COLENTA FNDX 9000 User manual

SERVICEMANUAL
11/2016TK
NDT-FILMPROCESSOR
FNDX9000
AT700 v2.8r14hand up
Produziertdurch COLENTA Labortechnik GmbH&Co.KG,Austria.
Producedby COLENTA Labortechnik GmbH&Co.KG,Austria

WichtigeInformation ImportantInformation
OBSERVANCE:
THIS SERVICEMANUAL CANONLYBE USEDINCOMBINATIONWITHTHE
CORRESPONDINGINSTRUCTIONMANUAL!
THEINDICES INTHIS SERVICEMANUALAREANADDITIONOFTHECHAPTERS
INTHE INSTRUCTIONMANUAL!
THIS SERVICEMANUAL IS ONLY INFORMATIONFORQUALIFIEDTECHNICIANS!
EACH POINTMAY USE ONLY BY ANAUTHORIZEDCOLENTATECHNICIAN!
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11/2016 TK
ServiceManualforFNDX9000
INDEX
1.BEFOREINSTALLATION..........................................................................................1
1.1LOCATION.....................................................................................................................1
1.2ELECTRICALSUPPLY..................................................................................................1
1.3WATER SUPPLY............................................................................................................1
2.INTERNALWATERCIRCUIT....................................................................................2
2.1WATER DRAIN................................................................................................................2
3.INTERNALCHEMISTRYCIRCUIT............................................................................3
3.1CHEMISTRYDRAINS....................................................................................................4
4.CHEMICALREPLENISHMENTSYSTEM.................................................................5
4.1REPLENISHMENTSYSTEMOVERVIEW.....................................................................5
4.2THE HOSE SYSTEM.....................................................................................................6
4.3THE REPLENISHMENTPUMPS..................................................................................7
4.5MANUALREPLENISHMENT.........................................................................................8
4.6AUTOMATICREPLENISHMENT...................................................................................9
4.7ADJUSTINGTHE REPLENISHMENTRATE................................................................9
5. TRANSPORTATIONONSITEAND ASSEMBLING................................................10
5.1ADDITIONALTOINSTALLATIONOFTHE RACKS.....................................................11
5.2ADDITIONALTOINSTALLATIONOFTHE DRYER-RACK..........................................11
6.THEFIRSTSTEPS..................................................................................................12
6.1ADDITIONALTOTHE FIRSTSTEPS.........................................................................12
6.2USINGTHE CHEMISTRIES........................................................................................12
6.2.1FIXER BATH.........................................................................................................12
6.2.2DEVELOPER BATH..............................................................................................12
7.PROCESSORFUNCTIONS....................................................................................13
8.ADDITIONALSAFETYDEVICES............................................................................13
9.FILTERSYSTEMFORDEVELOPER.....................................................................14
9.1HOWTOREPLACE THE FILTER INSERT.................................................................14
10.INTERNALCOOLINGCIRCUIT............................................................................16
11.ADDITIONFORAUTHORIZEDTECHNICANS.....................................................18
11.1SETUPJUMPER........................................................................................................18
11.2SETUPOFTHE PROCESSOR.................................................................................19
11.3DESCRIPTIONOFSETUPVALUES.........................................................................20

11/2016 TK
ServiceManualforFNDX9000
ThisServiceManualisonlyInformationforqualifiedtechnicians!
EachpointmayuseonlybyanauthorizedCOLENTA technician!
11.5FLOWCHARTOFPROGRAM..................................................................................21
11.6I2C-BUS -OVERVIEW................................................................................................23
11.7TESTINSTRUCTIONS FORTHE I2C-BUS SYSTEM.............................................24
11.7.1ConnecttheDisplaytothePDB (ST-17)..........................................................24
11.7.2Install aCablebetweenPDB (ST-16)and theI2C-Board(ST-6).....................24
11.7.3ConnectthesensorDRYER totheI2C-Board(ST-5)......................................25
11.7.4ConnectthesensorFIXtotheI2C-Board(ST-4).............................................25
11.7.5ConnectthesensorDEV totheI2C-Board(ST-3)...........................................26
11.7.6CONNECTtheSensorbartotheI2C-Board(ST-2).........................................26
11.7.7CONNECTtheMotorControlBoardtotheMAINBoardPDB (ST-15)..........27
11.7.9CONNECTtheSilverfit Interface totheMAINBoardPDB (ST-12)................28
12. TROUBLE SHOOTING..........................................................................................29

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1.BEFOREINSTALLATION
*) Sitepreparation,e.g., watersupply,drainage electricalsupplymustbe completedpriorinstallation.
1.1 LOCATION
*) Processorcanbeinstalled"through-the-wall" orcompletelyinthe darkroom.
Requiredmeasurementscanbetakenfromthe processorspecificationsheet.
For"through-the-wall",apurposebuiltpanelisrequired (optionalaccessory).
1.2 ELECTRICALSUPPLY
*) Allelectricalconnectionsmustmeet nationalsafetyrequirements.Correctfusesandelectrical
requirement can be taken fromthe processorspecificationsheet.
1.3 WATERSUPPLY
*) Theprocessormustbeconnected tothelocalwatersupplybyusing aDVGW-approvedsystem
separating deviceorpipeseparating device.
*) Thecoldwatersupplypipe musthaveastopcockfittedconnection totheprocessorandshouldbe
donebyusingthe3/4"hoseconnector,supplied.Easyaccessto the stopcockshouldbeprovidedas
ithasto beopened and closed daily.
*) Abuiltinmagneticvalvereduceswaterconsumptiontoamaximumof 2.0ltr./minute usingpressure
andquantitycontrol.
*) It isrecommendedtorunasecondcoldwatersupplywith 2.5metersofhosingtofacilitate easy
cleaningofthe racks andtanks(watersupplykit-optionalaccessory).
Mainswitchof
thefilmprocessor
Mainsupplyof
optionalexternalchiller
Mainsupplyof
optionalexternalloader
Waterconnection and
drainsinfront of the
processor

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2.INTERNALWATERCIRCUIT
2.1 WATERDRAIN
*) Thewash watershouldbe drained separatelyaccordingtolocalenvironmentalregulations.
Theprocessor comeswiththe suitablehoseconnections.
*) Thelevelofthe water drainshouldbeaslowas possiblewithaminimumdrainpipe
diameterofØ40 mm.
WASHTank
2-way-water-solenoid
(rinse watersupply)
CIRCULATION
freshwater overflow tube
level
stop-cock*
*...to settheflow trough,
whichdependson thepressureof
thewatersupply line
sewage
collector
1-way-water-solenoid
(washwatersupply)
FIXTank
DEV Tank

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level DEV / FIX
drainDEV/FIX
circulation inlettube
NOTE:
fortheDEV thereisadditionalafilterinstalled.
Seemoreinchapter"FilterSystemfor Developer"
3. INTERNALCHEMISTRYCIRCUIT
circulation pump
heatexchanger
drainDEV/FIX
drainDEV/FIX
heatexchanger circulation pump
Circulation
overflow tube
filter
spraybar
FIX
Draintap
Draintap

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3.1CHEMISTRYDRAINS
Draintaps:
CLOSED OPEN
DRAIN
WATER FIX DEV
WASH
WATER
supply
COOLING
IN COOLING
OUT

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NOTE:
ALEVELCONTROLDEVICEFORREPLENISHERTANK IS
OPTIONALAVAILABLEONREQUEST.
4.CHEMICALREPLENISHMENTSYSTEM
4.1REPLENISHMENTSYSTEM OVERVIEW
When operating aprocessorwhichuseschemicalsforthe continuousproduction ofplate/film
itisveryimportantthatthechemicalswithinthemachinearekeep ingoodworking orderso
astoprovideconsistentprocessingquality.
Toachievethisconsistencyweusereplenishmentsolutions,whichareformulated bythe
chemicalmanufacturerandinjectedintotheprocessorpreciselyforthearea ofmaterialbeing
produced.
Replenishmentofthe chemicaltanksisdoneautomaticallyusinginfrared sensorslocated at
theentrancetothe processor.Thesesensorsaccuratelymonitorthewidthofmaterialentering
theprocessor,thisinformationisinthenusedbythemicroprocessor(CPU)controlsoftware
tocalculatethe surfaceareaforeachfilmloadedintothe processor.
Eachsensor,whencovered,willgenerateapulse,whichisthenrecorded on adecoderand
counted–themoresensorsthatarecovered thenthefasterthecount.When thecount
reachestheprogrammedvalueofpulsecountsittriggersthe startofareplenishmentcycle.
Duringeachreplenishmentcyclethereplenishmentpumpsinjectfreshsolutionfromsmall
storagebottles/tankandintothe corresponding "working" tanksolutionsforapre-settime.
WARNING:
Donotusebrass orcopperinthedrainagesystem.
Chemistrydisposalmustbeinaccordancewithlocalenvironmental
regulations.
To avoidback pressureinthedrain,thehosesshouldbefree of
bendsand withaconstantdownwardgradient.
WARNING
WARNING:
Thereplenishmentratehas tobeREADJUSTEDwhenthe
processor isusedat60 Hz!
WARNING

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4.2 THEHOSE SYSTEM
ONLYATDEV:
USEFLOATINGLID
TOPROTECT
DEVELOPER
FROMOXYDATION
DEV/FIX
Cover
Standpipe
Filter
ReplenishmentPump
TankInlet
DEV /FIX Tank
OPTIONALWITH
LEVELSWITCH
checkingthehosesystem:
1)visiblecheckofhosesthattheyarenotbended
2)visiblecheckofhosesthatthereisnoblockadeinthehoses
3)check ifthe connections(tank,pump,inlet)ofthehosesarefixed
SYMBOLIC SCHEME

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openthefasteners
removetheplasticparts(valves)andthegasket
rings and cleanthemwithfresh water
AFTERCLEANINGfollownowtheinstructiontoassembleagain:
DraintheDEV/FIXtanks incorrectprocedure
before manipulatingthepumps.
closethefasteners
4.3THEREPLENISHMENTPUMPS
cleaningthe replenishmentpumps:

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4.5MANUALREPLENISHMENT
Tocheckthefunctionalityofthe replenishmentsystemyou canusethe softwarefuntionof
manualreplenishment.Youmayneed torun the replenishmentmanually,forinstanceduring
cleaning.
Todo thispress .With 6,movethe cursorunder
"Rep" andselectitwith 7.
Toreplenishtank1:
With 6,movethecursorunder"Rep1"andpress 7.
Thiswilladd100ml.TheOFFindicationwill changetoON,
meaningthatthe replenishmentpumpisworking.
If youneed morereplenishment,press 7again
toaddmorereplenishmentinstepsof100ml.
Thereisno need towaitforthereplenishmentpump
tofinish.
Fortank2,movethecursorunderRep2andrepeatthe procedure.
Press 4tojumpbacktothemainpage.
checkingthereplenishment:
makethe wholeprocedureforeachreplenishmentsystem(DEV/FIX)separately.
1) takethe hoseoutoftheDEV/FIX chemistrytank
2) activatemanualreplenishmentofabout200ml
3) ifthereplenishmentisworking well someairbubbles
havetoappearintheactivatedTankinlet.
4) putthehosebackintothe DEV/FIXchemistrytank.
5) activatemanualreplenishmentofabout200ml
6) visiblecheckduringthepumpisworking,ifthe pumpissucking well
thechemistryoutofthechemistrytank.
7) takeagraduated cylinder(max.500ml) andfillin500mlofchemistry.
8) activatemanualreplenishmentof400ml
9) check on graduatedcylinderthesuckedamountofchemistry
(toleranceof+/-20ml)
10) adjustthereplenishmentpumpsaccordingthechapter
"adjustingthereplenishmentrate"
Rep1 100 ml ON
Rep2 0ml OFF
NOTE:
Upto2000mlofmanualreplenishmentoramaximum of
25minpumpworking timeisallowed(whateverisgreater).
Start P1 Use
Rep Monitor

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4.7 ADJUSTINGTHEREPLENISHMENTRATE
Theflowrateofthereplenishmentpumpscanbe adjustedfrom0-100%.
Afterchecking the replenishmentrateaccordingthechapters
"manualreplenishment" and/or "automaticreplenishment"
itispossibletoadjustthereplenishmentratewitha
screwdriverforrecessed-head screws.
Toincreasethe replenishmentrateturnthescrewdriver
clockwiselikeshowninthepicture.
Todecreasethe replenishmentrateturnthescrewdriver
counterclockwise.
Afteradjustingthe replenishmentrateitisrecommendedtomeasuresomeautomaticand
somemanualreplenishmentcyclestochecktheadjustments.
4.6 AUTOMATIC REPLENISHMENT
Theprocessorisequippedwithafilmareameasuringsystem.Infrared sensorsinthe
sensorbarscanthe incomming platearea and whentheprogrammedamountoffilmper
replenishmentcycle(area)entersthe processor,areplenishmentcyclewill beactivated.How
muchchemistrywill be replenishedcanbesetintheprogrampoitR1/R2.
Thereplenishmentisalways doneforall chemistriesatonetime.
checkingtheautomaticreplenishment:
makethe wholeprocedureforeachreplenishmentsystem(DEV /FIX)separatly.
1) takeagraduated cylinder(max.500ml) andfillin500mlofchemistry.
2) feed inasmuchfilm area asneededtoreplenishasmuchaspossiblebutlessthan
500ml.Thishastobedone inrespectofminimumreplenishmentratesetinthe SETUP.
(replenishaftereach0.125 /0.250/0.500/1litres).
Forexample: R1=700 ml/m2andReplenishaftereach0.125 litres
=> Feed inabout0.375 m2-0.45m2offilm.
so3replenishmentcycleswill bedone
fromthegraduated cylindershouldhavebeen
suckedabout0.375litresofchemistry
3) visiblecheckduringthepumpisworking,ifthe pumpissucking well
thechemistryoutofthechemistrytank.
4) check on graduatedcylinderthesuckedamountofchemistry
(toleranceof+/-20ml)
5) adjustthereplenishmentpumpsaccordingthechapter
"adjustingthereplenishmentrate"
WARNING:
Thereplenishmentratehas tobeREADJUSTEDwhenthe
processor isusedat60 Hz!
WARNING

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5.TRANSPORTATIONONSITEANDASSEMBLING
Thetransporttotheinstallation areacanbedoneeasilybytwomen.
NOTE:
TheProcessormustbeinstalledleveledforoptimum
performance.
WARNING:
DURINGTRANSPORTALLRACKSAND DRYERMUSTBE
TAKENOUTOFPROCESSOR!!
WARNING

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5.1 ADDITIONALTOINSTALLATIONOFTHERACKS
*) Theprocessorisdelivered completeassembled,exceptthetransportracks,
dryerandfilmcatchtray.
*) Transportfixingsmustberemovedbeforeuse.
*) Inserteachrackatthe locationindicatedbyreferencenumberorlabel.
*) Rinsethetanks withwaterand thenfill ittothe red markeronthe tankwall.
*) Inserttheracks accordingthe referencenumberorlabel
*) Turnonthe transportmotorandcheckrotation
*) Insertrackscarefullyandslowly,avoiding chemistrysplashes.
RACK1 inthedevelopertank
RACK2 inthefixertank
RACK3 inthewatertank
5.2 ADDITIONALTOINSTALLATIONOFTHEDRYER-RACK
DryerRack in the dryer
Samplephotos

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6.THEFIRSTSTEPS
6.1 ADDITIONALTOTHEFIRSTSTEPS
Werecommendthatthemachineisfullywatertestedon installation beforefillingwithchemistry–this is
justasafetyprocedureincaseoftransportdamage.
*) Thoroughlycleanprocessorensuring nopackingmaterialsrestrictsthe freerunningoftheprocessor.
Payspecialattentionto the racksand inside ofthetanks.
*) Closethe draintapsforthe developer,fixerandwash.
*) Fillthetanks(Dev,Fix andWash)with waterto the markers onthetankwall.
*) Switchon the processor
*) Checkforsignsofleakage.
6.2USINGTHECHEMISTRIES
*) Onlyusechemistrysuitableforrollertransportsystems.
*) Followinstructionsofchemistrymanufacturers.
6.2.1 FIXERBATH
*) Emptyfixertankbyopening thefixdraintap.
*) RemovetheFixer-rack.
*) Checkfixertankis freeofalienmaterial.
*) Closefixdraintap.
*) Fillfixertankwithready-to-use-fixersolution totheredmarkeronthetankwall.
InserttheFixer-rackverycarefullyandslowly,addhardenersolutionifadvised bythechemistry
manufacturer.
6.2.2DEVELOPERBATH
*) Emptydevelopertankbyopeningdevdraintap.
*) RemovetheDeveloper-rack.
*) Checkdevelopertankis freeofalienmaterial.
*) Closedevdraintap.
*) Filldevelopertankwithready-to-use-developersolutiontothered markeronthetankwall.
Insertthe developer-rackverycarefullyand slowly.Replenishment tanks maybe usedto mixthe
chemistry.Anyremaining can be used forreplenishment.CAUTION:
Even the smallestquantityoffixercouldcontaminatethe developersolution.Therefore,always
fill withfixerfirst.
When removingthe fixerrack,alwayscoverthe developertank.
Forremovingthe fixerrackuse rackcarriertray(optionalaccessory).
CAUTION:
Eventhesmallestquantityoffixercouldcontaminatethe
developersolution.Therefore,alwaysfill withfixerfirst.
Whenremoving thefixerrack,alwayscoverthedevelopertank.
For removing thefixerrack use rack carriertray
(optionalaccessory).
DANGER
WARNING:
Separate theFilmProcessorfrom mains. Todo so, switchthemainpower
switchof theFilmprocessorto„0“position.Wearsafetygoggles,protection
gloves and clothing.
CAUTION

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7.PROCESSORFUNCTIONS
Programming:
Automaticprocessingparameters,e.g.,temperature,speed andreplenishment rates,canbestored
in9different programmes.
Warm-UpTime:
Onceprogrammed,temperaturesettingsareaccuratelycontrolled.Constantsolution temperatures
aremaintained intheprocessing tanks.Temperaturestolerances+/-0.2 °Careachievedbythe
microprocessorcontrolunitwhilethe solutionsarecirculated bycirculationpumps.
Whentemperaturehasreached PRE-SETlevels,theprocessorenters STANDBYmode and
is readyforuse.
Standby:
In caseno filmisinprocess-afterafixed periodof timeandwhen,afterthe lastplateleavesthe
dryer,the processortransport, dryerandwatersupplyisswitched off automatically.Theprocessor
goestostandbymode.During standby,the processoractivatestwoimportant features:
ANTI-OXIDATIONandANTI-CRYSTALIZATIONprogrammes.
Anti-Oxidation:
During STANDBYmode -andinlong periodsofnoproduction, apreprogrammable
ANTI-OXIDATIONcycle(replenishmentcycle)isinitiated.Theadditionalreplenishment
compensatesthe impactof airoxidationof the chemistryduring standbymode and maintain
chemistrylevels inthe tanks,inordertocompensate evaporation ofthewaterinthesolutions.
Anti-Crystalization:
During STANDBYmode -withinaprogrammablecycleperiod-the transportrollers and the gum
pumpareactivated -thishelpsto preventcrystalization build-up on the rollers.
Automatic Replenishment:
Theprocessoris equippedwithafilmareameasuring system.Infrared sensorsscan theincomming
plate area and when the preprogrammedamount ofplate (area)enterstheprocessor,
areplenishment cyclewill beactivated.
Automatic (Start-Stop):
Infraredsensorsalsoautomaticallycontrolthestartcycleofthefilmprosessor.The filmprocessor
changesfromSTANDBYto RUN onceafilmhasinterruptedthelight barrier.Astherollersturn,
waterissuppliedto thewashtankandtothe intermediate rinsebath system.Oncethe lastfilmhas
passed through,the filmprocessorrevertsto STANDBY.The filmcan be takenout ofthe receivin
basket ortopcoverlid.
8.ADDITIONALSAFETYDEVICES
*) ThermostaticallycontrolledsolutionheaterwithoverheatingCUT-OUTand AUTO-RESET.
*) Thermostaticallycontrolleddryerheaterwith overheatingCUT-OUTand MANUAL-RESET.
*) Allelectricmotors areequippedwiththermalCUT-OUTand AUTO-RESET.
*) Eachelectricalcomponentis protectedbyafuseonthepowerdistribution board(PDB).

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9.1 HOWTOREPLACETHEFILTERINSERT
1. Switchofftheprocessorusing the Mainpowerswitch
9. FILTERSYSTEMFORDEVELOPER
DEV
FIX
4.Takeouttheusedfiltecartridge 5.Checkposition ofthe O-ringinside
thefilterhousing
2.Open andremovethe closingsheet 3.RemovetheFilterCover

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Pressthebutton 3,use 6 tomovethecursor
under"Options",press 7 ,youwillsee
"StandbyRefill FilterService".
Use 6 againtomovethe cursorto"Filter"and
press 7.
Use 6tomovethe cursorto"Log"and
then press 7.
Toresetthefilterlog,use tomovethe
cursor to"Clear"and thenpress 7.
CAUTION:
Aftertheinserthas beenreplaced,place thefilterinsidethe
processor again.
NOTE:
Afterthefilterhasbeenreplaced,resetthefilterlog.
Goto programming modemenu Options/Filter/Log and clear the
processedareato0000.
CAUTION
6.Putinthe newfiltercartridge 7.Closethe filtersysteminthereversed
slowlyandcarefully squenceasdescribedbefore(step 2)
8.Resetthe FilterLog(clearthe processed areato0000).
Standby Refill
Filter Service
0000.00
Exit Clear
ProgramSetup
Options
Area Log

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10.INTERNALCOOLINGCIRCUIT
fixertank
developertank
cooling coil assy
2-way-water-solenoid
(chillerIN /coldwatersupply)
chillerOUT/
coldwaterDRAIN