COLENTA PrintlineProcessor 56 RA User manual

Instruction Manual
MP700 V5.2r04/05/06
06/2003 AN
forCOLENTA
PrintlineProcessor
56/66/80 RA

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TechnicalSpecifications:
Processingapplications: RAPhotopaperfordigitalapplicationsincl.Duratrans
Paper width: max.80 cm(31 inch)
MicroprocessorControl: -with9preprogrammableprocessing cycles
TransportSpeed(at45 sec DEV-Time): -70 cm/min(42 inch/min)
-95 cm/min(42 inch/min)
-120 cm/min(42 inch/min)
(preprogrammable20 to116 sec.)
Tankcapacity Temperature* Repl. Rate*
Developer : xlt 18 -43°C 40-2000ml/m²
Bleachfix : xlt 18 -43°C 40-2000ml/m²
Superstabi1 : xlt 18 -43°C 40-2000ml/m²
Superstabi2 : xlt 18 -43°C 40-2000ml/m²
Superstabi3 : xlt 18 -43°C 40-2000ml/m²
Replenishment: -controlled byup to10-sensors,measuring mediaarea
-activated after0,1-0,999m² *materialfed intothe processor
-antioxidation/standbyreplenishment, activated after0-9hours *
Anticrystalisation/
SelfcleaningCycle
during Standby: -activated : each1-20 min *
-cycletime: duration 1-3min *
Filter ReplacementProgramming: 0-9999 m² *
.........*all values preprogrammable
Control:-Activateand Monitoring features inform,warnand alerttheoperatortoanerrorin thesystem.
SolutionLevels: -LowLevelmonitoring inDev-,Bleachfix,and all Superstabi-Tanks
ofprocessor**
-High Levelmonitoring inOverflowCollection Tanks(wastemanagement)**
-LowLevelinRepl.TanksforDev-,Bleachfixand Superstabi**
Temperatures: High /Lowlevelmonitoring ofthe Dev,Bleachfix,Superstabiand Dryer
Work in Progress : Detailsthe position ofthe mediathrough the processor.
Transport: -drivemotoroverload monitoring **
-securitycoverlidswitch **
-manualfeed facility
** whenactivatedwill operateanaudiblewarning and amessagealerttoconfirm theerrortype.
AdditionalAccessories and Features:
-Chillerunit(optional)
-Adrawerunitwithinthe mainframetohousethe replenishmentand wastecollection tanks.
Technicalspecification subjecttochangewithoutnotice.
PrintlineProcessor
56/66/80 RA 70/95/120 -5T

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DIMENSIONS: RAxx 5TSST
Y for RA56 860 mm
YforRA66 960 mm
YforRA80 1100 mm
COLENTA56/66/80 RA-xx 5T

INDEX
1.INTRODUCTION/SAFETYINSTRUCTIONS 1-6
2.BEFOREINSTALLATION 7
3. TRANSPORTAND ASSEMBLY 8-10
4.PROCESSORFUNCTIONS 11
5.INFRAREDSENSORBAR 12
6.REPLENISHMENTSYSTEM 13,14
7.HEATING/COOLING/CIRCULATION 15-17
8. TESTRUN AND TANK FILL 18
9.WORKINGWITHTHECHEMISTRY 18
10.WORKINGWITHTHEPROCESSOR 19
11.CONTROLPANEL 20-31
12.MAINTENANCE 32
13.RECOMENDEDMAINTENENCEEVERY3-6 MONTH 33
14. SAFETYINSTRUCTIONS 34,35
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1
1.INTRODUCTION
Congratulationsupon yourdecision tobuya
COLENTARA-Processor.
Yourpurchasehasbeen designed tomeetthe highesttechnicalstandards.
Someoutstanding design featuresinclude:
*) compact, space-saving design
*) full automaticprocessing cycle
*) smoothrollertransport system
*) lowtankvolumes
*) electronicallycontrolled temperaturesystem
*) automaticreplenishment
*) lowenergyconsumption
Thismanualisaguide toinstallation and routine useofyour
COLENTARA-Processor.

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1.1 GENERALSAFETYINSTRUCTIONS
*) Staff incharge ofmaintenanceofthe processor(see chapter11and 12)need tobe
thoroughlyfamiliarwiththe equipment.
*) Onlythe Top Coverofthe Filmprocessormaybe removed bythe operator(see picture
below)
.
*) The filmprocessormustbe separated frommainspriortocarrying outanymaintenance.To
do so,switchthe mainsswitchofthe machine to„0“position.Always wearsafetygoggles
and protectiveclothing when handlingchemicals.
*) The filmprocesormaynotbe inoperation withoutsupervision.
*) Makesurethatclothing orotherobjectscannotgetentrapped ingeardrivesorsimilarofthe
filmprocessor.
*) The installation,service,repairaswell asthe initialoperation ofthe machine maybe carried
outbyqualified and trained servicepersonnelonly.
*) Built-insafetydevicesmaynotbe eluded ormade inoperative.UseonlyoriginalCOLENTA
sparepartswhen exchanging failedelectricalcomponents.
*) Donotwearanyloosenecklacesorbracelets!
1.2 CHEMICALHANDLING
*) Observeall safetytechnicalregulationsofthe chemicalmanufacturer.
*) Wearsafetygogglesand protectiveclothing when handling chemicals.
*) Ensureproperventilation ofthe roominwhichthe chemicalsareprepared.
*) Spillage oroverflowofchemicalshastobe removed instantly.
*) Incaseofcontactwiththe eyesflushwithplentyofcoldwaterforapproximatelyfifteen
minutesand consultan physician.
*) Chemicaldisposalhastobe inaccordancewiththe localenvironmentalcodes.Contactyour
localwatertreatmentand sewerdistrictauthoritiesformoreinformation.
Top covers
Mainswitchof
thefilmprocessor
2

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ProcessorOperation
Makesurethatno long hair,looseclothing or
jewellry can getentrapped inthe geardrives
orinthe mediatransportarea.
The „Service ManualforColentaPrintline
Processor" isforthe useofqualified
servicepersonnelonly.
Do notclean the processorwithrunning
water.
Electricaland MechanicalHazards
Observeall safetywarningstominimizethe riskof
electricalshock,burnsorequipmentdamage.
PhotographicProcessorsarecomplex
machineswithmanyelectricaland mechanical
partsaswell
aswithaconsiderableamountofchemicals.
Fire Prevention
The area around the processormustbe kept
clean atall times.Keep dust,wood shavings,
scrap paperorotherinflamablematerialsout
ofthe dryercompartment.
Fireextinguishersmustbe availableinthe
roomwherethe processorisinstalled.
ChemicalHandling and AccidentPrevention
Misuseofalmostanychemicalmaycreate
ahazardofsometype.Generallyphotochemicals
arenotanymoredangerousasmostofthe regular
cleaning agents.However,thereisalwaysaresidual
risk.When handling chemicalsobservethe procedures
below.
1).Neversniff acontaineroropen bottleto
determine itscontents.Acautioussniff of
the cap orlidissafer.
2).When handling chemicalswearprotective
clothing,safetygogglesand rubbergloves.
3).Labelstorage containersproperly.Avoid
storing hazardouschemicalson high
shelvesorinunprotected glass containers.
Keep chemicalsawayfromchildren.Do
notstorechemicalsinarefrigeratorused
forfood becausetheymaycontaminate
food orbe mistaken foredibles.
4).Ensureproperventilation inthe area where
chemicalsareused orstored.
5).Observethe manufacturer’srecommen-
dationsforusing and mixing chemicals.
Overexposuretophotographic
chemistry maycauseskinirritation to
certainindividuals.
PHOTOGRAPHICCHEMICALEMERGENCIES
AND FIRSTAIDPROCEDURES:
• SKIN -Rinsethoroughlywithwater.
• EYES -Rinsethoroughlywithwaterand
consultaphysician.
• INGESTION -Consultaphysician imme-
diately.
1.3 IMPORTANTWARNINGAND SAFETYINSTRUCTIONS
(Please readthese instructionscarefully.)
Theracks mustbecleanedwithrunning
water outsidetheFilmProcessor.
3

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ChemicalDisposal
Wastefromphotographicprocessing normally
containsdiluted chemicals. Thesechemicals
shouldbe collected and disposed inaccordance
withlocal environmentalcodes.Dumping
chemicalsintoadrainsystemcouldlead toa
pollution problem.Contactyourlocalwater
treatmentand sewerdistrictauthoritiesbefore
disposing chemicals.
All plumbing mustcomplywithlocaland
nationalcodes.The DRAINmustbe made of
chemicalresistantand non-corrosivematerial.
UsePVCorequivalent
Exhaust,TemperatureandHumidity
It isnecessary toensureproperventilation
inordertoreceivegood processing results.
Makesurethatthe exhausthoseofthe
built-inexhaustfan isproperlyconnected
tothe exhaustairsocket(Picture1).
The built-inexhaustfan exhauststhe
fumesfromthe processor.
Thesechemicalfumesarecorrosive.The top
coveroftheprocessorshouldbe removed over
night.
Roomtemperaturesbetween 18-26 °C
(65-80 °F)witharelativehumiditybetween 35%
and 75%areidealforphotographicprocessing
and working.
The filmprocessorisacomplex
machine withmoving partssuchasthe gear
trainand mediatransfercomponents.It uses
photoprocessing chemicalswhichareirritating
toeyes,lungsand skin.High voltage isused to
powerthe processor.
The dryercompartmentproducesheat.
·High voltage maycauseelectricshocks,
burnsoreven death.
·Handsorfingersmaybe pinched or
injured bymoving partsorwhen handling
heavyparts.
·Dryercompartmentheatmayignite
combustiblematerialsand causefires.
·Eyes,skinand lungsmaybe irritated
byphotochemicals.Beforeusing photo
processing chemicalsalwaysread the
MaterialSafetyDataSheets(MSDSs)
forinformation aboutthe hazardsof
the particularchemicalsand howtouse
themsafely.
·Do notoperatethe filmprocessorafter
consuming alcoholortaking strong
medication.
·Do notwearjewellery orlooseclothing
when operating the processor.
Electronicaland ElectricalHazards
HAZARDOUSVOLTAGECANCAUSE
ELECTRICSHOCK,BURNSOREVEN
DEATH·
Qualified servicepersonnelmustverifyduring
installation thatthe processorispermanently
and reliablegrounded according to
standardsinthe NationalElectricalCode.
Picture1
Airgrille
4

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Carry outthe following stepspriorremoval
ofthe top cover:
1.Train operators oftheprocessor.
2.Switchoff themain power switch
(„0“-position)and secure against
restartbylocking withapadlock
(see picture below).
Fire Hazards
DRYERCOMPARTMENTPRODUCES
HEAT-PAPEROROTHERCOMBUSTI-
BLES CANBE IGNITED
·Keep the area within10 feetofthe processor
clean.Do notstorecombustiblematerials,
including paper,closetothe filmprocessor.
·Verifythatafunctional10 lb.ABCfire
extinguisherislocated closed tothe processor.
BurnHazard
DRYERCOMPARTMENTPRODUCES
HEAT-DRYERPANELSAND GUARDS
GETHOT
·Thereforedo nottouchdryerpanelsorguards
when dryerinoperation
Corrosive Liquids
CHEMICALSMAY IRRITATEEYES,
LUNGS,SKINAND DIGESTIVE TRACT
#Wearsafetygoggles,protectiveglovesand
chemicalapronsasindicated on Material
SafetyDataSheets(MSDSs)when handling
chemistry.
#Draintankscarefully,avoidsplashing.
Alwaysdrainthe systemthoroughlybefore
working on anyofthe externalhosesystems.
#Read the MSDSsformoreinformation
regarding the propersafetyproceduresfor
working withphotoprocessing chemicals.
#Do notallowuntrained personneltohandle
photoprocessing chemicalsortooperate
the filmprocessor.
#Toavoidhazardoussituations,keep floors
and floorcoveringsaround the processorand
associated drainsclean and dry atall times.
Anyaccumulation offluidsoutside the film
processor,shouldbe cleaned up
immediately
5
Mainswitchof
theprocessor

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Inthe eventofan accumulation
ofliquiddue tobackup,overfloworother
malfunctionsofthe drainassociated withthe
processorcall aplumberorothercontractor
tocorrectthe problemwiththe drain.
Colentaassumeanyresponsibilityorliability
whatsoeverforthe serviceabilityofany
drainconnected tothe processor.
Suchdrainsarethe soleresponsibility
ofthe customer.
DRAINS mustbe made ofchemically
resistantand non-corrosivematerial.
ChemicalHazards
Chemicalscan be the sourceforerrors,
contaminatethe wastewater,irritateskin
oreyes.
Spillsmustbe cleaned up immediatelyas
follows:
1.Preventthe spilled chemicalsfromentering
awastewaterdrain.
2.Clean up the spill withamoistmop orrag.
CAUTION!
Whenhandling chemicals,especiallyfixer,
wear protective clothing, safetygoggles
and rubber gloves.
Ifprocessorchemicalsmakecontactwiththe
eyes,rinsethemthoroughlywithlots
ofwater.Ifirritation persists,consultaphysician.
3.Disposecleaning materialsand collected waste
waterfromthe clean up according to
environmentalregulationsand localscodes.
4.Avoidanyinhalation ofchemicalsas
thisisdangeroustohealth.
5.Observeall environmentalregulationsfor
storage and disposalofwastechemicals.
6.Usethismanualtogetherwiththe
instructionsforchemicals.
When handling chemicalswear
protectiveclothing,safetygogglesand rubbergloves,
Corrosive Vapours
CHEMICALVAPOURSMAYIRRITATE
EYES,LUNGSAND SKINIF ALLOWEDTO
ACCUMULATEINWORKAREA
Assurean adequatesupplyoffresh
outdoorairthrough naturalormechanical
ventilation.
·Makesurethatqualified servicepersonnel
ischecking the externalexhaustsystemat
regularintervals.
·Read the MaterialSafetyDataSheets
(MSDSs)formoreinformation regarding
the propersafetyproceduresforworking
withphotoprocessing chemicals.
6

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2.BEFORE INSTALLATION
Sitepreparation shouldbe completed beforedeliveryand installation.
2.1 LOCATION
Location.All dimensionsforthe processoraredetailed inthe technicaldatasheet.
It isimportantthatthe processorlocation iswell ventilated and withthe required air
changesperhour–followall recommendationsfromthe chemicalsupplier.
Werecommend aminimumwalking spaceof 60cmaround the processor.
2.2 ELECTRICALSUPPLY
*) All electricalconnectionsmustmeetnationalsafetyrequirements.Correctfusesand
electricalrequirementcan be taken fromthe processorspecification/datasheet.
multiterminalblock
powercord
inlinecircutbreaker
2.3 WATERSUPPLY(OPTIONAL)
It isnecessarytoconnectthe processordirectlytoafreshwatersupplyforcooling
and rinse.Todo this,locatethe installed 2-waymagneticvalve.See the picturebelow:
Werecommend that awatersupply(preferablywarmwater) and working area are
availableclose-bytothe machine forthe purposeofcleaning rollersand tanks.
MagneticValve
7

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3.TRANSPORTAND ASSEMBLY
Afterre-assemblyand withthe maschine inposition -levelthe unitforthe optimum
performance-useagood qualityleveling device.
Processor
Tocarrytheprocessortotheworkingarea, take caretothepointsbelow:
- takeoutthe racks and the dryerduring carrythe
processor
- takeoff all kind ofpanelsand covers
- movethe Chillerunitseparately(optional)
Levelfoot
Levelfoot
Keyno.13
8

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9
3.1INSTALLATIONOFTHETRANSPORTRACKS
The processorisdeliverdcompletelyassembled.Exeptthe transportracks,the dryer
unitand the externalchillerunithastobe installed.Followthe illustrationsbelowtodo that:
*) Takecarethatall transportfixingsareremoved
*) Removeall packing materials
*) Insertthe racks according the referencenumberorlabel
*) Avoidanysplashesofchemistry
DEVBF SS1SS2 SS3
Don'tforget
tofixtheracks! Don'tforget
tofixtheracks!
Attention:
Takethatall gearsareinstalled
asshown.

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3.2INSTALLATIONOFTHEDRYER
Followthe illustrationsbelowtoinstall the dryer:
10
1. Openthedryerlid.
2.Putthedryerinand
close thedryerlid.
3.Check theposition
ofthedrivegear.
1...Drivegear/ Chain
2...Drivegear/Dryer
12

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4.PROCESSORFUNKTIONS:
11
4.1 PROCESSORFUNCTIONS
PROGRAMMING: Automaticprocessing parameters,e.g.,temperature,speed and
replenishmentrates,can be stored in9differentprogrammes.
WARMING-UP: Onceprogrammed,temperaturesettingsareaccuratelycontrolled.
Heating commenceswithswitching on atthe mains.Constantsolution
temperaturesaremaintained inthe processing tanks.Temperatures
tolerances+/-0,2°Careachieved bythe microprocessorcontrolunit
whilethe solutionsarecirculated bycirculation pumps.When
temperaturehasreached PRE-SETlevels,the processorenters
STANDBYmode and isreadyforuse.
WORKMODE: Iswhen all process parametersarereached (asprogrammed
before).Inthiscondition the machine confirmsREADY
SLEEP MODE: Sleep mode isan automaticfeatureformonitoring and keeping the
chemistryingood order.It isactivated during nightand weekend
timeswhen the machine isinactivei.e.periodswhen the machine will
notbe used forproduction and when standbyreplenishmentisdisabled.
ANTICRYSTALLI- During STANDBYmode -withinaprogrammablecycleperiode -transport
ZATIONCYCLE isactivated -thispreventcristallization buildup on crossoverrollers.
ANTI-OXIDATION During STANDBYmode -and no materialisprocessed during settime-
CYCLE anpreprogrammableANTIOXIDATIONcycle(replenishmentcycle)
isavailable.
The additionalreplenishmentcompensatesthe impactofairoxidation of
the chemistryduring standbymode und topsup the chemistry
levelsinthe tanks,compensating evaporation ofthe waterinthe
solutionsduring standby.
AUTO The processorcomesequipped withamediaarea measuring facility.
REPLENISHMENT: Infrared sensorsscan the materialarea touchless and when
the preprogrammed amountofmaterial(area)entered the processor,
areplenish-cycleisactivated.
AUTOMATIC Infrared sensorsalsoautomaticallycontrolthe startcycleofthe
START-STOP: prosessor.The processorchangesfromSTANDBYtoRUN oncematerial
hasinterrupted the lightbarrier.Asthe rollersturn,waterissupplied to
the washtankand tothe intermediaterinsebathsystem.Oncethe last
filmhaspassed through,the processorrevertstoSTANDBY.The film
can be taken outofthe receiving basketortop coverlid.
4.2 SAFETYDEVICES
*) Thermostaticallycontrolled solution heaterwithoverheating CUT-OUTand AUTO-RESET.
*) Thermostaticallycontrolled dryerheaterwithoverheating CUT-OUTand MANUAL-RESET.
*) All electricmotorsareequipped withthermalCUT-OUTand AUTO-RESET.
*) Eachelectricalcomponentisprotected byafuseon the powerdistribution board(PDB).

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5.INFEED -SENSORBAR
Aninfrared sensorbarassemblyislocated atthe entrancetothe processor.Assoon as
mediapassesacross the sensorbaraprocess cycleisinitiated whichinturnstartsthe
transportmotorand triggerstiming circuitsforthe controlof”timed”processing sequences–
washoff, standby, dryeron. Timed sequencesaresettooperatetopre-programmed
automaticrequirementsand arealsoused forproviding avisualreferenceon the material
location asitpassesthrough the processor.
Important: Specialcaremustbe taken toensurethatthe processorentrancerollersare
always clean and dry–anyspillage ofchemicalorwaterontothe feed tray/feed rollers
orsensorbarmustbe avoided.Anyspillage mustbe cleaned immediately.
Flatfront
Infeed-SensorBar
Frame
Developer-
rack
Cover
Infeed-Sensor
Bar
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13
6.CHEMICALREPLENISHMENTSYSTEM
When operating aprocessorwhichuseschemicalsforthe continuousproduction ofpaperitis
veryimportantthatthe chemicalswithinthe machine arekeep ingood working ordersoasto
provide consistentprocessing quality.Toachievethisconsistency weusereplenishment
solutions,whichareformulated bythe chemicalmanufacturerand injected intothe processor
preciselyforthe area ofmaterialbeing produced.Replenishmentofthe chemicaltanks isdone
automaticallyusing infrared sensorslocated atthe entrancetothe processor.Thesesensors
accuratelymonitorthe widthofmaterialentering the processor,thisinformation isthen used by
the microprocessor(CPU)controlsoftwaretocalculatethe surfacearea foreachsheetloaded
intothe processor.Eachsensor,when covered,will generateapulse,whichisthen recorded on
adecoderand counted –the moresensorsthatarecovered then the fasterthe count. When the
countreachesthe programmed value ofpulsecountsittriggersthe startofareplenishment
cycle.During eachreplenishmentcyclethe replenishmentpumpsinjectfreshsolution from
small storage bottles/tankand intothe corresponding ”working”tanksolutionsforapre-settime.
DEV BFSS1SS2SS3
DEVBF SS
DEV
BF
SS
3x30 replenishertanks with
levelcontrol
NOTE:TankSS1, SS2andSS3areconnected(Overflow Cascadesystem)

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14
6.1DRAINCONNECTION
It isnotnecessarytoconnectthe processortoan externaldrainfacility–the processoris
supplied with3x10 litrecontainerwhichareused tocollectthe wasteDeveloper,Bleachfixand
Superstabisolutions.The containersarefitted withahigh-levelalarmdevice,when full theyhave
tobe emptied.
The abovementioned levelsensorisused tocontrolthe levelinside the wastecontainer.
Incaseone ofthe sensorsisrecognizing high level,the processorwill bring the message
"WasteXhighlevel".Thisindication informsthe operatorthatthe wastecontainermust
be emptied orreplaced withafreshemptytank.
Levelsensor
(Highlevel)
DEV
BF
SS
Levelsensor
(Highlevel)
Levelsensor
(Highlevel)
The wastetanks arefilled intwoways:
•manually,byopening the overflow
pipesinthe tanks (todrainthe tank)
•automatically,through the overflow
pipesinthe tanks.
Full wastetanks havetobe collected
byan authorised wastetreatment
company.
OverflowSS
OverflowBF
OverflowDEV
6.2WATERDRAIN(OPTIONAL)
Asmentioned before,incasethe processorissupplied withasanon-washless
version,the corresponding drain-tube hastobe connected.

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Circulation pump Superstabi3
Circulation pump Superstabi2
Circulation pump Superstabi1
Circulationpump Bleachfix
Circulation pump Developer
7.HEATING/COOLING/CIRCULATION
15
The working temperatureofall solutionsisaccuratelymonitored and electronically
controlled tothe precisepre-programmed specifications.Eachsolution isheated bya
dedicated heatexchange ”flowheater” unitlocated inthe circulation lines,whichprovides
an efficientheating systemwithlowmaintenancerequirements.
1-Circulation tube Developer
2-Circulation tube Bleachfix
3-Circulation tube Superstabi1
4-Circulation tube Superstabi2
5-Circulation tube Superstabi3
54321
Dev&BF
Microprocessor
DEV BF
Heatexchange ”flowheater”
Heatexchange ”flowheater”
DEV
BF

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Externalthermostat Superstabi3
Externalthermostat Superstabi2
Externalthermostat Superstabi1
Superstabi
16
Toadjustthe temp.forthe SuberStabi1,2and3,usethe externalthermostats
pointed below:
7.1 HOWTODRAINTHEPROCESSOR
Todrainthetanks,removethesidepanel,
openthestop cock ofthecorresponding
tank.