Instruction Manual
MP700 V5.2r04/05/06
06/2003 AN
for COLENTA
PrintlineProcessor
56/66/80 RA
AN 06/2003
Technical Specifications:
Processing applications: RA Photopaper for digital applications incl. Duratrans
Paper width: max. 80 cm (31 inch)
Microprocessor Control: - with 9 preprogrammable processing cycles
Transport Speed (at 45 sec DEV-Time): - 70 cm/min (42 inch/min)
- 95 cm/min (42 inch/min)
- 120 cm/min (42 inch/min)
(preprogrammable 20 to 116 sec.)
Tankcapacity Temperature* Repl. Rate*
Developer : x lt 18 - 43°C 40-2000ml/m²
Bleachfix : x lt 18 - 43°C 40-2000ml/m²
Superstabi1 : x lt 18 - 43°C 40-2000ml/m²
Superstabi2 : x lt 18 - 43°C 40-2000ml/m²
Superstabi3 : x lt 18 - 43°C 40-2000ml/m²
Replenishment: - controlled by up to 10-sensors, measuring media area
- activated after 0,1 - 0,999m² *material fed into the processor
- antioxidation/standby replenishment, activated after 0-9 hours *
Anticrystalisation/
Selfcleaning Cycle
during Standby: - activated : each 1 - 20 min *
- cycle time : duration 1 - 3 min *
Filter Replacement Programming: 0 - 9999 m² *
.........* all values preprogrammable
Control: - Activate and Monitoring features inform, warn and alert the operator to an error in the system.
Solution Levels: -Low Level monitoring in Dev-, Bleachfix, and all Superstabi- Tanks
of processor **
-High Level monitoring in Overflow Collection Tanks (waste management) **
-Low Level in Repl. Tanks for Dev-, Bleachfix and Superstabi **
Temperatures: High / Low level monitoring of the Dev, Bleachfix, Superstabi and Dryer
Work in Progress : Details the position of the media through the processor.
Transport: - drive motor overload monitoring **
- security cover lid switch **
- manual feed facility
** when activated will operate an audible warning and a message alert to confirm the error type.
Additional Accessories and Features:
- Chiller unit (optional)
- A drawer unit within the main frame to house the replenishment and waste collection tanks.
Technical specification subject to change without notice.
PrintlineProcessor
56/66/80 RA 70/95/120 - 5T
AN 06/2003
DIMENSIONS:
RA xx 5T SST
Y for RA 56 860 mm
Y for RA 66 960 mm
Y for RA 80 1100 mm
COLENTA 56/66/80 RA-xx 5T
INDEX
1. INTRODUCTION / SAFETY INSTRUCTIONS 1-6
2. BEFORE INSTALLATION 7
3. TRANSPORT AND ASSEMBLY 8 - 10
4. PROCESSOR FUNCTIONS 11
5. INFRARED SENSORBAR 12
6. REPLENISHMENT SYSTEM 13,14
7. HEATING / COOLING / CIRCULATION 15-17
8. TEST RUN AND TANK FILL 18
9. WORKING WITH THE CHEMISTRY 18
10. WORKING WITH THE PROCESSOR 19
11. CONTROL PANEL 20-31
12. MAINTENANCE 32
13. RECOMENDED MAINTENENCE EVERY 3-6 MONTH 33
14. SAFETYINSTRUCTIONS 34,35
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1
1.INTRODUCTION
Congratulations upon your decision to buy a
COLENTA RA-Processor.
Your purchase has been designed to meet the highest technical standards.
Some outstanding design features include:
*) compact, space-saving design
*) full automatic processing cycle
*) smooth roller transport system
*) low tank volumes
*) electronically controlled temperature system
*) automatic replenishment
*) low energy consumption
This manual is a guide to installation and routine use of your
COLENTA RA-Processor.
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1.1 GENERAL SAFETY INSTRUCTIONS
*) Staff in charge of maintenance of the processor (see chapter 11and 12) need to be
thoroughly familiar with the equipment.
*) Only the Top Cover of the Filmprocessor may be removed by the operator (see picture
below)
.
*) The film processor must be separated from mains prior to carrying out any maintenance. To
do so, switch the mains switch of the machine to „0“ position. Always wear safety goggles
and protective clothing when handling chemicals.
*) The filmprocesor may not be in operation without supervision.
*) Make sure that clothing or other objects cannot get entrapped in gear drives or similar of the
film processor.
*) The installation, service, repair as well as the initial operation of the machine may be carried
out by qualified and trained service personnel only.
*) Built-in safety devices may not be eluded or made inoperative. Use only original COLENTA
spare parts when exchanging failed electrical components.
*) Do not wear any loose necklaces or bracelets!
1.2 CHEMICAL HANDLING
*) Observe all safety technical regulations of the chemical manufacturer.
*) Wear safety goggles and protective clothing when handling chemicals.
*) Ensure proper ventilation of the room in which the chemicals are prepared.
*) Spillage or overflow of chemicals has to be removed instantly.
*) In case of contact with the eyes flush with plenty of cold water for approximately fifteen
minutes and consult an physician.
*) Chemical disposal has to be in accordance with the local environmental codes. Contact your
local water treatment and sewer district authorities for more information.
Top covers
Main switch of
the film processor
2
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Processor Operation
Make sure that no long hair, loose clothing or
jewellry can get entrapped in the gear drives
or in the media transport area.
The „Service Manual for Colenta Printline
Processor" is for the use of qualified
service personnel only.
Do not clean the processor with running
water.
Electrical and Mechanical Hazards
Observe all safety warnings to minimize the risk of
electrical shock,burns or equipment damage.
Photographic Processors are complex
machines with many electrical and mechanical
parts as well
as with a considerable amount of chemicals.
Fire Prevention
The area around the processor must be kept
clean at all times. Keep dust ,wood shavings,
scrap paper or other inflamable materials out
of the dryer compartment.
Fire extinguishers must be available in the
room where the processor is installed.
Chemical Handling and Accident Prevention
Misuse of almost any chemical may create
a hazard of some type.Generally photo chemicals
are not any more dangerous as most of the regular
cleaning agents. However, there is always a residual
risk. When handling chemicals observe the procedures
below.
1).Never sniff a container or open bottle to
determine its contents. A cautious sniff of
the cap or lid is safer.
2).When handling chemicals wear protective
clothing, safety goggles and rubber gloves .
3).Label storage containers properly.Avoid
storing hazardous chemicals on high
shelves or in unprotected glass containers.
Keep chemicals away from children.Do
not store chemicals in a refrigerator used
for food because they may contaminate
food or be mistaken for edibles.
4).Ensure proper ventilation in the area where
chemicals are used or stored.
5).Observe the manufacturer’s recommen-
dations for using and mixing chemicals.
Overexposure to photographic
chemistry may cause skin irritation to
certain individuals.
PHOTOGRAPHIC CHEMICAL EMERGENCIES
AND FIRST AID PROCEDURES:
• SKIN - Rinse thoroughly with water.
• EYES -Rinse thoroughly with water and
consult a physician.
• INGESTION -Consult a physician imme-
diately.
1.3 IMPORTANT WARNING AND SAFETY INSTRUCTIONS
(Please read these instructions carefully.)
The racks must be cleaned with running
water outside the Film Processor.
3
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Chemical Disposal
Waste from photographic processing normally
contains diluted chemicals. These chemicals
should be collected and disposed in accordance
with local environmental codes.Dumping
chemicals into a drain system could lead to a
pollution problem.Contact your local water
treatment and sewer district authorities before
disposing chemicals.
All plumbing must comply with local and
national codes.The DRAIN must be made of
chemical resistant and non-corrosive material.
Use PVC or equivalent
Exhaust,Temperature and Humidity
It is necessary to ensure proper ventilation
in order to receive good processing results.
Make sure that the exhaust hose of the
built-in exhaust fan is properly connected
to the exhaust air socket (Picture 1).
The built-in exhaust fan exhausts the
fumes from the processor.
These chemical fumes are corrosive. The top
cover of the processor should be removed over
night.
Room temperatures between 18-26 °C
(65-80 °F)with a relative humidity between 35%
and 75%are ideal for photographic processing
and working.
The filmprocessor is a complex
machine with moving parts such as the gear
train and media transfer components.It uses
photo processing chemicals which are irritating
to eyes,lungs and skin.High voltage is used to
power the processor.
The dryer compartment produces heat.
· High voltage may cause electric shocks,
burns or even death.
· Hands or fingers may be pinched or
injured by moving parts or when handling
heavy parts.
· Dryer compartment heat may ignite
combustible materials and cause fires.
· Eyes,skin and lungs may be irritated
by photo chemicals.Before using photo
processing chemicals always read the
Material Safety Data Sheets (MSDSs)
for information about the hazards of
the particular chemicals and how to use
them safely.
· Do not operate the film processor after
consuming alcohol or taking strong
medication.
· Do not wear jewellery or loose clothing
when operating the processor.
Electronical and Electrical Hazards
HAZARDOUS VOLTAGE CAN CAUSE
ELECTRIC SHOCK,BURNS OR EVEN
DEATH ·
Qualified service personnel must verify during
installation that the processor is permanently
and reliable grounded according to
standards in the National Electrical Code.
Picture1
Air grille
4
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Carry out the following steps prior removal
of the top cover:
1.Train operators of the processor.
2.Switch off the main power switch
(„0“-position) and secure against
restart by locking with a padlock
(see picture below).
Fire Hazards
DRYER COMPARTMENT PRODUCES
HEAT -PAPER OR OTHER COMBUSTI-
BLES CAN BE IGNITED
· Keep the area within 10 feet of the processor
clean.Do not store combustible materials,
including paper, close to the filmprocessor.
· Verify that a functional 10 lb.ABC fire
extinguisher is located closed to the processor.
Burn Hazard
DRYER COMPARTMENT PRODUCES
HEAT -DRYER PANELS AND GUARDS
GET HOT
· Therefore do not touch dryer panels or guards
when dryer in operation
Corrosive Liquids
CHEMICALS MAY IRRITATE EYES,
LUNGS, SKIN AND DIGESTIVE TRACT
# Wear safety goggles,protective gloves and
chemical aprons as indicated on Material
Safety Data Sheets (MSDSs)when handling
chemistry.
# Drain tanks carefully,avoid splashing.
Always drain the system thoroughly before
working on any of the external hose systems.
# Read the MSDSs for more information
regarding the proper safety procedures for
working with photo processing chemicals.
# Do not allow untrained personnel to handle
photo processing chemicals or to operate
the filmprocessor.
# To avoid hazardous situations,keep floors
and floor coverings around the processor and
associated drains clean and dry at all times.
Any accumulation of fluids outside the film
processor, should be cleaned up
immediately
5
Main switch of
the processor
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In the event of an accumulation
of liquid due to backup,overflow or other
malfunctions of the drain associated with the
processor call a plumber or other contractor
to correct the problem with the drain.
Colenta assume any responsibility or liability
whatsoever for the service ability of any
drain connected to the processor.
Such drains are the sole responsibility
of the customer.
DRAINS must be made of chemically
resistant and non-corrosive material.
Chemical Hazards
Chemicals can be the source for errors,
contaminate the waste water, irritate skin
or eyes.
Spills must be cleaned up immediately as
follows:
1.Prevent the spilled chemicals from entering
a waste water drain.
2.Clean up the spill with a moist mop or rag.
CAUTION!
When handling chemicals, especially fixer,
wear protective clothing, safety goggles
and rubber gloves.
If processor chemicals make contact with the
eyes,rinse them thoroughly with lots
of water.If irritation persists,consult a physician.
3.Dispose cleaning materials and collected waste
water from the clean up according to
environmental regulations and locals codes.
4.Avoid any inhalation of chemicals as
this is dangerous to health.
5.Observe all environmental regulations for
storage and disposal of waste chemicals.
6.Use this manual together with the
instructions for chemicals.
When handling chemicals wear
protective clothing, safety goggles and rubber gloves,
Corrosive Vapours
CHEMICAL VAPOURS MAY IRRITATE
EYES,LUNGS AND SKIN IF ALLOWED TO
ACCUMULATE IN WORK AREA
Assure an adequate supply of fresh
outdoor air through natural or mechanical
ventilation.
· Make sure that qualified service personnel
is checking the external exhaust system at
regular intervals.
· Read the Material Safety Data Sheets
(MSDSs)for more information regarding
the proper safety procedures for working
with photo processing chemicals.
6
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2.BEFORE INSTALLATION
Site preparation should be completed before delivery and installation.
2.1 LOCATION
Location. All dimensions for the processor are detailed in the technical data sheet.
It is important that the processor location is well ventilated and with the required air
changes per hour – follow all recommendations from the chemical supplier.
We recommend a minimum walking space of 60cm around the processor.
2.2 ELECTRICAL SUPPLY
*) All electrical connections must meet national safety requirements. Correct fuses and
electrical requirement can be taken from the processor specification/data sheet.
multi terminal block
power cord
inline circut breaker
2.3 WATER SUPPLY (OPTIONAL)
It is necessary to connect the processor directly to a fresh water supply for cooling
and rinse. To do this, locate the installed 2-way magnetic valve. See the picture below:
We recommend that a water supply (preferably warm water) and working area are
available close-by to the machine for the purpose of cleaning rollers and tanks.
Magnetic Valve
7
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3. TRANSPORT AND ASSEMBLY
After re-assembly and with the maschine in position - level the unit for the optimum
performance - use a good quality leveling device.
Processor
To carry the processor to the working area, take care to the points below:
- take out the racks and the dryer during carry the
processor
- take off all kind of panels and covers
- move the Chiller unit separately (optional)
Level foot
Level foot
Key no.13
8
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9
3.1INSTALLATION OF THE TRANSPORT RACKS
The processor is deliverd completely assembled. Exept the transport racks, the dryer
unit and the external chiller unit has to be installed. Follow the illustrations below to do that:
*) Take care that all transport fixings are removed
*) Remove all packing materials
*) Insert the racks according the reference number or label
*) Avoid any splashes of chemistry
DEV BF SS1 SS2 SS3
Don't forget
to fix the racks!
Don't forget
to fix the racks!
Attention:
Take that all gears are installed
as shown.
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3.2INSTALLATION OF THE DRYER
Follow the illustrations below to install the dryer:
10
1. Open the dryerlid.
2. Put the dryer in and
close the dryerlid.
3. Check the position
of the drive gear.
1...Drive gear / Chain
2...Drive gear / Dryer
1 2
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4. PROCESSOR FUNKTIONS:
11
4.1 PROCESSOR FUNCTIONS
PROGRAMMING: Automatic processing parameters, e.g., temperature, speed and
replenishment rates, can be stored in 9 different programmes.
WARMING-UP: Once programmed, temperature settings are accurately controlled.
Heating commences with switching on at the mains. Constant solution
temperatures are maintained in the processing tanks. Temperatures
tolerances +/- 0,2 °C are achieved by the microprocessor control unit
while the solutions are circulated by circulation pumps. When
temperature has reached PRE-SET levels, the processor enters
STANDBY mode and is ready for use.
WORK MODE: Is when all process parameters are reached (as programmed
before). In this condition the machine confirms READY
SLEEP MODE: Sleep mode is an automatic feature for monitoring and keeping the
chemistry in good order. It is activated during night and weekend
times when the machine is inactive i.e. periods when the machine will
not be used for production and when standby replenishment is disabled.
ANTI CRYSTALLI- During STANDBY mode - within a programmable cycle periode - transport
ZATION CYCLE is activated - this prevent cristallization build up on crossover rollers.
ANTI-OXIDATION During STANDBY mode - and no material is processed during set time -
CYCLE an preprogrammable ANTI OXIDATION cycle (replenishment cycle)
is available.
The additional replenishment compensates the impact of airoxidation of
the chemistry during standby mode und tops up the chemistry
levels in the tanks, compensating evaporation of the water in the
solutions during standby.
AUTO The processor comes equipped with a media area measuring facility.
REPLENISHMENT: Infrared sensors scan the material area touchless and when
the preprogrammed amount of material (area) entered the processor,
a replenish-cycle is activated.
AUTOMATIC Infrared sensors also automatically control the startcycle of the
START-STOP: prosessor. The processor changes from STANDBY to RUN once material
has interrupted the light barrier. As the rollers turn, water is supplied to
the wash tank and to the intermediate rinse bath system. Once the last
film has passed through, the processor reverts to STANDBY. The film
can be taken out of the receiving basket or top cover lid.
4.2 SAFETY DEVICES
*) Thermostatically controlled solution heater with overheating CUT-OUT and AUTO-RESET.
*) Thermostatically controlled dryer heater with overheating CUT-OUT and MANUAL-RESET.
*) All electric motors are equipped with thermal CUT-OUT and AUTO-RESET.
*) Each electrical component is protected by a fuse on the power distribution board (PDB).
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5. INFEED - SENSOR BAR
An infra red sensor bar assembly is located at the entrance to the processor. As soon as
media passes across the sensor bar a process cycle is initiated which in turn starts the
transport motor and triggers timing circuits for the control of ”timed” processing sequences –
wash off, standby, dryer on. Timed sequences are set to operate to pre-programmed
automatic requirements and are also used for providing a visual reference on the material
location as it passes through the processor.
Important: Special care must be taken to ensure that the processor entrance rollers are
always clean and dry – any spillage of chemical or water onto the feed tray / feed rollers
or sensor bar must be avoided. Any spillage must be cleaned immediately.
Flatfront
Infeed-Sensor Bar
Frame
Developer-
rack
Cover
Infeed-Sensor
Bar
12
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13
6. CHEMICAL REPLENISHMENT SYSTEM
When operating a processor which uses chemicals for the continuous production of paper it is
very important that the chemicals within the machine are keep in good working order so as to
provide consistent processing quality. To achieve this consistency we use replenishment
solutions, which are formulated by the chemical manufacturer and injected into the processor
precisely for the area of material being produced. Replenishment of the chemical tanks is done
automatically using infra red sensors located at the entrance to the processor. These sensors
accurately monitor the width of material entering the processor, this information is then used by
the microprocessor (CPU) control software to calculate the surface area for each sheet loaded
into the processor.Each sensor, when covered, will generate a pulse, which is then recorded on
a decoder and counted – the more sensors that are covered then the faster the count. When the
count reaches the programmed value of pulse counts it triggers the start of a replenishment
cycle. During each replenishment cycle the replenishment pumps inject fresh solution from
small storage bottles/tank and into the corresponding ”working” tank solutions for a pre-set time.
DEV BF SS1 SS2 SS3
DEV BF SS
DEV
BF
SS
3x30 replenisher tanks with
level control
NOTE: TankSS1, SS2 and SS3 are connected (Overflow Cascade system)
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14
6.1DRAIN CONNECTION
It is not necessary to connect the processor to an external drain facility – the processor is
supplied with 3 x 10 litre container which are used to collect the waste Developer, Bleachfix and
Superstabi solutions. The containers are fitted with a high-level alarm device, when full they have
to be emptied.
The above mentioned level sensor is used to control the level inside the waste container.
In case one of the sensors is recognizing high level, the processor will bring the message
"WasteX high level".This indication informs the operator that the waste container must
be emptied or replaced with a fresh empty tank.
Levelsensor
(Highlevel)
DEV
BF
SS
Levelsensor
(Highlevel)
Levelsensor
(Highlevel)
The waste tanks are filled in two ways:
• manually, by opening the overflow
pipes in the tanks (to drain the tank)
• automatically, through the overflow
pipes in the tanks.
Full waste tanks have to be collected
by an authorised waste treatment
company.
Overflow SS
Overflow BF
Overflow DEV
6.2WATER DRAIN (OPTIONAL)
As mentioned before, in case the processor is supplied with as a non-washless
version,the corresponding drain-tube has to be connected.
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Circulation pump Superstabi 3
Circulation pump Superstabi 2
Circulation pump Superstabi 1
Circulation pump Bleachfix
Circulation pump Developer
7. HEATING / COOLING / CIRCULATION
15
The working temperature of all solutions is accurately monitored and electronically
controlled to the precise pre-programmed specifications. Each solution is heated by a
dedicated heat exchange ”flow heater” unit located in the circulation lines, which provides
an efficient heating system with low maintenance requirements.
1-Circulation tube Developer
2-Circulation tube Bleachfix
3-Circulation tube Superstabi 1
4-Circulation tube Superstabi 2
5-Circulation tube Superstabi 3
54321
Dev & BF
Microprocessor
DEV
BF
Heat exchange ”flow heater”
Heat exchange ”flow heater”
DEV
BF
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External thermostat Superstabi 3
External thermostat Superstabi 2
External thermostat Superstabi 1
Superstabi
16
To adjust the temp. for the SuberStabi1,2 and3, use the external thermostats
pointed below:
7.1 HOW TO DRAIN THE PROCESSOR
To drain the tanks, remove the side panel,
open the stop cock of the corresponding
tank.
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