 cm (13.8x5.1x4.7’’) for processing roll films.

129 films 24x30 cm (10x12“) per hour (standard model, film fed in crosswise)

Standard 90 s Mammography 135 s *Option 167 s

Standard 56 cm/min. (22 in/min) Mammography 37 cm/min (14.5 in/min) *Option 30 cm/min (11.8 in/min)

Standard 25 s Mammography 37 s *Special 46 s

Developer, fixer and washing 5 litres each (1.3 gal)

Circulation system:

Replenishment:

Developer temperature:

Fixer temperature:

Water connection:

Water consumption:

Drain capacity:

Noise level:

Heat emission:

Environmental conditions:

Developer and fixer are continiuously circulated by a circulation pump

Automatic replenishment by film detection, in relation to film length

Adjustable 28 - 37 °C (82.4 - 98.6 °F)

Adjusted to developer temperature by heat exchanger.

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

1.9 litres per minute (0.5 gal/min) when processing.

7 litres per minute (1.85 gal/min)

Less than 58 dB(A).

Stand-by: 0.1 kJ/s Processing: 1.4 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), linear decreasing to 50% at 40 °C (104 °F)

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

4) Indoor use

Pollution degree:

4 OPTIMAX

Technical Specifications

System protection:

Power source:

Power consumption:

Weight (processor):

Dimensions (LxWxH):

Floor space required:

* Depending on machine type and used gears processors have different speeds.

** Height incl. optional working table resp. base cabinet.

IP 20

Electrical specifications are indicated on model nameplate. Type 117x-1-0000: 220 - 240 V~, 8.8 A, 50 Hz. Type 117x-2-0000: 220 - 240 V~, 8.8 A, 60 Hz. Machine tested for overvoltage category II according to IEC 1010 (EN 61010, VDE 0411) Type 117x-4-0000: 110 / 120 V~ ±10%, 15 A, 60 Hz.Machine tested for overvoltage category II according to UL 3101 and CSA 22.2-1010

Stand-by: 0.12 kWh Processing: 1.4 kWh

Empty 35 kg (77 lbs) Filled 50 kg (110 lbs)

77x59x42 (** 112) cm 30.3x23.2x16.5 (** 44.1)’’

0.45 m

(4.8 sqft)

Safety Instructions

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 manufacturer´s instructions. In general: Non-diluted chemicals 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. In case of chemicals getting into the eyes, rinse eyes immediately with cold, running water for approximately 15 minutes, and contact a 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 processor switch off the unit and unplug it from the electrical socket. Service and repairs must be performed by trained service technicians only. Use only manufacturers replacement parts.

OPTIMAX

Installation

1. Requirements for installation

a. Fresh water connection: Stop cock with 3/4" outer-thread diameter (washing

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

Drainage connection: Plastic tube - inner diameter 50 mm (2”) or larger. A ventilated syphon which serves as odor preventor should be included in the planning. The drainage tubes should be installed with a fall of minimum 5 %. Local Water Authorities regulations should be complied with.

b. Electrical connection: Fused wall socket with ground connection according to

electrical data (see Technical Specification, page 5). It is also required to install a ground fault interrupt (with 25 A / 30 mA nominal error current).

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

2. Set up of processor

Unpack the Processor. Remove cover and transport securing brackets on the sides of the roller racks. Remove roller racks - start with the dryer rack.

In 220-240 V version the OPTIMAX® is delivered as a tabletop processor with a two part floorplate. If the machine is upgraded with the optional stand or cabinet, the small plastic strip has to be removed.

In 110-120 V version the OPTIMAX®is delivered as a tabletop processor with a three part floorplate. If the machine is upgraded with the optional stand or cabinet, both small plastic strips and the metal plate have to be removed and a special main plate must be reconnected.

Table-top installation

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

Attention! Machine should not be installed on table-top without adjustable feet, as this would block the ventilation openings under the machine and cause overheating.

Installing on processor stand or base cabinet

In the event that the processor is to be installed on the stand or cabinet (optional accessory), the processor will be mounted directly to it. Mount processor according to manual included with stand or cabinet (the adjustable feet inside the accessory bag are not required).

Finally the processor needs to be leveled:

Place level across the sidewalls of processor and adjust the leveling feet accordingly. Replace the racks into the processor and close the latches.

6 OPTIMAX

Installation

3. Connecting the processor

English

Drainage and collecting containers

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 8): Connect the enclosed hoses according to color system onto the front of the machine. Put hose clamps (enclosed in accessory bag) over hose end, before attaching to connection. Warm up hose end (with hot water or lighter) and push onto the respective connection. Finally push clamp 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.

Connect the suction pipes to the hose ends for the replenishment tanks using hose clamps. Put suction pipes through cover opening into respective replenishment tanks and snap them in.

The overflow and drainage hoses from the developer and 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.

min. 70 cm

OPTIMAX

Installation

Hose connections

DEV FIX

Developer (red) Fixer (blue) Water (clear)

Overflow

Outlet

Replenishment tanks

Pay attention to the correct color connections:

Developer: red Fixer: blue Water: clear

Replenishment tanks

Overflow

Outlet

Replenishment

Overflow

Outlet

Danger of Overflow!

Use the included cable ties (accessory bag) to secure the hoses. Fix all hose ends which guide into syphon or collecting 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 fall. The hoses should be as short as possible and without bends and kinks. This is very important for the water overflow hose. Bad piping work will 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.

8 OPTIMAX

Initial Operation

1. Test run

Important! Processor should not be run dry! Upon commissioning and every refilling the pumps must be vented.

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. If fluid does not flow, an air lock may be present. Momentarily open the drain hose valves to ventilate the system.

b. Ventilation of the replenishment pump:

Set temperature dial to position “Manual pumping”. Keep dial to this position until no more air bubbles rise in the tanks.

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.

2. Fill processor with chemicals

Prepare chemicals inside the replenishment containers according to manufacturers instructions.

Fill up 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.

Using replenishment pump

Filling of processor can also be done by use of the replenishment pump (this takes much more time). Snap each suction pipe into the respective cover of it’s replenishment container and close it carefully. Place containers under processor. Now set temperature dial to “Manual pumping”. Keep dial in this position until tanks are filled. After 20 minutes this function stops automatically - to restart a cycle, turn dial to another position and return to “Manual pumping”. Limitation: The function may fill up tanks of developer and fixer to different levels. This may be due to different causes. If this happens, then use a suitable container to fill up the tanks completely.

English

OPTIMAX

Operation

Short overview and control panel

LED displays

• Film feed Wait with the next film until light goes off.

• Power When power is on the LED lights up.

• Bath temperature Flashes when temperature is not reached.

Temperature dial

Manual pumping

Important!

Safety function stops film transportation when cover is removed. Therefore keep cover placed on the machine when processing films.

*Only machines with cassette box:

When processing roll films in cassettes, pull approx. 10 cm of film out of the cassette and fold the corners. Place cassette into cassette box and feed film into the infeed. Notice that on processors with cassette box, the film switch is located in the middle of the infeed.

Film input Light protection cover

Control panel

*Roll film cassette

Film switch

Developing

Replenishment Developer

Power switch

10 OPTIMAX

Operation

Attention:

Upon first operation and each refilling of a developer check the function of the circulation pump and vent the pump if required (see page 9).

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. If the temperature has not been reached, the bath temperature light is flashing.

6. Run cleaning films through processor.

Working procedure

7. Processing films: Open light protection cover. Important: Put film first on left side of feed tray and then feed in. During processing films please watch the display “Film Feed”. If this is lit, wait until it goes off again and an audible tone can be heard, before inserting the next film.

English

After work...

8. Switch processor off.

9. Close water tap.

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

Film exit

Drying

Fixing

Washing

Do not place any object on the processor.

Replenishment Fixer

OPTIMAX

Fresh water inflow

Operation

Stand-by mode

When no film is being processed, the machine switches to Stand-by. The chemicals remain at a constant temperature. The film transport and water inflow activate at intervals to avoid crystallization of the chemicals on the transport rollers. Entry of the next film is possible at any time.

Switching the machine on

The processor is switched on at the main power switch on the front side. After switching on, the water tank will be filled up and a replenishment cycle will be carried out. The developer will be heated up. Until the tempearture is reached the LEDdisplay “Bath temperature” will be flashing. When the processor is ready and the bath temperature reached, a long signal tone can be heard.

Bath temperature

The processor heats up the chemicals automatically to the dial-set temperature. When this temperature is reached for the first time after switching on the machine, a long signal tone can be heard. This is also the case when the temperature is changed by the dial switch.

If the difference between actual and dial-set temperature is more than 1 °C, the bath temperature LED will flash. If a film has been fed in and the temperature is not reached, a warning sound will be heard.

Display “Film feed”

If films are fed into the processor without clearance one after an other, then this may cause a film jam. The light “Film feed” is on during feeding of a film. After the film has been fed in completely the light goes off. Additionally an audible tone indicates that the next film can be fed in.

Manual pumping

The function “Manual pumping” activates the replenishment pump and it pumps chemicals into the tanks in addition to automatic replenishment. Turn the dial to the position “Manual pumping” and chemicals will be pumped into the tanks. This function is only available during stand-by (no film in process). If the dial is left in this position, the pumping function is stopped automatically after 20 minutes. To restart a cycle turn dial to a temperature and return to “Manual pumping”.

Please note: Films cannot be processed when dial is set to “Manual pumping”. Also bath temperature is set automatical to 28 °C during “Manual pumping”. After ending the manual pumping the temperature must be set again by turning the dial. It takes some time until the temperature is reached (look at the bath temperature display).

Both chemical pumps - fixer and developer - are driven parallel by only one motor and therefore they operate in unison.

Anti-crystallisation function

During the stand-by mode, the film transport, the dryer ventilation, the dryer heater 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.

12 OPTIMAX

+ 28 hidden pages

Protec Optimax User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual