Processor-Carestream - 101 - 102 - 103-Operation Manual
Processor-Carestream - 101 - 102 - 103-Operation Manual
Processor-Carestream - 101 - 102 - 103-Operation Manual
AA5529_en
2013-01-31
Operator Manual
Table of Contents
Table of Contents
Introduction .............................................................................................. 3
To Order Parts or for Technical Specifications ........................................ 3
Technical Specifications............................................................................ 4
Safety Instructions..................................................................................... 5
Installation ................................................................................................. 6
Initial Operation ......................................................................................... 9
Operation ................................................................................................ 11
Daily Care ............................................................................................... 15
Weekly Care............................................................................................ 15
Thorough Cleaning.................................................................................. 16
Film Defects ............................................................................................ 17
Machine Errors........................................................................................ 18
Accessories............................................................................................. 19
The information contained herein is based on the experience and knowledge relat-
ing to the subject matter gained by Carestream Health, Inc. prior to publication.
No patent license is granted by this information.
Carestream Health, Inc. reserves the right to change this information without notice,
and makes no warranty, express or implied, with respect to this information. Care-
stream Health shall not be liable for any loss or damage, including consequential or
special damages, resulting from any use of this information, even if loss or damage
is caused by Carestream Health’s negligence or other fault.
2 AA5529_en
Table of Contents
Introduction
The Carestream Health processor is a compact, automatic table-top sheet and roll
film processor. The film materials are developed, fixed, rinsed and dried. The pro-
cessor has automatic film-registration and a Stand-by mode. The developing solu-
tions are temperature-regulated, circulated and automatically replenished.
This User’s Guide contains instructions for installation, operation and servicing of
the processor. Read the User’s Guide carefully to ensure reliable and satisfactory
operation.
AA5529_en 3
Technical Specifications
Technical Specifications
Film formats: In general: Sheet and roll films up to 35.8 cm (14.1 in.) width;
roll films with leader from 70.0 mm (2.8 in.) width; smallest film format
10 x 10 cm (4 x 4 in.).
Tank capacities: Developer, fixer and washing 5 litres each (1.3 gal)
Circulation system: Developer and fixer are continuously circulated by a circulation pump
Water consumption: 1.9 litres per minute (0.5 gal/min) when processing.
Environmental condi- 1) Temperature 21–26 °C (68–79 °F), ventilated room, room tempera-
tions: ture should be lower than set bath temperature.
2) Relative humidity 15 –50 % RH
3) Height above sea level less than 2000 m (6666 ft)
4) Indoor use
Power source: 101: 110–120 V (ac) 50/60 Hz, 102: 220–240 V (ac) 50 Hz,
103: 220–240 V (ac) 60 Hz
Dimensions (LxWxH): 77 x 59 x 42 (** 112) cm (30.3 x 23.2 x 16.5 (** 44.1) in.)
* Depending on machine type and gears used, processors have different speeds.
** Height including optional working table or base cabinet.
4 AA5529_en
Technical Specifications
Safety Instructions
NOTE: Always follow local regulations for handling and disposing chemicals.
To ensure the safe operation of this processor, installation and use should always
conform to the instructions contained in this manual.
Prior to handling, the Material Safety Data Sheets (MSDS) and product labels, for
the processor chemicals should be read and understood. MSDS for
Carestream Health products can be downloaded from the internet at
www.carestream.com/msds.html. Safe handling measures outlined on the MSDS
for each product should be followed. Impervious gloves and protective clothing
are recommended to prevent direct skin contact. Safety glasses with side
shields, goggles, or a face shield are recommended to prevent accidental eye
contact from a splash. Proper industrial hygiene practices should always be fol-
lowed to prevent accidental ingestion. Promptly wash after handling these chem-
icals. Do not eat, drink, or smoke in areas where chemicals are used or stored. In
addition, chemical-holding tanks should be equipped with tightly fitted lids to min-
imize chemical evaporation. Drains should be operating properly to prevent
gases and vapors from backing up into the processing area. Spills and leaks
should be cleaned up promptly.
Before opening the processor, switch off the unit and unplug it from the
electrical socket. Service and repairs must be performed by trained ser-
vice technicians only. Use only manufacturers replacement parts.
AA5529_en 5
Installation
Installation
2. Setup of processor
Unpack the Processor. Remove cover and transport securing brackets on the sides
of the roller racks. Remove roller racks - start with the dryer rack.
In 220-240 V (ac) version, the processor is delivered as a tabletop processor with
a two part floorplate. If the machine is upgraded with the optional stand or cabinet,
the small PVC-part has to be removed.
In 110-120 V (ac) version, the processor is delivered as a tabletop processor with
a three part floorplate. If the machine is upgraded with the optional stand or cabinet,
both small PVC-parts have to be removed and main plate must be reconnected.
Table-top installation
For tabletop installation, screw on the adjustable feet.
Attention!
Machine should not be installed on table-top without adjusta-
ble feet, as this would block the ventilation openings under the
machine and cause overheating.
6 AA5529_en
Installation
min. 70 cm
Drainage and
collecting
containers
Water connection: Connect the water hose from the back of the processor to the
fresh water supply.
All other hoses (see diagram Page 8): Connect the enclosed hoses according to
colour system onto the front of the machine. Put hose clip (enclosed in accessory
bag) over hose end, before attaching to connection. Warm up hose end (with hot
water) and push onto the respective connection. Push the clip over hose and con-
nection.
Cut hoses to required length. Then integrate the stop cocks into the three drainage
hoses in such a position, that they are easy to reach.
Connect the suction pipes to the hose ends for the replenishment tanks using hose
clips. Put suction pipes through cover opening into respective replenishment tanks
and snap them in.
Place the developer and fixer overflow and drainage hoses into their respective col-
lecting containers.
The overflow and the drainage of the water can either be placed into the drainage
syphon or into respective collection containers.
AA5529_en 7
Installation
Hose connections
Outlet
Danger of Overflow!
Use the included cable binders (accessory bag) to secure the
hoses. Fix all hose ends which guide into syphon or collecting
container, so that they do not drop into the liquid.
Very important:
The hose piping should be straight (without the hoses going
up and down) with a constant fall. The hoses should be as
short as possible and without bends and kinks. This is very
important for the water overflow hose. Inadequate piping work
will cause the machine to overflow!
8 AA5529_en
Initial Operation
Initial Operation
1. Test run
Important!
Processor should not be run dry!
a. Close the three drainage stop cocks and fill the tanks and replenishment con-
tainers with water. Open water inflow tap. Connect electrical socket and
switch the machine on. Water now flows into water tank. The circulation pump
activates, however the hosing of the machine must be ventilated.
b. Ventilation of the replenishment pump:
Set temperature dial to position “Manual pumping”. Keep dial to this position
until no more air bubbles rise in the tanks.
c. Ventilation of the circulation pump:
If air is in the circulation pump, a loud running noise can be heard. Switch the
machine off again. Open the stop cocks of the developer and fixer for five sec-
onds and switch machine on again. Repeat this procedure until no more air
bubbles are visible in the developer and fixer baths and until the circulation
pump runs quietly.
d. Check all hose connections for leakage. Switch machine off and drain water
out.
2. Install racks
Important!
Be careful to install racks properly and in correct position.
a. Install racks, starting with developer (red), then fixer (blue), then dryer (beige).
b. Make sure they are seated properly, so film transports correctly.
Important notice:
Ensure that the racks are firmly installed and keep the secur-
ing latches on the drive shafts closed.
Don’t operate processor with empty replenishment tanks.
Don’t use the included drip catcher plastic forms as bath cov-
ers placed on top of the racks.
AA5529_en 9
Initial Operation
Snap each suction pipe into the respective cover of it’s replenishment container and
close it carefully. Place containers under processor.
Using replenishment pump
Filling of processor can also be done by use of the replenishment pump (this takes
much more time). Snap each suction pipe into the respective cover of it’s replenish-
ment container and close it carefully. Place containers under processor. Now set
temperature dial to “Manual pumping”. Keep dial in this position until tanks are filled.
After 20 minutes this function stops automatically - to restart a cycle, turn dial to an-
other position and return to “Manual pumping”. Limitation: The function may fill up
tanks of developer and fixer to different levels. This may be due to different causes.
If this happens, then use a suitable container to fill up the tanks completely.
10 AA5529_en
Operation
Operation
Control panel
LED displays
• Infeeding film
Wait with the next film until light goes off.
• Power
When power is on the LED lights up.
• Bath temperature
Flashes when temperature is not reached.
Temperature dial
Manual pumping
Important!
Safety function stops film transportation when cover is re-
moved. Therefore keep cover placed on the machine when
processing films.
Control panel
Developing
*Roll film cassette Film
switch
Replenishment Developer
Power switch
AA5529_en 11
Operation
Startup
1. Close water-drainage stop cock.
2. Open water tap for water supply.
3. Switch processor on.
4. Check liquid level in replenishment and drainage collecting containers.
5. Wait until the developer temperature is reached. If the temperature has not
been reached, the bath temperature light is flashing.
6. Run cleaning films through processor.
Working procedure
7. Processing films:
Open light protection cover. Important: Put film first on left side of infeed tray
and then feed in. During processing films please watch the display “Infeeding
film”. If this is lit, wait until it goes off again and an audible signal can be
heard, before inserting the next film.
Shutdown
8. Switch processor off.
9. Close water tap.
10. Open water-drainage stop cock and drain water out of the machine.
Stand-by mode
When no film is being processed, the machine switches to Stand-by. The chemicals
remain at a constant temperature. The film transport and water inflow activate at in-
tervals to avoid crystallization of the chemicals on the transport rollers. Entry of the
next film is possible at any time.
Film exit
Drying
Fixing Washing
Replenishment Fixer
12 AA5529_en
Operation
Bath temperature
The processor heats up the chemicals automatically to the dial-set temperature.
When this temperature is reached for the first time after switching on the machine,
a long signal tone can be heard. This is also the case when the temperature is
changed by the dial switch.
If the difference between actual and dial-set temperature is more than 1 °C, the
bath temperature LED will flash. If a film has been fed in and the temperature is not
reached, a warning sound will be heard.
Manual pumping
The function “Manual pumping” activates the replenishment pump and pumps
chemicals into the tanks in addition to automatic replenishment. Turn the dial to the
position “Manual pumping” and chemicals will be pumped into the tanks. This func-
tion is only available during stand-by (no film in process). If the dial is left in this po-
sition, the pumping function is stopped automatically after 20 minutes. To restart a
cycle turn, dial to a temperature and return to “Manual pumping”.
Please note: Films cannot be processed when dial is set to “Manual pumping”. Also
bath temperature is set automatically to 28 °C during “Manual pumping”. After end-
ing the manual pumping the temperature must be set again by turning the dial. It
takes some time until the temperature is reached (look at the bath temperature dis-
play).
Remark: Both chemical pumps - fixer and developer - are driven parallel by only
one motor and therefore they run simultaneously.
Anticrystalisation function
During the stand-by mode, the film transport, the dryer blower, the dryer heating
and the water inflow are activated every 20 minutes for a period of 20 seconds. This
prevents the build-up of crystals on the rollers.
AA5529_en 13
Operation
Automatic replenishment
The chemicals are replenished automatically based on the amount of film pro-
cessed. This is done by pumping chemicals from the replenishment containers. The
film-detection switch calculates the processed film surface area at the film-infeed
and after 0,25 m,2 a replenishment cycle of 40 seconds duration is automatically
activated. The replenishment quantity per cycle (at pump setting 100 %) amounts
to 150 ml. The chart below shows the replenishment rate in ml per m2 film surface
in reliance on film width and setting of the pump.
Replenishment Rate
Rollfilms without leader films should be folded on the corners as per diagram dis-
played on the right.
14 AA5529_en
Daily Care
Daily Care
Before use
• Remove dirt and dust from film-infeed with soft cloth.
• Run 2–3 cleaner films through processor to remove all accumulated dirt and
dust from the rollers.
• Check the liquid level in the replenishment containers and if necessary refill.
• Leave light protection cover open when no film is in the processor. This avoids
condensation on feed tray.
After use...
• When work has been completed at the end of the day, drain water out of the
machine. This avoids the growth of algae in the water.
Weekly Care
The developer chemicals cause residue buildup in the machine. This residue has a
negative effect on the developing process of the film material. For this reason the
processor should be regularly cleaned. Proceed as follows:
1. Switch machine off and remove cover.
2. Loosen the securing latches (red, blue and beige) of the drive shafts of each
roller rack at the right side.
3. Wear protective equipment, outlined in the processing chemical’s MSDS.First
of all remove the large dryer-rack (beige). The racks are easier to remove and
insert when they are slightly tilted. Use the grey drip catcher forms to ensure
that no chemicals splash when being carried. Then remove the fixer (blue)
and developer (red) racks in sequence.
4. Rinse all racks thoroughly under warm running water and then leave to drain
off. It is advisable to use a soft sponge (do not use scouring-pad, as this
would scratch the rollers) and remove the residue from the rollers.
5. Replace the racks: Red = Developer, Blue = Fixer. Beige = Washing/Drying.
Ensure that the racks are firmly installed and do not forget to close the secur-
ing latches on the drive shafts.
6. Replace machine cover and ensure it is securely closed.
7. Clean processor outer shell with damp cloth. Do not use abrasive cleaners or
solvents.
AA5529_en 15
Thorough Cleaning
Thorough Cleaning
Every three months (maybe earlier) a thorough cleaning is necessary, depending
on the quantity of films processed. Tank cleaners are available for developer and
water baths. The fixer bath is cleaned with water. When preparing chemical tank
cleaners, follow manufacturers instructions explicitly and refer to the MSDS for safe
handling guidelines. Discharge, treatment disposal of used chemicals may be sub-
ject to national, state or local laws or guidelines.
How to proceed:
1. Switch the machine off and empty all tanks by opening the stop cocks.
2. Remove machine cover. When all tanks are emptied, close stop cocks again.
Now fill the fixer-tank with water. Prepare cleaner solutions for developer and
water baths and fill into respective tanks.
3. Remove suction pipes from the replenishment containers and place them in a
water filled bucket. Attention: Do not add chemical cleaners here!
4. Close machine cover and switch machine on.
5. Start film transportation and keep running for 10–20 minutes. Place a film in
the infeed so that it activates the film switch but will not be pulled into the pro-
cessor. During the operation with water, the installed roller racks will be
cleaned.
6. Important: After completion of tank cleaning, the tank should be rinsed thor-
oughly with clean water. To do this, fill the machine with fresh water twice and
each time, let the machine run for a 10-minute period. Empty the tanks and
re-close the stop cocks.
7. Take out the roller-racks and rinse them thoroughly with running water.
Remove remaining dirt from the rollers by using a sponge and clean thor-
oughly. Doing this, the rollers can be turned by turning the drive shaft.
Remove the sheet metal covers from the dryer rack and clean the rack with
mild soap. Reinstall the roller-racks in the machine.
8. Refill the tanks with respective chemicals. Replace the suction pipes into the
replenishment containers. In certain circumstances the circulation system
must be ventilated: see Page 9, item 1c.
9. For quality check, process test films.
Extended shutdown
In the event that your processor will not be in use for longer than two weeks, all the
chemicals have to be emptied out of the tanks. If you don't want to do a complete
tank cleaning at this time, then fill the tanks with water after emptying.
16 AA5529_en
Film Defects
Film Defects
Your processor has been constructed for long term use. If however irregularities
might occur, you will find help to locate the problem below. Please check the listed
points, before calling your service-technician.
Cloudy film
• Level in developer is too low.
• First guide bar of fixer rack is dirty (condensate or crystals). Clean roller-
racks.
• Developer is old or circulation not working.
• Try processing films by feeding them with emulsion side up.
AA5529_en 17
Machine Errors
Machine Errors
Machine does not switch on
• Ensure that electrical plug is firmly inserted into socket.
• Ensure that electrical socket has power supply by testing with an appliance
(e.g. tablelight).
Important notice:
Ensure that the racks are firmly installed and keep the secur-
ing latches on the drive shafts closed.
Don’t operate processor with empty replenishment tanks.
After a long machine shut down check bath level and refill if
necessary.
Don’t use the included drip catcher plastic forms as bath cov-
ers placed on top of the racks.
18 AA5529_en
Machine Errors
Accessories
Water filter
Install the water filter between water tap and water connection of processor. Do not
assemble the water filter directly at the solenoid valve of processor.
Assemble the filter to the wall with a secure assembly kit.
Important! A
Please note the right flow direction and the right position of
the filter. (See drawing)
Attention: Do not open the water tap immediately after assem- B
C
bling of water filter.
Level Indicator
If the level of the developer falls below the ideal level the symbol “Manual pumping”
appears until the ideal level is reached again.
To reach the ideal level please see Page 13 “Manual pumping” in the operating
manual.
When the symbol “Manual pumping” disappears the pump-process can be stopped
by turning the temperature switch on the same position you had before when start-
ing “Manual pumping”.
AA5529_en 19
Publication History
Made in Germany.