FujiFilm FNDX 5 User manual

SERVICEMANUAL
08/2009 FR
MF800V2.8r09a
NDTFILMPROCESSOR
FNDX 5
ProduziertfürFUJIFILMdurch COLENTA LabortechnikGmbH&Co. KG, Austria.
ProducedforFUJIFILMby COLENTA LabortechnikGmbH&Co. KG, Austria

08/2009 FR
WichtigeInformation FNDX5 ImportantInformation
OBSERVANCE:
THISSERVICEMANUALCANONLYBEUSEDINCOMBINATIONWITHTHE
CORRESPONDINGINSTRUCTIONMANUALFORTHE FNDX5 !
THEINDICES INTHISSERVICEMANUALAREANADDITIONOFTHE
CHAPTERSINTHEINSTRUCTIONMANUAL!
THISSERVICEMANUALISONLYINFORMATIONFORQUALIFIED
TECHNICIANS!
EACH POINTMAYUSE ONLYBYANAUTHORIZEDCOLENTATECHNICIAN!
ATTENTION!!!
TAKECARETOFOLLOWTHESAFETYINSTRUCTIONS
INCAPTURE1OFTHE
INSTRUCTIONMANUALFNDX5 !
ACHTUNG!!!
BEFOLGENSIEGENAUDIESICHERHEITSHINWEISE
INKAPITEL1VONDER
BEDIENUNGSANLEITUNGFNDX5 !
ZUR BEACHTUNG:
DASSERVICEMANUALKANN NURINVERBINDUNGMITDER
BEDIENUNGSANLEITUNG FNDX5 VERWENDETWERDEN!
DIEINHALTEINDIESEMSERVICEMANUALSIND EINEERWEITERUNGVON
DENKAPITELNINDERBEDIENUNGANLEITUNG!

08/2009 FR
Index
Beforeinstallation
Location
Electricalsupply
InternalWatercircuit
Waterdrain
Internalchemistrycircuit
Chemestrydrains
Chemicalreplenishmentsystem
Transportationonsiteandassembling
Assemlythe fixrack withspraybar
Mountingofrollersfixrack 1
Mountingofspraybar
Adjustmentofspraybar
Mountingofrollersfixrack 2
Additionaltothe fixrack
Additionaltoinstallationofthe racks
Additionaltoinstallationofthe dryerrack
Thefirststeps
Additionaltothe firststeps
Using the chemistries
page
1
1
1
2
2
3
3
4
5
6
6
6
7
7
8
8
8
9
9
9
FNDX5
NDT-Filmprocessor

THISSERVICE MANUALISONLY INFORMATION FORQUALIFIED
TECHNICIANS!
EACHPOINTMAYUSEONLY BYANAUTHORIZEDCOLENTATECHNICIAN!
08/2009 FR
Index
Processorfunctions
Additionalsafetydevices
Filtersystemofdeveloper
Howtoreplacethe filterinsert
Systemofchillerassy
Howtofill thecooling liquid
Setupjumper
Setupofthe processor
Thebeforementionedvaluesaredefinedasfollowing
Flowchart
I2CBusoverview
Testinstruction forI2C Bussystem
Troubleshooting
Servicereport
Notes
page
10
10
11
11
13
13
15
16
17
18
19
20
23
27
lastsites
FNDX5
NDT-Filmprocessor

Service ManualforFNDX5
08/2009FR
1.1.1BEFOREINSTALLATION
*) Sitepreparation,e.g.,watersupply,drainageelectricalsupplymustbecompletedpriorinstallation.
1.1.2 LOCATION
*) Processorcanbeinstalled "through-the-wall"orcompletelyinthedarkroom.
Requiredmeasurementscanbetaken fromtheprocessorspecificationsheet.
For"through-the-wall",apurposebuiltpanelisrequired(optionalaccessory).
1.1.3 ELECTRICALSUPPLY
*) Allelectricalconnectionsmustmeetnationalsafetyrequirements.Correctfusesand electrical
requirementcanbetaken fromtheprocessorspecificationsheet.
1.1.4 WATERSUPPLY
*) Theprocessormustbeconnected tothe local watersupplybyusing aDVGW-approved system
separatingdeviceorpipeseparatingdevice.
*) The coldwatersupplypipe musthaveastopcock fitted connectiontothe processorand shouldbe
done byusingthe 3/4"hoseconnector,supplied.Easy access tothe stopcock shouldbeprovided as
ithastobe opened andclosed daily.
*) Abuiltinmagneticvalvereduceswaterconsumptiontoamaximumof2.0ltr./minuteusingpressure
andquantitycontrol.
*) It isrecommended torun asecond coldwatersupplywith2.5metersofhosing tofacilitateeasy
cleaning ofthe racks and tanks(watersupplykit-optional accessory).
Powercordwithplug
CEE3P+N+PE16-6h
415V16A
Mainswitch
Waterconnectionand
drainsinfrontofthe
processor(seepage3)
Page1

Service ManualforFNDX5
08/2009FR
1.1.5 INTERNALWATERCIRCUT
2.1.1 WATERDRAIN
*) Thewashwatershouldbedrainedseparatelyaccordingtolocalenvironmentalregulations.
The Processorcomeswiththe suitablehoseconnections.
*) The levelofthe waterdrainshouldbe aslowaspossiblewithaminimumdrainpipe
diameterofØ40mm.
watertank
1-way-water-solenoid
(watersupply)
CIRCULATION
freshwater overflowtube
level
stop-cock
*...tosettheflowtrough,
whichdependsonthepreasureof
thewatersupplyline
sewage
collector
Page2

Service ManualforFNDX5
08/2009FR
Circulation
level
DEV /FIX
heatexchanger350W circulationpump
withcooling
drainDEV/FIX
drainDEV/FIX
overflowtube circulationinlettube
2.1.3CHEMISTRYDRAINS
OPEN
CLOSED
NOTE:
forthe DEV thereis
additionalafilterinstalled.
Seemoreinchapter5.1.3
"FilterSystemforDeveloper"
2.1.2 INTERNALCHEMISTRYCIRCUIT
Drain WASHWATERFIX DEV WaterSupply
circulationpump
heatexchanger
Page3

Service ManualforFNDX5
08/2009FR
WARNING:
*) Do notusebrass orcopperinthe drainage system.
*) Chemistry disposalmustbe inaccordancewithlocal
environmentalregulations.
*) Toavoidbackpressureinthedrain,the hosesshould be
freeofbendsandwithaconstantdownwardgradient.
Cover
DEV FIX
FIX
USE FLOADINGLID
TOPROTECT
DEVELOPER
AGAINSTOXYDATION
DEV
Cover
NOTE:
ALevelcontroldeviceforreplenishertankisoptionalavailableonrequest.
Standpipe
Filter
3.1.1 ChemicalReplenishmentSystem
Whenoperatingaprocessorwhichuseschemicalsforthecontinuousproductionofplate/filmitisvery
importantthatthe chemicalswithinthe machine arekeepingood working ordersoastoprovide consistent
processingquality.
Toachievethisconsistencyweusereplenishmentsolutions,whichareformulated bythechemical
manufacturerandinjectedintotheprocessorpreciselyfortheareaofmaterialbeingproduced.
Replenishmentofthechemicaltanksisdone automaticallyusing infrared sensorslocatedatthe entrance
totheprocessor.Thesesensors accuratelymonitorthe widthofmaterialenteringthe processor,this
informationisinthenused bythe microprocessor(CPU)controlsoftwaretocalculatethesurfaceareafor
eachplateloaded intothe processor.
Eachsensor,whencovered,will generateapulse,whichisthenrecorded on adecoderand counted –
themoresensorsthatarecovered thenthefasterthe count.Whenthe countreachestheprogrammedvalue
ofpulsecountsittriggersthestartofareplenishmentcycle.
Duringeachreplenishmentcyclethereplenishmentpumpsinjectfreshsolution fromsmallstorage bottles/
tankand intothe corresponding"working"tanksolutionsforapre-settime.
DEV
Replenishment
(Canister)
ReplenishmentPump
tothepump
Standpipe
Filter
Page4

Service ManualforFNDX5
08/2009FR Page5
4.1.1TRANSPORTATIONONSITEANDASSEMBLING
The transporttothe installation areacan be done easilybytwo men.
IMPORTANT:
TheProcessormustbeinstalledleveledforoptimumperformance.
WARNING:
DURINGTRANSPORTALLRACKSANDDRYERMUSTBETAKENOUTOFPROCESSOR!!

Service ManualforFNDX5
08/2009FR
16
5.1.2 MOUNTINGOFTHEROLLERS16 AND 22 INTHECORRECTORDER
5.1.3 MOUNTING OFTHESPRAYBAR
22
5.1.1ASSEMBLYTHEFIXTANKWITHSPRAYBAR
23
16
22
CAUTION:
PayattentiontotheRollerconfiguration
abouttheFIXRack!
16 90 16606 Einzugswalzegerillt,PE 32 schwer Inputrollerfluted,PE32heavy
22 90 17425 EinzugswalzePE 25 schwer Inputroller,PE25heavy
23 90 15179 EingangswalzeFix,Stahl19 InputrollerFix,Steel19
Position TeileNr. Beschreibung Description
partno.
Page6

Service ManualforFNDX5
08/2009FR Page7
fixingnut
5.1.4 ADJUSTMENTOFTHESPRAYBAR
fixingnut
adjustableflowrateregulator
23
5.1.5 MOUNTING OFTHEROLLER23 INTHECORRECTORDER
hoseconnectorforspray-bar
Besure,thatthespray-barsheetnotcontactthesteelroller-nottoshearof.

Service ManualforFNDX5
08/2009FR Page8
6.1.1 ADDITIONALTOINSTALLATIONOFTHERACKS
*) The processorisdeliveredcompleteassembled,exceptthe transportracks,dryerand filmcatchtray.
*) Transportfixingsmustberemovedbeforeuse.
*) Inserteachrackatthe location indicated byreferencenumberorlabel.
*) Rinsethe tankswithwaterand then fillittothe red markeron the tankwall.
*) Inserttheracksaccordingthe referencenumberorlabel
*) Turnonthe transportmotorandcheckrotation
*) Insertrackscarefullyand slowly,avoiding chemistrysplashes.
RACK1 inthedevelopertank
RACK2 inthe fixertank
RACK3 inthe watertank
6.1.2ADDITIONALTOINSTALLATIONOFTHEDRYER-RACK
DryerRack inthe dryer
5.1.6 ADDITIONALTOTHEFIXRACK
hoseconnectorforspraybar
heatexchanger circulationpump
circulation fix
level
fixinletpipe
valvetoswitchthefixer
forthespray-bar
Samplephotos

Service ManualforFNDX5
08/2009FR Page9
7.1.1 THEFIRSTSTEPS
WARNING:
Separatethe FilmProcessorfrommains.Todo so,switchthe mainpowerswitch
oftheFilmprocessorto"0"position.
Wearsafetygoggles,protectionglovesandclothing!
7.1.2ADDITIONALTOTHEFIRSTSTEPS
Werecommendthatthemachineisfullywatertested oninstallation beforefilling withchemistry –thisis
justasafetyprocedureincaseoftransportdamage.
*) Thoroughlycleanprocessorensuring nopackingmaterialsrestrictsthefree runningoftheprocessor.
Payspecialattentiontothe racksandinside ofthe tanks.
*) Closethedraintapsforthe developer,fixerandwash.
*) Fill the tanks (Dev,Fixand Wash)withwatertothe markerson the tankwall.
*) Switchon the processor
*) Checkforsignsofleakage.
7.1.3USINGTHECHEMISTRIES
*) Onlyusechemistry suitableforrollertransportsystems.
*) Followinstructionsofchemistrymanufacturers.
FIXERBATH:
*) Emptyfixertankbyopening thefixdraintap.
*) RemovetheFixer-rack.
*) Checkfixertankisfreeofalien material.
*) Closefixdraintap.
*) Fillfixertankwithready-to-use-fixersolution tothered markeron thetankwall.
InserttheFixer-rackverycarefullyandslowly,addhardenersolutionifadvisedbythechemistry
manufacturer.
DEVELOPERBATH:
*) Emptydevelopertankbyopeningdevdraintap.
*) RemovetheDeveloper-rack.
*) Checkdevelopertankisfreeofalienmaterial.
*) Closedevdraintap.
*) Filldevelopertankwithready-to-use-developersolutiontotheredmarkeronthetankwall.
Insertthedeveloper-rackverycarefullyand slowly.Replenishmenttanksmaybeusedtomixthe
chemistry.Anyremainingcanbeusedforreplenishment.CAUTION:
Eventhesmallestquantityoffixercouldcontaminatethedevelopersolution.Therefore,always
fill withfixerfirst.
When removingthe fixerrack,always coverthedevelopertank.
Forremoving the fixerrack userack carriertray(optionalaccessory).
CAUTION:
Eventhesmallestquantityoffixercouldcontaminatethedeveloper
solution.Therefore,alwaysfill withfixerfirst.
When removingthe fixerrack,always coverthedevelopertank.
Forremoving the fixerrack userack carriertray(optionalaccessory).

Service ManualforFNDX5
08/2009FR Page10
8.1.1PROCESSORFUNCTIONS
Programming:
Automaticprocessingparameters,e.g.,temperature,speedandreplenishmentrates,can be stored
in9differentprogrammes.
Warm-UpTime:
Onceprogrammed,temperaturesettingsareaccuratelycontrolled.Constantsolution temperatures
aremaintainedintheprocessingtanks.Temperaturestolerances+/-0.2°Careachieved bythe
microprocessorcontrolunitwhilethesolutionsarecirculatedbycirculation pumps.
WhentemperaturehasreachedPRE-SETlevels,theprocessorentersSTANDBYmodeand
isreadyforuse.
Standby:
Incaseno filmisinprocess-afterafixed period oftimeandwhen,afterthelastplateleavesthe
dryer,theprocessortransport, dryerand watersupplyisswitchedoffautomatically.The processor
goestostandbymode.During standby,the processoractivatestwoimportantfeatures:
ANTI-OXIDATIONandANTI-CRYSTALIZATIONprogrammes.
Anti-Oxidation:
DuringSTANDBYmode-andinlongperiodsofnoproduction,apreprogrammable
ANTI-OXIDATIONcycle(replenishmentcycle)isinitiated.Theadditionalreplenishment
compensatestheimpactofairoxidation ofthechemistry duringstandbymodeand maintain
chemistrylevelsinthetanks,inordertocompensateevaporationofthe waterinthe solutions.
Anti-Crystalization:
DuringSTANDBYmode-withinaprogrammablecycleperiod -thetransportrollersand thegum
pumpareactivated-thishelpstopreventcrystalization build-uponthe rollers.
AutomaticReplenishment:
Theprocessorisequipped withafilmarea measuringsystem.Infrared sensorsscantheincomming
plateareaandwhenthe preprogrammedamountofplate(area)enterstheprocessor,
areplenishmentcyclewillbeactivated.
Automatic(Start-Stop):
Infraredsensorsalsoautomaticallycontrolthestartcycleofthefilmprosessor.Thefilmprocessor
changesfromSTANDBYtoRUN onceafilmhasinterrupted thelightbarrier.Asthe rollersturn,
waterissupplied tothe washtankandtothe intermediaterinsebathsystem.Oncethe lastfilmhas
passedthrough,thefilmprocessorrevertstoSTANDBY.Thefilmcanbetakenoutofthereceivin
basketortopcoverlid.
9.1.1ADDITIONALSAFETYDEVICES
*) ThermostaticallycontrolledsolutionheaterwithoverheatingCUT-OUTandAUTO-RESET.
*) ThermostaticallycontrolleddryerheaterwithoverheatingCUT-OUTandMANUAL-RESET.
*) AllelectricmotorsareequippedwiththermalCUT-OUTandAUTO-RESET.
*) Eachelectricalcomponentisprotectedbyafuseon thepowerdistributionboard(PDB).

Service ManualforFNDX5
08/2009FR
10.1.1FILTERSYSTEMFORDEVELOPER
10.1.2 HOWTOREPLACETHEFILTERINSERT
1. Switchoff the processorusingthe
2. Openthe closing sheet
Mainpowerswitch
CAUTION:
Tochangethe filtercartridgeitis
necessary thatthe filtersystem
isfixedon themainframe.
NOTE:
Mountthe sidepaneltothe processor
and fixitwiththe mounting screws.
Duringworking,thefilterhastobeinstalledinsidetheprocessor.
Ifyouwanttochange/replacethefilterinsert, mountthe filteron theframelikeinthe pictures.
Page11

Service ManualforFNDX5
08/2009FR Page12
3. RemovetheFilterCover 4. Takeouttheusedfiltecartridge
5. CheckpositionoftheO-ringinsidefilterhousing 6. Putin the newfiltercartridge slowly
andcarefully
7. Closethefiltersysteminthereversedsquenceasdescribed before(step 2)
CAUTION:
Aftertheinserthasbeen replaced,
placethe filterinsidethe processoragain.
IMPORTANT:
Afterthe filterhasbeen replaced,resetthefilterlog.
Goto programming modemenu Options/Filter/Logand cleartheprocessedarea to0000.

Service ManualforFNDX5
08/2009FR Page13
11.1.1SYSTEMOFTHECHILLERASSY
Ifyouwanttochange/addthe Cooling liquid,followthestepsbelow:
11.1.2 HOWTOFILL THECOOLINGLIQUID
1. Switchoff theprocessorusingthe Mainpower switch
2. Open the markedStop cock totheChillerAssy

Service ManualforFNDX5
08/2009FR Page14
3. Pressthe redbutton allthe timeduringthe filling!
4. FillinCoolingLiquidcarefullyup to3/4ofthe Filterusing afunnel,whilepressingthered button!
CAUTION:
Donotfillinmorethan
up to3/4 ofthe
CoolingLiquidTank!
5. Closethe marked Stop cock totheChillerAssy
Fill in up to3/4
(about2litres)
IMPORTANT:
Afterthe firstcooling cyclus,control
thelevelofthecoolingliquid.
Contingentlyfillupthecoolingliquid
totherightlevel.
Inspectionglass should filled3/4.

Service ManualforFNDX5
08/2009FR Page15
ADDITIONFORAUTHORIZEDTECHNICANS
12.1.1 SETUPJUMPER
It ispossible tosee dataand tochangeworkingdatainthe SETUPmenu buttosaveanynewdataentered
intothe SETUPmenu then itwill be necessarytoinsertajumperon themainboardofthe processor:
When selecting Save inthe setupmenu,theprogramwill refusetosavethedataunless thiswirejumperis
present.
DONOTforgettoremovetheJumperafterservice!
Otherwisethe cooling isswitched continousely!!!
CAUTION:
Theshaftofthemaindrivemotorhasatachometerinstalled.
Whenthe drivemotorstartsthetachowill rotatetogenerateaspeed counter
whichsendspulsestothe ProcessorCPU.
By using thesepulsesthe CPUisabletoaccuratelycontrol
thetransportspeed/timingsequencesafterenteringtheSetup-Menue:
Main drive motor
withtachometer
8765432187654321
ST17 ST14
PDBMF800

Service ManualforFNDX5
08/2009FR Page16
12.1.2 SETUPOFTHEPROCESSOR
nextpage Gear isthe numberofmotorpulsescorrespondingto1m
with advanceofthematerial.It isneededtocalculatethe
processedfilmarea(forthereplenishment)andthe
processing speed incm/min.
Pump isthe numberofmilliliters persecond ofthe
replenishmentpump.
nextpage Sensordistance isthe distancebetween twosensors
with ofthesensorbar.Itisneededforthefilmareacalculation.
nextpage Powersave.Ifsetto1(yes)thetank2heaterwill be
with switchedoffwheneverthetank1andthedryerheatersare
bothon,regardlessofthe tank2temperature.Thisto
keepthe totalpowerconsumption inlegallimits.
nextpage Replenishafter.Thisisthatarea,afterone
with replenishmentcyclehastobeactivated.
nextpage Pausebetweenswheaters.Isused topreventany
with possibledistrurbancesback tothe powerline /powersupply
(Dryerheaterpowerissplitted/swichedtime-delayed)
nextpage T1Str- startpointoftheDEV-rack
with T1End-endpointofthe DEV-rack
nextpage T2End - startpointoftheFix-rack
with T3End-endpointofthe WASH-rack
DREnd-endpointafterthedryer
nextpage Wat.reft_out-TimeoutfromautomaticWaterrefill
with (Ifwaterlevelsensorisnotreached in thistime-
Errormessage:Can'tfillwater)
nextpage
with WatStr- startpointwhen the washvalveison
WatEnd- endpointwhenthewashvalveisoff
nextpage 0=Normalmode
with 1=Feeder mode,ifthe machine isOnlinewithaAuto
Feeder,setthe valueto"1".Filmischecked frominput
tofeederuntil inputtoprocessorbeforethenextfilmis
loadedintothefeeder.
nextpage Use Save tostoreyouradjustments
with (Thesetupjumper desribedbeforehastobeinstalled
and onPDBLD9 ison)oruse Cancel toleave.
Gear137 pls/m
Pump06.7ml/s
Sensordistance
072mm
Pausebetweensw
heaters1000 ms
T1Str0012 pls
T1End0091pls
T2End0180pls
T3End0269pls
DR End0344pls
Wat.reft_out20
Powersave1
(1-yes,0-no)
Replenishafter
each0.125 sq.m.
WatStr0135pls
WatEnd 0274pls
Filmchecking0
(1-yes,0-no)
Switchon the processor,use 31-timeand you willsee:
Use 6tomoveto Setup and confirmwith 7.
Thereareabout10 pages,whichdependonthemechanicalconstruction and mustbe enteredduringthe
factorysetup.
ProgramSetup
OptionsRS232
SaveCancel
Valuessee:Testwerte_xx.pdf
DONOTforgettoremove thesetupjumper !Otherwisethecooling isswitchedcontinousely!!!