Kodak X-Omat 270 RA PROCESSOR User manual

Publication No. 2B6845
5/94
Supersedes 636718
4/91
SERVICE MANUAL
for the
Kodak X-Omat 270 RA PROCESSOR
H104_0107DA
 Eastman Kodak Company, 1994

PLEASE NOTE
The information contained herein is based on the experience and knowledge relating to the subject matter gained by
Eastman Kodak Company prior to publication.
No patent license is granted by this information.
Eastman Kodak Company reserves the right to change this information without notice, and makes no warranty, express
or implied, with respect to this information. Kodak shall not be liable for any loss or damage, including consequential or
special damages, resulting from the use of this information, even if loss or damage is caused by Kodak’s negligence or
other fault.
To avoid hazardous conditions, keep floors and floor coverings around your Kodak X-Omat 270
RA PROCESSOR and associated drains clean and dry at all times. Any accumulation of fluids
from mixing tanks, drain lines, etc, should be cleaned up immediately. In the event of an
accumulation of liquid due to backup, overflow, or other malfunctions of the drain associated with
your X-Omat PROCESSOR, call a plumber or other contractor to correct any problem with the
drain. Kodak accepts no responsibility or liability whatsoever for the serviceability of any drain
connected to or associated with a Kodak X-Omat PROCESSOR. Such drains are the sole
responsibility of the customer.
This equipment includes parts and assemblies sensitive to damage from electrostatic discharge.
Use caution to prevent damage during all service procedures.
2 2B6845

Table of Contents
Description Page
Introduction........................................................................................................................................................1-1
Special Tools ...............................................................................................................................................1-1
Electrostatic Discharge ................................................................................................................................1-2
Processor Overview.....................................................................................................................................1-3
Identifying and Removing the Covers and Panels...............................................................................1-3
Identifying the Racks and Crossovers..................................................................................................1-4
Service Overview.........................................................................................................................................1-5
Deenergizing and Energizing the Processor........................................................................................1-5
Removing the Racks with Solutions in the Tanks ...............................................................................1-6
Draining the Tanks ...............................................................................................................................1-8
Filling the Tanks ...................................................................................................................................1-9
Roller Transport ................................................................................................................................................2-1
Adjusting the Feed Shelf .............................................................................................................................2-2
Adjusting the Squareness of the Crossovers..............................................................................................2-3
Adjusting the Squareness of the Developer, Fixer, and Wash Racks .......................................................2-4
Replacement of the D Roller Assemblies in the Wash Rack of Early Processors ....................................2-5
Cleaning the Spray Bars in the Wash Rack ...............................................................................................2-7
Main Drive..........................................................................................................................................................3-1
Removing the Drive Shaft and the Worm Gears........................................................................................3-2
Adjusting the Tension on the Drive Chain ..................................................................................................3-5
Removing the Drive Chain...........................................................................................................................3-6
Removing the Drive Motor B6 and the Gear Box.......................................................................................3-7
Removing the Feed End Bearing from the Drive Shaft..............................................................................3-8
Removing the Dryer End Bearing from the Drive Shaft .............................................................................3-9
Dryer Assembly.................................................................................................................................................4-1
Removing the Blower Assembly B1............................................................................................................4-2
Removing the Dryer Over-Temperature Thermostat...................................................................................4-3
Removing the Dryer Thermistor RT3 ..........................................................................................................4-4
Removing the Dryer Heater HR3 ................................................................................................................4-5
Removing the Air Flow Switch S3...............................................................................................................4-7
Plumbing............................................................................................................................................................5-1
Developer Recirculation System..................................................................................................................5-2
Removing the Recirculation Pump B5 .................................................................................................5-2
Removing the Impeller Housing or the Impeller ..................................................................................5-3
Removing the Developer Heater HR1..................................................................................................5-4
Removing the Developer Filter.............................................................................................................5-6
Removing the Developer Thermistor RT1............................................................................................5-7
Removing the Developer Cooling Solenoid L2....................................................................................5-8
Removing the Heat Exchanger ............................................................................................................5-9
Fixer Recirculation System..........................................................................................................................5-10
Removing the Fixer Heater HR2..........................................................................................................5-10
Removing the Fixer Thermistor RT2....................................................................................................5-12
Wash System...............................................................................................................................................5-13
Removing the Water Solenoid Valve L1..............................................................................................5-13
2B6845 3

Description Page
Replenishment System................................................................................................................................5-14
Removing the Replenisher Strainer Assemblies and Screens............................................................5-14
Removing the Developer or Fixer Replenishment Pump, B3 or B4....................................................5-15
Removing the Poppet Valves for the Replenishment Pumps..............................................................5-16
Electrical.............................................................................................................................................................6-1
Removing the Autotransformer T1 ..............................................................................................................6-2
Removing the Feed End Panel ...................................................................................................................6-3
Removing the EMI Line Filter LF1 ..............................................................................................................6-5
Removing the Safelight Receptacle J35 .....................................................................................................6-6
Removing the AC Circuit Breaker CB1.......................................................................................................6-7
Adjusting the Intensity of the Lamp on the 200 Circuit Board, the Control Interface ................................6-8
Removing the 200 Circuit Board, the Control Interface..............................................................................6-9
Removing the 500 Circuit Board, the Microprocessor................................................................................6-10
Removing a Solid State Relay ....................................................................................................................6-12
Removing the Drive Motor Controller A2....................................................................................................6-13
Removing the Level Sensor Housing and the Level Sensor Probes.........................................................6-15
Removing the Quad Power Supply A1 .......................................................................................................6-16
Removing the 5600 Circuit Board, the Universal Film Detector.................................................................6-17
Adjusting the Alarm Volume on the 5600 Circuit Board.............................................................................6-18
Installation of the New Style Film Detector Switches, S1 and S2..............................................................6-19
Checking the Detector Switches..................................................................................................................6-21
Adjusting the Film Detector Switches..........................................................................................................6-23
Preventive Maintenance ...................................................................................................................................7-1
Weekly Preventive Maintenance .................................................................................................................7-1
Monthly Preventive Maintenance.................................................................................................................7-2
Every 3 Months, or as Required, Preventive Maintenance ........................................................................7-5
Publication Change Table................................................................................................................................8-1
4 2B6845

Introduction
Table of Contents
Description Page
Special Tools.......................................................................................................................................................1-1
Electrostatic Discharge .......................................................................................................................................1-2
Processor Overview............................................................................................................................................1-3
Identifying and Removing the Covers and Panels......................................................................................1-3
Identifying the Racks and Crossovers.........................................................................................................1-4
Service Overview................................................................................................................................................1-5
Deenergizing and Energizing the Processor...............................................................................................1-5
Removing the Racks with Solutions in the Tanks.......................................................................................1-6
Draining the Tanks.......................................................................................................................................1-8
Filling the Tanks...........................................................................................................................................1-9
Special Tools
IMPORTANT
Use qualified personnel to service the PROCESSOR. Dangerous Voltage. Before you
replace electrical components, move
the main wall CIRCUIT BREAKER to
‘‘OFF’’. Lock the wall CIRCUIT
BREAKER and attach a MAGNETIC
Tool No. Description POWER WARNING SIGN TL-1926 to
TL-2431 Air Meter warn others not to energize the
TL-1434 Carpenter’s Level, approximately PROCESSOR while you are
30 cm (12 in.) long performing service.
TL-2170 Clamps
699574 Diagnostics Diskette
TL-4430 Extraction Tool
TL-3346 Grounding Kit
TL-4391 Interface Cable
TL-2324 Lithium Ball and Roller Bearing
Grease 1The following applies to the PORTABLE
TL-1926 Magnetic Power Warning Sign
-- Portable Computer1COMPUTER:
TL-3230 Sealant • An IBM compatible computer with MS-DOS version
TL-4460 Spray Bar Brush 3.0 or higher installed on the hard disk and with a
TL-2192 Thermal Grease 720 kilobyte, 3 ⁄
12-in. disk drive.
• A serial communications port configured as COM 1:
Refer to the user manual for the PORTABLE
COMPUTER.
2B6845 1-1

Preventive Measures
Electrostatic Discharge
• Always look for an ESD warning label before doing
Overview any procedure involving static-sensitive
components such as CIRCUIT BOARDS. All
ESD--electrostatic discharge--is a primary source of: static-sensitive components are marked with bright
graphic labels, which frequently include
• product downtime instructions. Follow all label instructions.
• lost productivity • If the work area is carpeted, spray the carpet with
• costly repairs an antistatic solution. In low-humidity
environments, spray carpets periodically with an
antistatic preparation, available at local stores or
While one cannot feel a static charge of less than through Kodak as TL-3832.
3,500 volts, as few as 30 volts can damage or • Wear a grounding strap when handling
destroy essential components in electronic static-sensitive components. Always make certain
equipment. that the clip remains attached to a properly
Effective ESD control requires following these grounded, unpainted, clean surface.
guidelines. • Repair static-sensitive components at an
ESD-protected work station or use a portable
grounding mat. For help in setting up an
Personnel Awareness ESD-protected work station, contact your Kodak
Everyone within the organization needs to be aware representative.
of ESD, because partial ESD control is no ESD • When moving static-sensitive components from one
control at all. Please note: area to another, insert and transport the
components in ESD-protective packaging.
• ESD is a primary source of Transparent antistatic bags are available from a
frustrating equipment failures and variety of manufacturers and will help shield
intermittent malfunctions. components from ESD damage.
• ESD affects productivity and
profitability.
• ESD can be controlled.
General Precautions
•Do not store trash near static-sensitive equipment.
•Do not place plastic materials near electronic
components. Trash-can liners and styrofoam cups
generate static electricity, which can damage or
destroy electronic components.
1-2 2B6845

Processor Overview
Identifying and Removing the Covers and Panels
Before you do most of the procedures in this service manual, you must remove certain PANELS or COVERS
from the PROCESSOR. To remove the FEED END PANEL, see page 6-3.
To remove the DRIVE SIDE PANEL, the NON-DRIVE SIDE PANEL, or the EXIT PANEL:
[1] Lift the TOP COVER.
[2] Loosen the 2 CAPTIVE SCREWS on the PANEL to be removed.
[3] Lift the PANEL to release it from the 2 CLIPS under the PANEL.
H104_0460DA
FRONT
PANEL
PANEL
SIDE
NON-DRIVE
SIDE PANEL
STAND CLIP
COVER
TOP
H104_0460DCA
EXIT
PANEL
SIDE PANEL
SCREW
CAPTIVE
DRIVE
Identifying and Removing the Covers and Panels
2B6845 1-3

Identifying the Racks and Crossovers
H104_0467HA
RACK
DRYER
TOP EXIT
RACK
EVAPORATION
COVER (2)
FIXER/
CROSSOVER
RACK
WASH WASH FIXER
RACK
H104_0467HCA
DEVELOPER/FIXER
CROSSOVER
DETECTOR
DEVELOPER
CROSSOVE
R
RACK
WET SECTION
COVER
Identifying the Racks and Crossovers
1-4 2B6845

Service Overview
Deenergizing and Energizing the Processor
For most of the service procedures, the
PROCESSOR must be deenergized. To deenergize
the PROCESSOR, move the CIRCUIT BREAKER
CB1 on the PROCESSOR to the ‘‘O’’ position and
the main wall CIRCUIT BREAKER to ‘‘OFF’’.
To energize the PROCESSOR, move the main wall
CIRCUIT BREAKER to ‘‘ON’’ and the CIRCUIT
BREAKER CB1 on the PROCESSOR to the ‘‘|’’
position.
H104_0035CA
H104_0035CCE
CB1
BREAKER
CIRCUIT
Deenergizing and Energizing the Processor
2B6845 1-5

Removing the Racks with Solutions in the Tanks
NOTE
To install the RACKS, see page 1-7.
[1] Deenergize the PROCESSOR. See page 1-5.
[2] Lift the TOP COVER.
[3] Remove:
• WET SECTION COVER
• EVAPORATION COVERS
• YOKE, see the figure on page 2-8
• FIXER/WASH CROSSOVER
• DEVELOPER/FIXER CROSSOVER
• DETECTOR CROSSOVER
H108_0035AA
SPLASH
GUARD
DRIP
TRAY
H108_0035ACC
[4] To remove the DEVELOPER RACK: (b) Lift the FIXER RACK slowly out of the
PROCESSOR. Tilt the FIXER RACK
(a) Lift the DEVELOPER RACK slowly out to drain the fixer into the fixer TANK.
of the PROCESSOR. Tilt the
DEVELOPER RACK to drain the (c) Hold a DRIP TRAY under the FIXER
developer into the developer TANK. RACK.
(b) Hold a DRIP TRAY under the [6] To remove the WASH RACK:
DEVELOPER RACK. (a) Disconnect the WATER DISCONNECT
[5] To remove the FIXER RACK: from the non-drive side of the WASH
RACK. See the figure on page 2-8.
(b) Lift the WASH RACK from the WASH
TANK.
[7] To remove the TOP EXIT RACK:
Do not allow fixer to contaminate the
developer solution. (a) Rotate the TOP EXIT RACK a small
distance.
• Use DRIP TRAYS.
• If removing both the FIXER RACK and the (b) Slowly and carefully lift the TOP EXIT
DEVELOPER RACK, remove the RACK from the PROCESSOR.
DEVELOPER RACK first. [8] To remove the DRYER RACK:
• When removing the FIXER RACK, place the (a) If the PROCESSOR has a TOP EXIT
SPLASH GUARD between the developer RACK, remove it. See Step [7].
and fixer TANKS. Lift the FIXER RACK
slowly and drain it before moving it to the (b) Lift the DRYER RACK straight up from
work station. the PROCESSOR.
(a) Place the SPLASH GUARD between
the developer and fixer TANKS.
1-6 2B6845

[9] To install the RACKS: (f) If the PROCESSOR has a TOP EXIT
RACK, install the TOP EXIT RACK.
IMPORTANT
The 4 LOCKING TABS must engage.
To prevent contamination of the
developer when installing the Check that the LOCKING TABS on the TOP EXIT
DEVELOPER RACK and the FIXER engage the LOCKING TABS on the DRYER RACK.
RACK, See the figure.
• Use the SPLASH GUARD. (g) Check that the RACKS and the
• Install the FIXER RACK first. CROSSOVERS are seated correctly.
(h) Install:
(a) Place the SPLASH GUARD between
the developer and fixer TANKS. • YOKE
(b) Slowly install the FIXER RACK in the • EVAPORATION COVERS
fixer TANK. • WET SECTION COVER
(c) Remove the SPLASH GUARD. (i) Connect the WATER DISCONNECT
(d) Slowly install the DEVELOPER RACK. [10] Close the TOP COVER.
(e) Install:
• WASH RACK
• DETECTOR CROSSOVER
• FIXER/WASH CROSSOVER
• DEVELOPER/FIXER CROSSOVER
• DRYER RACK
H104_0386BA
H104_0386BCB
TOP EXIT
RACK
TAB (2)
LOCKING
RACK
DRYER
LOCKING TAB (2)
RACK
TOP EXIT
Engaging the Locking Tabs on the Top Exit Rack and the Dryer Rack
2B6845 1-7

Draining the Tanks
[1] Deenergize the PROCESSOR. See page 1-5.
NOTE
The REPLENISHMENT PUMPS will be
deenergized and the flow of developer
and fixer from the REPLENISHMENT
TANKS will stop when the
PROCESSOR is deenergized.
[2] Open:
• FIXER DRAIN VALVE
• DEVELOPER DRAIN VALVE
• Drains must be made of chemically
resistant, non-corrosive material.
Use PVC or the equivalent.
• The drain must have a minimum diameter of
7.6 cm (3 in.) and be free of obstruction.
• Drain service must comply with all local
codes.
H104_0466CA
VALVE
DRAIN
FIXER
EXHAUST
AIR
VALVE
DRAIN
DEVELOPER
H104_0466CCA
Draining the Processing Tanks
1-8 2B6845

Filling the Tanks
[1] To fill the processing TANKS, close:
• FIXER DRAIN VALVE
• DEVELOPER DRAIN VALVE
• TOP COVER
[2] Energize the PROCESSOR.
[3] On the DISPLAY PANEL on top of the
PROCESSOR, press:
•‘‘GO TO SETUP’’ key
• 4-digit access code, 4213
•‘‘OPTIONS’’ key
•‘‘REPLEN MODE’’ key
•‘‘TANK FILL’’ key
NOTE
See the Operator Manual, Publication
Part No. 636716, for more details on
draining and filling the processing
TANKS.
H104_0466CA
VALVE
DRAIN
FIXER
EXHAUST
AIR
VALVE
DRAIN
DEVELOPER
H104_0466CCA
Filling the Processing Tanks
2B6845 1-9

BLANK PAGE
1-10 2B6845

Roller Transport
Table of Contents
Description Page
Adjusting the Feed Shelf.....................................................................................................................................2-2
Adjusting the Squareness of the Crossovers.....................................................................................................2-3
Adjusting the Squareness of the Developer, Fixer, and Wash Racks...............................................................2-4
Replacement of the D Roller Assemblies in the Wash Rack of Early Processors ...........................................2-5
Cleaning the Spray Bars in the Wash Rack.......................................................................................................2-7
2B6845 2-1

Adjusting the Feed Shelf
[1] Loosen the 4 SCREWS.
[2] Adjust the position of the FEED SHELF to
approximately 1 mm (1/16 in.) below the NIP
of the DETECTOR CROSSOVER ENTRANCE
ROLLERS.
[3] Tighten the 4 SCREWS.
FEED SHELF
SCREW (4)
H104_0045ACA
H104_0475AA
NIP
DETECTOR
CROSSOVER
ENTRANCE
ROLLERS
H108_0038ACA
SCREW (4)
1mm (1/16 in.)
Adjustment of the Feed Shelf
2-2 2B6845

Adjusting the Squareness of the Crossovers
NOTE
Use this adjustment procedure to adjust the squareness of any of the 3 CROSSOVERS:
• DETECTOR CROSSOVER
• DEVELOPER/FIXER CROSSOVER
• FIXER/WASH CROSSOVER
[1] Remove the CROSSOVER.
[2] Place the CROSSOVER on a smooth, flat surface.
[3] Check that the SIDE PLATES of the CROSSOVER touch the flat surface evenly. If not, apply pressure
to the assembly.
NOTE
The GUIDE SHOES are not adjustable.
[4] Check that the longer edges of the GUIDE SHOES are pointed in the direction of film travel.
H104_0137BA
DETECTOR
CROSSOVER DEVELOPER/FIXER or
FIXER/WASH CROSSOVER
GUIDE
SHOE
film
travel
H104_0137BCB
SIDE
PLATE
Checking the Crossover for Squareness
2B6845 2-3

Adjusting the Squareness of the Developer, Fixer, and Wash Racks
[1] Place the entrance side of the RACK on a
smooth, flat surface.
[2] Check that the SIDE PLATES are flat on the
flat surface.
[3] If necessary, apply pressure to the SIDE
PLATES. See the figures.
NOTE
The GUIDE SHOES of the
DEVELOPER RACK are not
adjustable.
[4] Check that the longer edges of the GUIDE
SHOES are pointed in the direction of film
travel.
H104_0097AA
SIDE PLATE (2)
H104_0097ACA
Developer or Fixer Rack
H104_0139AA
Wash Rack
2-4 2B6845

Replacement of the D Roller Assemblies in the Wash Rack
of Early Processors
Description: WASH RACKS in current
PROCESSORS have new D ROLLER ASSEMBLIES.
Use this procedure to install these new style
D ROLLER ASSEMBLIES in early PROCESSORS.
The GEAR in the new assemblies has a HUB that
interlocks with the GEARS on B and C ROLLER
ASSEMBLIES. See the figure. This change was not
a Modification Kit.
The Part Number of the new style D ROLLER
ASSEMBLY is 246979.
NOTE
• The new style D ROLLER
ASSEMBLIES have no INNER
E-RINGS.
H104_0331AA
H104_0331ACA
ROLLER ASSEMBLY
Part No. 246979
HUB
no HUB
ROLLER
ASSEMBLY
Part No.
943441
• B and C ROLLER ASSEMBLIES, Part The Difference Between the New
No. 911660, have not changed. and the Original D Roller Assemblies
A
BD
D
H104_0456HA
C
CD
D
SHAFT
BEARING (2)
SPRING (2)
white
H104_0456HCA
E-RING (2)
OUTER
E-RING (2)
INNER
original
ASSEMBLY
ROLLER
911660
The Original D Roller Assemblies in Early Processors
2B6845 2-5

[1] Remove the WASH RACK from the [3] For each new D ROLLER ASSEMBLY, install:
PROCESSOR. • new style D ROLLER ASSEMBLY 246979
[2] For each existing original D ROLLER on the existing SHAFT
ASSEMBLY, remove: • 2 white BEARINGS
• 2 OUTER E-RINGS and keep • 2 SPRINGS
• 2 SPRINGS and keep • 2 OUTER E-RINGS
• 2 white BEARINGS and keep IMPORTANT
• 2 INNER E-RINGS and discard
• existing ROLLER ASSEMBLY 911660 from Do not install the INNER E-RINGS on
the SHAFT and discard the new style D ROLLER
ASSEMBLIES.
A
BD
D
H104_0457HA
C
C
D
D
white
BEARING (2)
SPRING (2)
246979
ASSEMBLY
ROLLER
SHAFT
H104_0457HCA
OUTER
E-RING (2)
Installing New Style D Roller Assemblies in the Wash Rack
2-6 2B6845