Kodak X-Omatic MULTILOADER 300 User manual

Publication No. MA 3058-42
6/96
MODIFICATION INSTRUCTIONS
for the
KODAK X-Omatic MULTILOADER 300
Service Code 3058
MODIFICATION No. 42
Type 1 SELECTIVE
PURPOSE:
To raise the humidity inside the XML300 to the correct level.
IMPORTANT : Use qualified service personnel to install this modification !
SERIAL NUMBERS : All XML300
INSTALLATION TIME : SN < 3000 approx. 5 hours
: SN > 3000 approx. 2.5 hours
SPECIAL TOOLS : POWER DRILL
: SABRE SAW
PARTS : SN < 3000 Mod. Kit 42 PN 9226505
: SN > 3000 Mod. Kit 42 PN 9226506

PLEASE NOTE
The information contained herein is based on the experience and knowledge relating to the subject
matter gained by Kodak prior to publication.
No patent license is granted by this information.
Kodak 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.
MA 3058-42 2 KODAK AG Stuttgart

CHAPTER PAGE
CHAPTER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
PACKING LIST FOR XML300 with SN < 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
PACKING LIST FOR XML300 with SN > 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
CHAPTER 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
INSTALLATION of MOD 42 for XML300 with SN < 3000 . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
INSTALLATION of MOD 42 for XML300 with SN > 3000 . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
ALTERING THE LEFT-HAND SIDE PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
FINAL TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
REPLACEMENT OF THE HUMIDIFIER FILTER CARTRIDGE. . . . . . . . . . . . . . . . . . . . . 5-2
TABLE OF CONTENTS
KODAK AG Stuttgart 3 M A 3058-42

CHAPTER 1
PACKING LIST FOR XML300 with SN < 3000
PART-NUMBER DESCRIPTION QTY
9226505 MODIFICATION KIT No. 42 consists of:
MA 3058-42 MODIFICATION INSTRUCTIONS 1
------------ HUMIDIFIER ASSEMBLY 1
9198266 HUMIDIFIER FILTER CARTRIDGE 1
9226646 TWIN WATER VALVE ASSEMBLY 1
9226744 PCB A16 1
9288426 HUMIDITY SENSOR 1
9226632 RESISTOR 56 Ω1
9226622 HARNESS 1
9226613 DRAIN HOSE 1
9226614 T-ADAPTER 1
9226561 OVERFLOW 1
9226681 OVERFLOW BASE 1
4282841 SCREW M4x12 2
4853251 NUT M4 1
9219131 HOSE CLAMP 25-40 4
9170191 HOSE CLAMP 10-16 2
4512650 WIRE TIE, large 5
6081850 WIRE TIE, small 10
8327578 SELF ADHESIVE WIRE TIE SOCKET 7
9226751 DVGW APPROVAL LABEL 1
4266540 SCREW M4x25 1
4853251 NUT M4 2
9198211 BIOLOGICAL GROWTH LABEL 1
9214662 MANUAL DOOR RELEASE left-hand 1
9226841 FOAM RUBBER selfadhesive 1
9226946 FILTER CARTRIDGE ACCESS COVER 1
9226901 FILTER CARTRIDGE ACCESS FRAME 1
9226926 FILTER CARTRIDGE ACCESS MOUNTING PLATE 1
4268110 SCREW 6
9226931 TEMPLATE, self adhesive 1
9226971 DRILL BIT 3 mm 1
9226961 HOLE CUTTER 30 mm 1
5001972 EDGE PROTECTOR (grey) 70 cm
9226981 GROMMET STRIP (white) 20 cm
4480171 WASHER 5.3 mm 5
9210341 FITTING PLATE 1
KODAK AG Stuttgart 1-1 MA 3058-42

PACKING LIST FOR XML300 with SN > 3000
PART
NUMBER DESCRIPTION QTY
9226506 MODIFICATION KIT No. 42 consists of:
MA 3058-42 MODIFICATION INSTRUCTIONS 1
------------ HUMIDIFIER ASSEMBLY 1
9198266 HUMIDIFIER FILTER CARTRIDGE 1
9226646 TWIN WATER VALVE ASSEMBLY 1
9226744 PCB A16 1
9288426 HUMIDITY SENSOR 1
9226632 RESISTOR 56 Ω1
9226613 DRAIN HOSE 1
9226561 OVERFLOW 1
9219131 HOSE CLAMP 25-40 2
9170191 HOSE CLAMP 10-16 1
4512650 WIRE TIE, large 5
6081850 WIRE TIE, small 10
8327578 SELF ADHESIVE WIRE TIE SOCKET 7
9226751 DVGW APPROVAL LABEL 1
4266540 SCREW M4x25 1
4853251 NUT M4 2
9198211 BIOLOGICAL GROWTH LABEL 1
9226946 FILTER CARTRIDGE ACCESS COVER 1
9226901 FILTER CARTRIDGE ACCESS FRAME 1
9226926 FILTER CARTRIDGE ACCESS MOUNTING PLATE 1
4268110 SCREW 6
9226931 TEMPLATE, self adhesive 1
5001972 EDGE PROTECTOR 70 cm
MA 3058-42 1-2 KODAK AG Stuttgart

INTRODUCTION
NOTE
THIS MODIFICATION SUPERSEDES MODIFICATION 14.
The purpose of this modification is to raise the humidity inside the XML300 to 50% Rh. This reduces
the STATIC MARKS, FILM CURL and FILM SEPARATION problems. The moistened air circulates
inside the XML300 cabinet. This increases the efficiency of the HUMIDIFIER.
BASIC FUNCTION:
If the humidity inside the XML300 is below 50% Rh, the FAN is switched on and draws air through
the moistened HUMIDIFIER FILTER CARTRIDGE. This air absorbs humidity from the FILTER.
When the humidity reaches the set level, PCB A16 switches off the FAN.
NOTE
PCB A16 is also used with the ML700 HUMIDIFIER. The high voltage parts on it are only used with
the ML700 HUMIDIFIER. They are not used for the XML300 HUMIDIFIER.
The water level is controlled by the LEVEL SENSOR. If the water level is too low, the TWIN
WATER VALVE V1 is energised and the water reservoir is filled up. However the WATER VALVE
V1 can only be energised if the HUMIDITY is below the set level.
TWIN WATER VALVE V1
fresh WATER
LEVEL
SENSOR
DRAIN
FAN
FILTER CARTRIDGE
AIR FLOW
PCB A16
HUMIDITY
SENSOR
figure 1-1
KODAK AG Stuttgart 1-3 MA 3058-42

R1
10k
R2
1.13k
R3
10.2k
R4
27k
R6
10k
TP5
TP4
R7
1M
R8
5.6k
R9
5.6k
R10
1k
R12
1k
R11
560k
VDR
TP1
TP7
TP2
TP8
TP3 TP6
R5
10k
C8
100nF
C1
10nF
78L05
U3
W1
U1
TESTPOINTS
C5
680pF
C3
100nF
C2
330nF
Q1
Q2
Q3
BC547
BC547
BC637
C6
10nF
78L12
C7
330nF
U2
EG
1
4
2
3
GND PE
HUMIDIFIER
FAN
+24V
1
2
3
not used
U2
SSR DP 2110
16
1
10
8
- +
9
10 8
U1
11
47
5 6-
+
U1
812437 56
5.0V
SENSOR+
SENSOR GND
1
2
3
SENSOR
A16X1
A16X3
C4
100nF
2
1
VPE 51
27R
56R
A4X31
Twin Water
Valve V1
Level Sensor
PCB A16
A16X2 A16P2A16P1
figure 1-2
MA 3058-42 1-4 KODAK AG Stuttgart

HARNESS
figure 1-3
KODAK AG Stuttgart 1-5 MA 3058-42

INSTALLATION
NOTE
There are 2 different INSTALLATION KITS. One for the XML300s with SN < 3000 and one
for the XML300s with SN > 3000. All XML300s with SN > 3000 have the HARNESS, TWIN
WATER VALVE and T-ADAPTER already factory installed to ease the installation of this
modification.
MA 3058-42 1-6 KODAK AG Stuttgart

CHAPTER 2
INSTALLATION of MOD 42 ( PN 9226505) for XML300 with SN < 3000
1. Disconnect the XML300 from the mains.
WARNING
When installing the HARNESS and PCB A16 you are working in the close vicinity of 110 VAC.
To avoid an electrical shock disconnect the XML300 from the mains.
2. Take off the TOP COVER, REAR PANEL and SIDE PANELS.
3. Take out all MAGAZINES.
4. Rotate out PCB A1 and lift up PCB A8.
NOTE
Observe ESD procedures.
5. Open the CABLE DUCT in the MAGAZINE CHAMBER.
6. Route the HARNESS through the CABLE DUCT. The end with the INSULATING TUBE must be
on the same side as PCB A1.
7. Fix the HUMIDITY SENSOR with 2 large WIRE TIES to the front of the CABLE DUCT. Route its
cable through the DUCT to the side of PCB A1.
CABLE DUCT
figure 2-1
KODAK AG Stuttgart 2-1 MA 3058-42

8. Close the CABLE DUCT. Ensure that all wires are inside and not trapped by COVER.
9. Fix the HARNESS and the HUMIDIFIER CABLE to the existing HARNESS behind PCB A8.
10. Mount PCB A16 just to the left below the large HEAT SINK of PCB A8. PCB A16 is fixed with a
VELCRO STRIP to the BASE PLATE of the XML300.
11. Connect HARNESS CONNECTOR A16P2 to CONNECTOR A16X2 on PCB A16. Fig. 2-3.
12. Connect the HUMIDITY SENSOR(fig. 2-2) to A16X1 on PCB A16. Fig. 2-3.
WIRE TIE
HUMIDITY SENSOR
figure 2-2
PCB A16
A16X1
A16X2
figure 2-3
MA 3058-42 2-2 KODAK AG Stuttgart

13. Connect the HARNESS CONNECTOR A4X31 to the SOCKET A4X31 on PCB A4.
14. Fix the HARNESS and the HUMIDITY SENSOR CABLE with WIRE TIES and SELF ADHESIVE
WIRE TIE SOCKETS, so that they do not come into contact with the high voltage parts of PCB A8.
15. Take off the FRONT PANEL.
16. Replace the left-hand MANUAL DOOR RELEASE with the new one from the kit. See the
drawing on the next page.
NOTE
The MANUAL DOOR RELEASE and the left-hand INPUT FLAP GUIDE are mounted with the same
SCREW. Without taking off the FRONT PANEL it is not possible to take off the NUT which holds
the MANUAL DOOR RELEASE.
figure 2-4
KODAK AG Stuttgart 2-3 MA 3058-42

17. Mount the FRONT PANEL.
18. Mount the FAN ASSEMBLY with 4 SCREWS. Ensure that the cut-out in its bottom plate is
engaged with the XML300 FRAME.
MANUAL DOOR RELEASE
MOUNTING SCREW
INPUT FLAP GUIDE
FRAME
NUT
SPACER
WASHER NOTE
Do not tighten the NUT
too much. This could
block the MANUAL
DOOR RELEASE.
figure 2-5
MOUNTING SCREW
This CUT-OUT must be
engaged with the
XML300 FRAME.
figure 2-6
MA 3058-42 2-4 KODAK AG Stuttgart

19. Insert the WIRES and PINS from the LEVEL SENSOR into PINS 1 and 3 of the brown SOCKET
of the HARNESS. See WIRING DIAGRAM figure 1-3. Fix the WIRES with a WIRE TIE and a SELF
ADHESIVE WIRE TIE SOCKET to the HUMIDIFIER FRAME. See figure 2-7
20. Connect the brown SOCKET to the brown CONNECTOR.
21. Fix the RESISTOR with the CLAMP to the HUMIDIFIER FRAME.
NOTE
The HUMIDIFIER FRAME is used as a HEAT SINK for the RESISTOR.
22. Connect the HUMIDIFIER GROUND WIRE to the GROUND SCREW to the right of the
COMPRESSOR.
NOTE
The NUT of the GROUND SCREW and a STAR WASHER are in the PROCESSOR CHAMBER.
Ensure that they do not fall into the PROCESSOR.
Fix the RESISTOR with
this CLAMP
RESISTOR
Fix the LEVEL SENSOR
WIRES with a WIRE TIE and
a SELF ADHESIVE WIRE
TIE SOCKET.
figure 2-7
GROUND SCREW
Fix the GROUND WIRE with self
adhesive WIRE TIE SOCKETS and
with WIRE TIES that it cannot be
caught by the COMPRESSOR FAN
WHEEL.
figure 2-8
KODAK AG Stuttgart 2-5 MA 3058-42

23. Fix the HARNESS, installed in step 6, with a WIRE TIE to the BRACKET below the
HUMIDIFIER.
CAUTION
ENSURE that the HARNESS cannot be caught by the CASSETTE TRANSPORT BELTS.
24. Take off the RIVET. To take it out use a hammer and a chisel.
Fix the HARNESS,
installed in step 6,
with a WIRE TIE to
the BRACKET below
the HUMIDIFIER.
figure 2-9
Take out this RIVET
figure 2-10
MA 3058-42 2-6 KODAK AG Stuttgart

25. Mount the BASE of the OVERFLOW with a SCREW M4x12.
26. Insert the OVERFLOW and fix it with a WIRE TIE at the top and with a SCREW M4x12 to the
BASE.
27. Mark the positions for the 2 holes onto the BASE PLATE and drill 2 holes 3 mm diameter.
Fix the OVERFLOW
with a WIRE TIE
OVERFLOW
Fix the OVERFLOW with a
SCREW M4x12 to the
BASE
BASE
figure 2-11
120 mm
20 mm
BORE HOLE
12
40 mm
30 mm
35 mm
BORE HOLE
12
To gain access for the POWER DRILL take off
the WATER TRAP and the BRACKET for the
SIDE PANEL.
figure 2-12
KODAK AG Stuttgart 2-7 MA 3058-42

28. Cut both holes with the HOLE CUTTER 30 mm.
NOTE
To ease the cutting of the 30 mm holes, lubricate the tips of the HOLE CUTTER with oil.
29. SMOOTHEN THE SHARP EDGES OF THE 2 HOLES WITH A FILE. NO SHARP EDGES ARE
ALLOWED TO PREVENT THE WATER HOSES FROM BEING CUT. TAKE OUT ALL DRILL
FILINGS. If you took off WATER TRAP and SIDE PANEL BRACKET in step 27, install them
now.
30. Place the GROMMET STRIP at the hole for the WATER PRESSURE HOSE. The GROMMET
STRIP prevents the WATER PRESSURE HOSE from being cut. See figure 2-14.
31. Route the WATER PRESSURE HOSE and the HARNESS (with CONNECTOR V1) along the
FRAME to the rear and down through the CABLE DUCT. Mount the EDGE PROTECTORS to the
FRAME. See figure 2-13 and 2-14
WATER PRESSURE HOSE and
HARNESS with CONNECTOR V1.
Mount the EDGE
PROTECTORS here.
WIRE TIE
figure 2-13
MA 3058-42 2-8 KODAK AG Stuttgart

32. Connect the DRAIN HOSE to the HUMIDIFIER and secure it with a HOSE CLAMP.
33. Route the DRAIN HOSE to the rear of the XML300. Route the PRESSURE HOSE and the
HARNESS through the left-hand hole and the DRAIN HOSE through the right-hand hole down to
the PROCESSOR area. Place the GROMMET STRIP at the hole for the DRAIN HOSE. Do this
after the DRAIN HOSE is routed through the hole in the BASE PLATE.
34. Drill a hole 5 mm into the FRAME and mount the SCREW M4x30 with 2 NUTS and 2
WASHERS. Fix the DRAIN HOSE with a WIRE TIE to this SCREW. This ensures that the DRAIN
HOSE does not come in contact with moving parts. See figure 2-14.
CAUTION
Take care when drilling the hole. There might be PCB A11 (Modification 6) behind.
35. Replace the existing FITTING PLATE (see figure 2-15) with the FITTING PLATE from the
MOD-KIT. There is not enough space between the FITTINGS to install the new TWIN WATER
VALVE between them. Therefor the new altered FITTING PLATE has to be installed. Discard the
old SINGLE WATER VALVE.
NOTE
Do not flood the customer premises.
36. Install the TWIN WATER VALVE. See figure 2-15.
120 mm
20 mm
WATER PRESSURE HOSE and
HARNESS
DRAIN HOSE
Place the EDGE
PROTECTOR around the
CUT OUT in the vertical
frame.
Make the cuts into the
FOAM RUBBER and place it
around the 2 HOSES. This
FOAM RUBBER is used as
a seal.
SCREW M4x30
with 2 NUTS and 2
WASHERS.
figure 2-14
KODAK AG Stuttgart 2-9 MA 3058-42

37. Connect the black WIRE from the new HARNESS to one TERMINAL of the top WATER VALVE
V1. This is the WATER VALVE for the HUMIDIFIER. Connect the red WIRE with the 56 Ω
RESISTOR in line, to the other TERMINAL of V1. See figure 2-15.
CAUTION
If the 56 ΩRESISTOR is not in line with the WATER VALVE COIL V1, the COIL will become
overheated and after a short time it will fail.
38. Connect the separate 56 ΩRESISTOR from the KIT to one TERMINAL from the bottom
WATER VALVE V2. This is the WATER VALVE for the PROCESSOR. Connect the other end of the
RESISTOR to the existing harness.
CAUTION
If the RESISTOR 56 Ωis not in line with the WATER VALVE COIL V2, the COIL will become
overheated and after a short time it will fail.
39. Connect the WATER PRESSURE HOSE to V1 of the TWIN WATER VALVE. Secure the hose
with a HOSE CLAMP. As in figure 2-15.
V1
V2
V1 = WATER VALVE for HUMIDIFIER
V2 = WATER VALVE for PROCESSOR
T-ADAPTER
RESISTOR for V2
RESISTOR for V1
HUMIDIFIER DRAIN HOSE
Connect the WATER PRESSURE HOSE
to the ADAPTER of TWIN WATER VALVE V1
TWIN WATER VALVE
Connect the black and red wire
from the new HARNESS to V1
TW I N W A TER V A LV E
FITTING PLATE
figure 2-15
MA 3058-42 2-10 KODAK AG Stuttgart

40. Take the PROCESSOR DRAIN HOSE off the ELBOW FITTING.
41. Cut 2 pieces 70 mm long from the PROCESSOR DRAIN HOSE. Discard one.
WARNING
Be careful when cutting the DRAIN HOSE. Do not cut into your hand.
42. Mount the 70 mm piece to the ELBOW FITTING and secure it with a HOSE CLAMP.
43. Mount the T-FITTING to the open end of the 70 mm piece. Secure it with a HOSE CLAMP.
44. Mount the PROCESSOR DRAIN HOSE to the other end of the T-FITTING. Secure it with a
HOSE CLAMP.
45. Mount the HUMIDIFIER DRAIN HOSE to the upper opening of the T-FITTING. Secure it with a
HOSE CLAMP.
46. Fix the T-FITTING with a WIRE TIE to the HOSE SUPPORT.
47. Fix the new HARNESS of the TWIN WATER VALVE to the existing one. Carefully bend both
RESISTORS inside, so that they do not come in contact with the frame when the FITTING PLATE
is mounted.
48. Ensure that all HOSE CLAMPS are tight.
49. Modify the left-hand SIDE PANEL. See CHAPTER 4.
KODAK AG Stuttgart 2-11 MA 3058-42