Master Lab+
Uploaded by
mohamed_hilaly_1Master Lab+
Uploaded by
mohamed_hilaly_16HUYLFH 0DQXDO
0DVWHU /DE 0DVWHU /DE
98.22.56
Edition 3
(TXLSPHQW GHVFULSWLRQ ,QVWDOODWLRQ 6HUYLFH PHQX 0DLQWHQDQFH 3RZHU VXSSO\ 3ULQWHU HOHFWURQLFV
0DVWHU /DE 0DVWHU /DE
6HUYLFH 0DQXDO
2SWLFDO V\VWHP 0HDVXULQJ V\VWHP )LOP SDWK 3DSHU SDWK )LOP SURFHVVRU 3DSHU SURFHVVRU DQG $76 :HW SDUW HOHFWURQLFV 2SWLRQV
98.22.56 Edition 3
%LEOLRJUDSK\ JORVVDU\ DQG LQGH[
This document contains information proprietary to GRETAG IMAGING AG, and may be used solely for the purpose of operating and maintaining the equipment for which it is provided. 2000 by GREATG IMAGING AG, CH8105 Regensdorf, Switzerland all rights reserved. Reproduction of this manual in any form, in whole or in part, without written permission, is prohibited by law. Printed in Switzerland
7DEOH RI FRQWHQWV
98.22.56 Edition 3
1.1.1 1.1.2 1.2.1
(TXLSPHQW 'HVFULSWLRQ
,QWURGXFWLRQ About this documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Conventions used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6DIHW\ LQIRUPDWLRQ Symbols used in this manual only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Symbols used on or inside the machine and in this manual . . . . . . . . . . . . . 20 Symbols on transport boxes, crates and other packing material . . . . . . . . . . 21 Safe handling of photographic chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Sealed screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 (TXLSPHQW RYHUYLHZ The Master Lab+ family of products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+ 520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+ 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+ 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+ 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+ 740 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+ 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Lab+ 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Film processor side (ML+ 320, ML+ 340, ML+ 520 and ML+ 740) . . . . . . . . Film processor side (ML+ 120, ML+ 140, ML+ 220 and ML+ 240) . . . . . . . . Front view: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper processor side (ML+ 320, ML+ 340, ML+ 520 and ML+ 740) . . . . . . . Paper processor side (ML+ 120, ML+ 140, ML+ 220 and ML+ 240) . . . . . . . 23 23 24 24 24 24 25 25 25 26 26 26 27 27 28
1.2.2 1.2.3 1.3.1
1.3.2
Master Lab / Master Lab+
1.3.3 1.3.4 1.4.1 1.4.2 1.4.3 1.4.4
Labels on the Master Lab+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Safety and operating overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 7HFKQLFDO VSHFLILFDWLRQV Master Lab+ system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Printer part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Wet part, film processor (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Wet part, paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Service Manual
1.5.1 1.5.2
6KLSSLQJ NLW Printer part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Wet part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 $YDLODEOH RSWLRQV Film cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Passport and wallet lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External replenishment console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greeting card attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Various conversion kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 37 37 37 37 37 37
98.22.56 Edition 3 Master Lab / Master Lab+
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.3.1 2.3.2 2.3.3 2.3.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6
,QVWDOODWLRQ
,QWURGXFWLRQ 3UH,QVWDOODWLRQ UHTXLUHPHQWV Floor space requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Room height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Floor load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Site illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Room temperature and humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Air conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Room aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Mains socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 8QSDFNLQJ WKH 0DVWHU /DE Checking for shipping damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Transport to installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Tools required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Unpacking the Master Lab+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ,QVWDOODWLRQ Film processor tanks (not valid for ML+120 to ML+240) . . . . . . . . . . . . . . . . 47 Filling the paper processor tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Mechanical configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Voltage setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Mains cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Preparing the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Service Manual
2.4.7
Connecting the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Voltage / current ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 &KHFNLQJ WKH V\VWHP Check the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Check the film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Checking the paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Concluding checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Setting the wake-up times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Setting time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Master setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Saving the data of the initial setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
98.22.56 Edition 3
2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8
3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7
6HUYLFH PHQX
7KH V\VWHP 0DLQWHQDQFH 0HQX IRU WKH 3ULQWHU Maintenance menu for the paper processor. . . . . . . . . . . . . . . . . . . . . . . . . . 74 Maintenance menu for the film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Maintenance menu for the other system parts . . . . . . . . . . . . . . . . . . . . . . . . 79 Maintenance menu for optical index printer . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Maintenance menu for Customizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Debug menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Maintenance functions on the ALMLPLUS board . . . . . . . . . . . . . . . . . . . . . 83
Master Lab / Master Lab+
3UHYHQWLYH PDLQWHQDQFH
6WDQGDUG SUHYHQWLYH PDLQWHQDQFH *HQHUDO 3URFHGXUHV 3ULQWHU SDUW Optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.3.1 4.3.2 4.3.3
Service Manual
4.4.1 4.4.2 4.4.3 4.4.4
:HW SDUW General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Concluding procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
98.22.56 Edition 3 Master Lab / Master Lab+
5.2.1 5.2.2 5.2.3
3RZHU VXSSO\
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ 3RZHU VXSSO\ ZHW SDUW Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Backup batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Fuses in the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Old version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 New version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 3RZHU VXSSO\ SULQWHU SDUW Electronic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Lamp power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 34V Terminal regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Fuses in the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack with old PODIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack with new PODIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 110 111 112
5.3.1 5.3.2 5.3.3 5.3.4
5.3.5 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.5.1 5.5.2
Indicators in the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 6HUYLFLQJ Wet part power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Checking the backup batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Printer part power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Electronic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Supply for the exposure lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 6FKHPDWLFV Wet part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Printer part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Service Manual
98.22.56 Edition 3
3ULQWHU HOHFWURQLFV
2YHUYLHZ 0DLQ SURFHVVRU ERDUG &38 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 The processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Reset circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Code memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Data memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Backup supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Serial communication interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Parallel interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 A/D Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Memory card interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 General purpose input port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 General purpose output port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 ,QGLFDWRUV RQ WKH &38 ERDUG /LVW RI ',3 VZLWFKHV DQG MXPSHUV Software version below 3.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Software version 3.0 and higher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 3LQ DVVLJQPHQW RQ SRZHU VXSSO\ SOXJ - &RQWURO %RDUG &%2 DQG &%2 Overview CBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Overview CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Block diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 CBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Fuses on CBO and CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Fuses on CBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Fuses on the CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Indicators on the CBO and the CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12 6.2.13 6.2.14 6.4.1 6.4.2 6.6.1 6.6.2 6.6.3
Master Lab / Master Lab+
6.6.4
6.6.5
Service Manual
6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 6.7.6 6.7.7 6.8.1 6.8.2
.H\ERDUG Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Special connection of keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Special key combination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 0HPRU\ FDUG Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Restoring data from the memory card.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Restoring a film channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Restoring all data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 $GMXVWPHQWV UHSODFHPHQWV Adjustments on the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Replacing the CPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Replacing the backup battery on the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Clearing the RAMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Adjusting the CBO / CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Replacing the CBO / CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Contrast adjustment for the LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Replacing the backup battery in the memory card . . . . . . . . . . . . . . . . . . . . 145 6FKHPDWLFV
98.22.56 Edition 3 Master Lab / Master Lab+
6.9.1 6.9.2 6.9.3 6.9.4 6.9.5 6.9.6 6.9.7 6.9.8
7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 7.1.10 6
2SWLFDO V\VWHP
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ Lamp house . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Filter wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Block diagram and timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Light attenuator, testfilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Light shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Lens turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Lens code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Calculation of focal length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Zoom drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Service Manual
7.2.1 7.2.2
98.22.56 Edition 3
5HSODFHPHQWV DGMXVWPHQWV Replacing the exposure lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Adjusting the lamp voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Adjusting filter wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Adjusting the lens turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Lens code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Zoom lens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing the focus adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting with grain finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting without grain finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 162 162 163
7.2.3 7.2.4 7.2.5 7.2.6
7.2.7 7.2.8 7.2.9 7.2.10
Setting the home position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Focusing a fixed-focus lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Adjusting the optical axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Automatic Densitometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 6FKHPDWLFV
8.1.1 8.1.2 8.1.3 8.1.4 8.1.5
Master Lab / Master Lab+
0HDVXULQJ V\VWHP
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ Optic box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Measuring box with measuring board (scanner) . . . . . . . . . . . . . . . . . . . . . 172 Film positioning and DX-Code detection . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Measuring board (MESY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 5HSODFLQJ WKH PHDVXULQJ V\VWHP &KHFNLQJ WKH PHDVXULQJ V\VWHP 135 film. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 120 film. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 6FDQQHU FDOLEUDWLRQ IRU VWDWXV 0 Special tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 6HWWLQJ WKH WHPSHUDWXUH FRPSHQVDWLRQ Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 6FKHPDWLFV
8.3.1 8.3.2 8.4.1 8.4.2 8.5.1 8.5.2
Service Manual
9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.3.1 9.3.2 9.3.3 9.3.4 9.4.1 9.4.2 9.5.1 9.5.2 9.6.1 9.6.2 9.6.3 9.6.4 9.7.1 9.7.2
)LOP SDWK
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Positioning diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Viewing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Scanning position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Exposure position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 )LOP GHFN FRGLQJ %ORFN GLDJUDPV RI ILOP GHFNV Automatic 135 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Automatic 135 film deck for Fuji code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Automatic 110 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Universal film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 7KH DXWRPDWLF ILOP GHFNV 135 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 110 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 7KH XQLYHUVDO ILOP GHFN General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Inserts coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 &KHFNV DGMXVWPHQWV IRU DQG ILOP GHFNV Checking and positioning the DX-Code diodes . . . . . . . . . . . . . . . . . . . . . . 193 Adjusting exposure / viewing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Adjusting the pressure solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Adjusting the belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Master Lab / Master Lab+ 98.22.56 Edition 3
$GMXVWPHQWV RQ WKH XQLYHUVDO ILOP GHFN Adjusting home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Adjusting the exposure position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 /LVW RI VFKHPDWLFV
Service Manual
98.22.56 Edition 3
3DSHU SDWK
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ Paper cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Paper extractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Backprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Feeder / Panorama feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Distributor (ML X40 models only!) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Timing diagrams of paper path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 6HQVRU RYHUYLHZ 5HSODFHPHQWV DGMXVWPHQWV DQG FKHFNV Loading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Coding the paper cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Adjusting the paper cassette to different paper widths. . . . . . . . . . . . . . . . . 215 Checking the sensors of the paper extractor . . . . . . . . . . . . . . . . . . . . . . . . 218 Removing the paper extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Checking the knife function and its sensors . . . . . . . . . . . . . . . . . . . . . . . . . 219 Replacing the lower knife blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Replacing the rolling knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Removing the paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Adjusting the tension of the transport belts . . . . . . . . . . . . . . . . . . . . . . . . . 221 Adjusting the sidewise paper position (Y-axis). . . . . . . . . . . . . . . . . . . . . . . 222 Adjusting the longitudinal paper position (X-axis) . . . . . . . . . . . . . . . . . . . . 223 Changing the type of feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Adjusting the sensors in the panorama feeder. . . . . . . . . . . . . . . . . . . . . . . 225 Checking the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Manually moving the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Removing the distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Checking the distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the light barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 228 228 229
10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 10.1.8 10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.3.6 10.3.7 10.3.8 10.3.9 10.3.10 10.3.11 10.3.12 10.3.13 10.3.14 10.3.15 10.3.16 10.3.17 10.3.18
Master Lab / Master Lab+
6FKHPDWLFV
Service Manual
11.1.1 11.2.1 11.2.2 11.2.3 11.2.4 11.3.1 11.3.2 11.4.1 11.5.1 11.5.2 11.6.1
)LOP SURFHVVRU
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 +HDWLQJ V\VWHP Film processor heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Temperature / level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Heating management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 5HSOHQLVKPHQW V\VWHP Flow sensor / vacuum sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Replenishment management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 5HFLUFXODWLRQ V\VWHP Recirculation management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 7UDQVSRUW V\VWHP Principle of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Block diagram of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Motor energizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 )LOP ORDGLQJ VWDWLRQ M805 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Old version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . New version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 243 244 244
98.22.56 Edition 3 Master Lab / Master Lab+
11.8.1
5DFNV 5HSODFHPHQWV DGMXVWPHQWV Heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually switching the heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking / calibrating the tank temperatures . . . . . . . . . . . . . . . . . . . . . . . . Calibrating the dryer temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the temperature setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking temperature sensors / level sensors . . . . . . . . . . . . . . . . . . . . . . Replacing a temperature / level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 246 246 246 249 250 250 252
10
Service Manual
11.8.2
98.22.56 Edition 3
Replenishment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually switching the replenishment pumps . . . . . . . . . . . . . . . . . . . . . . . Checking the replenishment rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the replenishment rate for all chemistries together . . . . . . . . . . . Changing the replenishment rate for one tank only . . . . . . . . . . . . . . . . . . . Replacing a bellow of the replenishment pump . . . . . . . . . . . . . . . . . . . . . . Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually switching the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the belt tension of the transport motor . . . . . . . . . . . . . . . . . . . . . Removing the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing and aligning the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the transport speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the knife. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the sensor boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Racks in the processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dryer rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening a rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembling a rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning the gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
254 254 255 256 256 257 259 259 259 260 261 262 262 262 263 264 264 266 266 267 268 269 270
11.8.3
11.8.4
11.8.5
6FKHPDWLFV
12.1.1 12.2.1 12.2.2 12.2.3 12.2.4 12.3.1 12.3.2 12.4.1
3DSHU SURFHVVRU DQG $76
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 +HDWLQJ V\VWHP Paper processor heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Temperature and level sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Heating management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 5HSOHQLVKPHQW V\VWHP Flow sensor / vacuum sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Replenishment management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 5HFLUFXODWLRQ V\VWHP Recirculation management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Master Lab / Master Lab+
Service Manual
11
12.5.1 12.5.2 12.6.1 12.6.2 12.9.1
$XWRPDWLF WRSRII V\VWHP Automatic top-off management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Water quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 7UDQVSRUW V\VWHP Principle of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Block diagram of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Motor energizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 5DFNV 6RUWHU 5HSODFHPHQWV DQG DGMXVWPHQWV Heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually switching the heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking / calibrating the tank temperature. . . . . . . . . . . . . . . . . . . . . . . . . Calibrating the dryer temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the setting of the temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking temperature sensor / level sensors . . . . . . . . . . . . . . . . . . . . . . . Replacing the temperature / level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . Replenishment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually switching the replenishment pumps . . . . . . . . . . . . . . . . . . . . . . . Checking the replenishment rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the replenishing rate for all chemistries together . . . . . . . . . . . . . Changing the replenishing rate for one tank only. . . . . . . . . . . . . . . . . . . . . Replacing a bellow of the replenishment pump . . . . . . . . . . . . . . . . . . . . . . Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually switching the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking / adjusing the belt tension of the transport motor . . . . . . . . . . . . . Removing the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing and aligning the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the transport speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Racks in the processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dryer rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening a rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembling the rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 287 288 288 291 292 292 294 295 295 296 297 297 298 300 300 300 301 302 302 303 303 304 305 306
98.22.56 Edition 3 Master Lab / Master Lab+
12.9.2
12.9.3
12.9.4
12.9.5
Sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Checking the belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 6FKHPDWLFV
12
Service Manual
98.22.56 Edition 3
:HW SDUW FRPSXWHU V\VWHP
2YHUYLHZ 0&% ERDUG Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Functional units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backup supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog to digital converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timers interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power and reset logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 311 311 312 312 312 312 313 313
13.2.1 13.2.2
13.2.3
Rotary switch positions and jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Rotary switch positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Test points and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Test points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 0 ERDUG Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Functional units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater drivers (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor drivers (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport motor driver (24V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 317 317 317 317 317
13.2.4
13.3.1 13.3.2
13.3.3 13.3.4
Master Lab / Master Lab+
Fuses on the M802 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Indicators on the M802 board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 0 ERDUG Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Functional units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sorter driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater drivers (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor drivers (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer supply (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport motor driver (24V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 321 321 321 321 322 322
13.4.1 13.4.2
13.4.3 13.4.4
Fuses on the M803 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Indicators on the M803 board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Service Manual
13
13.5.1 13.5.2 13.5.3 13.5.4 13.7.1 13.7.2 13.7.3
$/0/3/86 ERDUG Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Pump driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Fuses on the ALMLPLUS board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Indicators on the ALMLPLUS board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 6&6% ERDUG $FFHVVLQJ $GMXVWLQJ UHSODFLQJ WKH ZHW SDUW HOHFWURQLF ERDUGV The MCB, M802, M803, RCB or ALMLPLUS boards. . . . . . . . . . . . . . . . . . 327 Replacing the battery on the MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 The SCSB board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 6FKHPDWLFV
98.22.56 Edition 3 Master Lab / Master Lab+
14.2.1 14.2.2 14.3.1 14.3.2
2SWLRQV
&XVWRPL]HU )LOP FOHDQHU General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 5HPRWH FRQWURO LQWHUIDFH General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Master Lab+ directly connected to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Master Lab+ connection via modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 5HSOHQLVKPHQW FRQVROH General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 /LQH SULQWHU General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Setting up the line printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIP switch DS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIP switch DS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended switch setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 343 343 344
14.4.1 14.4.2 14.5.1 14.5.2
14
Service Manual
14.5.3
Setting the serial / parallel converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 DIP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Jumpers (DTE selection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Connection cable line printer - Master Lab/Master Lab+ . . . . . . . . . . . . . . . 345 3DVVSRUW OHQV :DOOHW OHQV General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Aligning the lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Centering the prints on the paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 *UHHWLQJ FDUG DWWDFKPHQW General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 &RQYHUVLRQ DQG XSJUDGH NLWV Enlargement kit E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Speedup kit I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Speedup kit II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Digital upkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Film processor upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Upgrading the processor to KODAK - SM . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Automatic Densitometer (ADM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Lamp house upgrade kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 APS / Index kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 .LW GHVFULSWLRQV
98.22.56 Edition 3 Master Lab / Master Lab+
14.5.4 14.6.1 14.6.2 14.6.3
14.7.1 14.7.2 14.8.1
14.8.2
14.8.3
14.8.4
14.8.5
14.8.6 14.8.7
14.8.8
14.8.9
Service Manual
15
%LEOLRJUDSK\ JORVVDU\ DQG LQGH[
%LEOLRJUDSK\ *ORVVDU\ ,QGH[
98.22.56 Edition 3 Master Lab / Master Lab+
16
Service Manual
98.22.56 Edition 3
(TXLSPHQW 'HVFULSWLRQ
7KH LQVWUXFWLRQV JLYHQ LQ WKLV PDQXDO DUH PHDQW WR KHOS VHUYLFH HQJLQHHUV WR GR UHSDLU DQG PDLQWDLQ WKH 0DVWHU /DE WR HQDEOH LW WR SHUIRUP WR LWV RSWLPXP SHUIRUPDQFH
,QWURGXFWLRQ
This manual is part of the service training and given to trained service engineers only! 1RWH 'HWDLOHG LQIRUPDWLRQ RQ GDLO\ ZHHNO\ DQG PRQWKO\ PDLQWHQDQFH SURFHGXUHV DUH SURYLGHG LQ WKH 2SHUDWLQJ 0DQXDO DQG WKH 6HWXS 0DQXDO
Please read and observe the safety rules provided later in this chapter.
Master Lab / Master Lab+
$ERXW WKLV GRFXPHQWDWLRQ
Please read the following hints carefully; they will help you to use this manual efficiently. This manual enables you to carry out adjustments and service procedures. Furthermore, this manual contains the Master Lab+ specifications and information about available options. It is assumed, that you are familiar with Master Lab+ operation. You should at least be able to master all procedures outlined in the Operating Manual.
Service Manual
17
Equipment Description
This separating support easy access to the required information and avoids dealing with large volumes. For detailed information about the content of each manual, please refer to the respective table of contents.
&RQYHQWLRQV
&RQYHQWLRQV XVHG LQ WKLV PDQXDO
The following convention apply throughout this manual:
q
Actions to be carried out are proceeded by a number indicating the step of the work. All key designations are bracketed and printed in boldface e.g. 25'(5! All softkeys (keys with different meanings depending on the menu) are printed in boldface e.g. 3352&
q q
)RU \RXU VDIHW\
6DIHW\ LQIRUPDWLRQ
Please observe the following rules for safe operation of the Master Lab+:
q
The Master Lab+ may only be operated, maintained and serviced by sufficiently qualified persons who are familiar with the machine. In case there should still be any questions after reading this manual, please contact your local GRETAG IMAGING distributor, they will be glad to help you.
Master Lab / Master Lab+
Observe all relevant local, national and/or international safety regulations regarding the handling of electric/electronic equipment and chemicals. Always FROOHFW FKHPLFDOV LQ VDIH FRQWDLQHUV and dispose of according to the instructions of the manufacturer of chemicals and legal environmental guidelines and procedures. 1HYHU HYHU GLVSRVH RI FKHPLFDOV LQWR DQ\ VHZDJH V\VWHP VXFK DV WRL OHWWHV HWF Keep new and used chemicals out of the reach of unauthorized persons. Store chemicals in a lockable room.
(QYLURQPHQWDO JXLGHOLQHV
18
Service Manual
98.22.56 Edition 3
The Master Lab+ documentation includes four manuals: o Operating Manual o Operating Manual Program 3 SETUP (further called Setup Manual) o Service Manual (the manual your are reading now) o Spare parts list
Equipment Description
Always wear protective cloth (gloves, goggles, apron) when handling chemicals. Ask the supplier of the chemicals for the relevant MSDS (0aterial 6afety 'ata 6heet) explaining the characteristics, possible risks under defined conditions, protection and first aid measures. Avoid any contact with skin and eyes. Remove spilt chemicals by rinsing thoroughly with water. Avoid inhaling chemical vapors. If necessary contact your local doctor in due courses. The Master Lab+ must be connected to a ground socket. Do not disable protection by using an extension cord without protective grounding. Interruption of the protective conductor inside or outside the machine, or disconnecting protective earthing can endanger your live! Do not open the Master Lab+ while an order is processed. Trip the power switch on the right hand side of the Master Lab+ to switch off the unit before you open any covers.
saml01001a
98.22.56 Edition 3
q q
POWER
AT S
Never carry out any working steps if you are uncertain about the effect. If in doubt, consult your local GRETAG representative
Master Lab / Master Lab+
Service Manual
19
Equipment Description
6\PEROV XVHG LQ WKLV PDQXDO RQO\
98.22.56 Edition 3 Master Lab / Master Lab+
:$51,1*
If instructions marked with this sign are not carried out correctly, malfunction of the machine may result or personnel may be hurt.
/,9( 3$576
This sign is used in the manual only! Always switch off the machine before working on electrical parts. Not following the instruction endangers your life!
+($9< 3$576
This sign is used in the manual only. It indicates that you are handling a heavy part. If you are not careful you may hurt your back!
',6326( 2) %$77(5,(6 3523(5/<
Batteries should be exchanged by trained specialists only. Used batteries must be disposed of properly in accordance with the local regulations for the protection of the environment. They should be treated as special refuse and must not just be thrown into wastepaper baskets or dust bins.
6\PEROV XVHG RQ RU LQVLGH WKH PDFKLQH DQG LQ WKLV PDQXDO
/,9( 3$576 ,16,'(
Always switch off the machine before opening or removing a cover!
+($7
Wait until the part marked with the heat sign has cooled down other wise you may burn your fingers!
(/(&75267$7,& ',6&+$5*(
Dont touch such parts with bare fingers or ungrounded tools! Electrostatic discharges can destroy delicate electronic circuits or components!
527$7,1* 3$576
Wait until all rotating parts (fan, motor, etc.) stops turning otherwise injury on your fingers may result!
:($5 3527(&7,9( */29(6
Whenever you work with chemicals, wear protective gloves. Also, wear soft gloves, when cleaning or replacing mirrors, lenses, and color filters, in order not to scratch them!
20
Service Manual
Equipment Description
:($5 *2**/(6
98.22.56 Edition 3
Whenever you work with chemistry, wear goggles. Splashes in your eyes must be washed out immediately with water! Immediately get medical advice!
.((3 +$1'6 2))
Be careful not to hurt your hands when you close a part (e.g. a heavy lid or cover)
6+$53 %/$'(
C A U T I O N S H A R P B L A D E
Take special care when you are working with parts marked with this sign. You may get hurt if you disregard this sign!
6\PEROV RQ WUDQVSRUW ER[HV FUDWHV DQG RWKHU SDFNLQJ PDWHULDO
.HHS GU\
Store the equipment in a dry place (storage temperature not lower than 0 centigrade)!
7KLV VLGH XS
Always place transport boxes such that the arrows point upwards. Dont overturn the boxes when transporting, loading, unloading, storing, packing or unpacking.
)UDJLOH
The transport box contains delicate electronic, mechanical and optical equipment and must be handled with care. During transport, the box must not be shaken or dropped!
Master Lab / Master Lab+
Service Manual
21
Equipment Description
6DIH KDQGOLQJ RI SKRWRJUDSKLF FKHPLFDOV
98.22.56 Edition 3 Master Lab / Master Lab+
:$51,1*
.HHS LQ PLQG WKDW WKH FKHPLFDOV XVHG LQ WKH 0DVWHU /DE IRU GHYHORSLQJ EOHDFKLQJ DQG IL[LQJ DUH WR[LF VXEVWDQFHV WKDW PXVW EH KDQGOHG FRUUHFWO\ 2EVHUYH WKH VDIHW\ LQVWUXFWLRQV SURYLGHG E\ WKH VXSSOLHU RI WKH FKHPLFDOV 6SHFLDO DWWHQWLRQ PXVW EH SDLG WR WKH IROORZLQJ SRLQWV &RUUHFW KDQGOLQJ RI VXFK FKHPLFDOV 6DIHW\ SUHFDXWLRQV HJ SURWHFWLYH JORYHV DSURQ JRJ JOHV 0HDVXUHV WR EH WDNHQ LI D SHUVRQ VSLOOV VXFK FKHPLFDOV RYHU FORWKHV RU SDUWV RI WKH ERG\ 6DIH VWRUDJH HJ RXW RI UHDFK RI FKLOGUHQ QRW WRJHWKHU ZLWK IRRG 9HQWLODWLRQ GLVFKDUJH RI H[KDXVW IXPHV &RUUHFW GLVSRVDO RI FKHPLFDO ZDVWH DFFRUGLQJ WR WKH UHJX ODWLRQV FRQFHUQLQJ WKH SURWHFWLRQ RI WKH HQYLURQPHQW
9(5< ,03257$17
,QIRUP SHUVRQQHO RI SRVVLEOH GDQJHUV LQVWUXFW WKHP WKRU RXJKO\ KRZ WR UHDFW LQ FDVH VRPHWKLQJ RFFXUV $OZD\V NHHS WKH VXSSOLHUV DFFRPSDQ\LQJ GRFXPHQWDWLRQ KDQG\
6HDOHG VFUHZV ,03257$17
&HUWDLQ VFUHZV DUH VHDOHG ZLWK &2/25(' ODFTXHU 8VXDOO\ WKHVH VFUHZV VHUYH IRU PHFKDQLFDO RU HOHFWULFDO DGMXVWPHQW RU FDOLEUDWLRQ 7KH\ ZHUH VHW FRUUHFWO\ DW WKH IDFWRU\ DQG 0867 127 %( /226(1(' 816&5(:(' RU RWKHUZLVH $'-867(' ,1 7+( ),(/' ,I \RX IDLO WR REVHUYH WKLV ZDUQLQJ PLVDGMXVWPHQW PDOIXQFWLRQ RU ORVV RI TXDOLW\ PD\ UHVXOW
22
Service Manual
Equipment Description
98.22.56 Edition 3
(TXLSPHQW RYHUYLHZ
$ERXW WKH 0/ IDPLO\ The Master Lab+ processes all standard film and paper sizes.
Requiring a floor area of less than one square meter (80 x 120cm, approx. 10.8sq.ft.) the Master Lab+ housing incorporates the wet part and the printer part. The wet part comprises of film and paper developing units together with the corresponding dryers and the sorter on the paper side. The wet part is an independent assembly, i.e. the commands received from the printer will be executed independently. The wet part also accommodates the power supply for the whole machine. The printer part is powered from the wet part. The printer part consists of paper extracting, knife to cut the paper, backprinter (option), paper deck, film deck, lens, lamp house and control panel. The whole machine is controlled via the printer part, i.e. printing, setup and triggering special functions in operation or in service mode.
7KH 0DVWHU /DE IDPLO\ RI SURGXFWV
The Master Lab+ family comprises the eight models: o Master Lab+ 120 o Master Lab+ 320 o Master Lab+ 140 o Master Lab+ 340 o Master Lab+ 520 o Master Lab+ 740 o Master Lab+ 220 o Master Lab+ 240 The basic layout is the same for all machines. However, they differ in that single assemblies will be added or omitted.
Master Lab / Master Lab+
0DVWHU /DE
The Master Lab+ 520 is a basic model of the family. Film processor
Film sizes Capacity 110,126,135,120 and APS 21 film per hour (based on 135 film with 24 exposures)
Paper processor
Paper width Capacity 3.5 to 8.25 200 Prints per hour (based on 10 x 15cm /4 x 6 prints)
All interchangeable parts of the printer part, such as film deck, paper cassette, light shaft and lenses provided are coded. Upon installation of the film deck and
Service Manual
23
Equipment Description
the paper cassette the format is defined and the computer checks whether the remaining parts of the configuration are correct.
98.22.56 Edition 3 Master Lab / Master Lab+
0DVWHU /DE
The Master Lab+ 320 provides the same layout as the Master Lab+ 520. It uses an automatic film deck and handles 135 film and 4 paper only! Only one film size and one paper size will be handled. Therefore the lens is fixed part of the machine and cannot be interchanged. The lens has no code. The capacities are the same as for the Master Lab+ 520.
0DVWHU /DE
The Master Lab+ 120 provides the same layout as the Master Lab+ 320. It has no film processor, instead it has larger replenishment and recovery tanks installed. It uses an automatic film deck and handles 135 film and 4 paper only! Only one film size and one paper size will be handled. Therefore the lens is fixed part of the machine and cannot be interchanged. The lens has no code. The capacities are the same as for the Master Lab+ 320.
0DVWHU /DE
The Master Lab+ 340 provides the same layout as the Master Lab+ 320 but has twice the processing capacity. To achieve this capacity it features a shutter and a paper distributor. The paper distributor feeds two tracks in the paper processor. The shutter is used to protect the previously exposed print on the paper deck whilst the scanner measures the next frame. The paper sorter collects the prints from both paper tracks and separates consecutive orders. Paper processor
Paper width Capacity 3.5 to 8.25 400 Prints per hour (based on 10 x 15cm /4 x 6 prints)
0DVWHU /DE
The Master Lab+ 140 provides the same layout as the Master Lab+ 320. It has no film processor. The capacities are the same as for the Master Lab+ 340.
24
Service Manual
Equipment Description
To achieve this capacity it features a shutter and a paper distributor.
0DVWHU /DE
98.22.56 Edition 3
The Master Lab+ 740 features all the possibilities of the Master Lab+ 520 and the Master Lab+ 340. It handles all film sizes and paper widths of the Master Lab+ 520 but has twice the processing capacity.
0DVWHU /DE
The Master Lab+ 220 provides the same layout as the Master Lab+ 520. It has no film processor, instead it has larger replenishment and recovery tanks installed.
0DVWHU /DE
The Master Lab+ 240 provides the same layout as the Master Lab+ 220 but has twice the processing capacity.
Master Lab / Master Lab+
Service Manual
25
Equipment Description
2YHUYLHZ
98.22.56 Edition 3 Master Lab / Master Lab+
)LOP SURFHVVRU VLGH 0/ 0/ 0/ DQG 0/
saml01002a
! % $
# "
1 2 3
Printer Film dryer Film outlet station
4 5 6 7
Replenishment tanks for film processor Overflow tanks for film processor Printer control system Automatic Densitometer (ADM)
)LOP SURFHVVRU VLGH 0/ 0/ 0/ DQG 0/
saml01003a
! % $
# "
1 2 3
Printer Cover Print stacker
4 5 6 7
Overflow tanks for paper processor Replenishment tanks for paper processor Printer control system Automatic Densitometer (ADM)
26
Service Manual
Equipment Description
)URQW YLHZ
0/ 0/ 0/ DQG 0/
saml01004a
98.22.56 Edition 3
0/ 0/ 0/ DQG 0/
saml01005a
!
!
"
"
#
13 Exhaust connection 14 Wet part control system 15 Bleach air pump
3DSHU SURFHVVRU VLGH 0/ 0/ 0/ DQG 0/
saml01006a
"
#
' &
Master Lab / Master Lab+
$ %
14 15 16 17 18
Paper dryer Print stacker Overflow tanks for paper processor Repl. tanks for paper processor Mains socket
19 Connector for peripherals: o Densitometer (D188/D19C) o Modem Line printer Aux 1, Aux 2 20 Lost liquid sensor 21 Water tank for autom. top-off system
o o
Service Manual
27
Equipment Description
3DSHU SURFHVVRU VLGH 0/ 0/ 0/ DQG 0/
saml01007a
"
98.22.56 Edition 3
#
' &
14
Paper dryer
19 Connector for peripherals:
o o o o
Densitometer (D188) Modem Line printer Aux 1, Aux 2
15 18
Print stacker Mains socket
20 Lost liquid sensor 21 Water tank for autom. top-off system
/DEHOV RQ WKH 0DVWHU /DE
All together are five labels in a Master Lab+
saml01008a
!
Master Lab / Master Lab+
"
1 2 3
Printer serial number Printer status label Wet part serial number
4 5
Wet part status label Master Lab+ serial number
28
Service Manual
Equipment Description
q q 98.22.56 Edition 3
One label contains the machine serial number which is the main number Two labels contain the serial numbers of the printer part and the wet part. These are the serial numbers of the subunits. Two labels are service status labels. One for the printer part and one for the wet part. The status labels contain a number field with the numbers 1 to 50 or 51 to 100.
saml01009a
GRETAG
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
GRETAG SAN MARCO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
The circled or crossed out number on the status label indicates which modification has been installed. When several modifications are installed in the field or in the factory then the corresponding numbers are crossed with a line and the last number is circled. For any modification done in the field you must circle the number mentioned in the description included with the modification.
,03257$17
,W LV YHU\ LPSRUWDQW WKDW \RX FLUFOH WKH FRUUHVSRQGLQJ QXPEHU EHFDXVH WKLV LV WKH RQO\ ZD\ WR ILQG RXW ZKLFK PRGLILFDWLRQV KDYH EHHQ LQVWDOOHG ,W DOVR WHOOV DQ\ WHFKQLFLDQ LI WKH PDFKLQH LV XS WR GDWH ZLWK PRGLILFDWLRQV RU LI WKHUH LV DQ\ RQH PLVVLQJ WKDW QHHGV WR EH LQVWDOOHG
Master Lab / Master Lab+
Service Manual
29
Equipment Description
6DIHW\ DQG RSHUDWLQJ RYHUYLHZ
saml01010a
9, 10
Film processor side view
Paper processor side view
17
6, 7, 8 20 21 13 14, 15, 16 11
12
T op view
18
19
Front view
2, 3, 4, 5
17
1 2 3 4 5 6 7 8 9 10 11
Exhaust tube connector Main electric box Mains transformer Voltage selector (XT) Terminal block (X2) Mains inlet Mains cable terminal (X3) Line filter Voltage setup instruction Label of factory voltage setup Protective earthing terminal
12 13 14 15 16 17 18 19 20 21
Paper dryer cover locking screw Master Lab+ serial number Manufacturer model number Status label of wet part Electrical rating marking Film cutting knife blade Safety switch, paper processor Safety switch, film processor Indicator Power on Mains switch
30
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Equipment Description
98.22.56 Edition 3
7HFKQLFDO VSHFLILFDWLRQV
0DVWHU /DE V\VWHP
Dimension system Width 780mm (2.56ft.) Length 1226mm (4.02ft.) Height 1700mm (5.6ft.) Width 1070mm (3.5ft.) Length 1400mm (4.6ft.) Height 1960mm (6.4ft.) 1m2 (78 x 123cm) 10.3sq.ft. (2.56 x 4.02ft.) 320kg / 393kg 328kg / 401kg 326kg / 399kg 334kg / 407kg 280kg / 345kg 288kg / 353kg 274kg / 339kg 282kg / 347kg 1 phase 200/208/220/230/240Vac +/- 10%, 50/60Hz 3 phase 220Vac +/- 10%, 50/60Hz 3 phase 380Vac +/- 10%, 50/60Hz ML+ 320 - 740 ML+ 120 - 240 ML+ 320 - 740 ML+ 120 - 240 max. 3300VA; average: 2450VA max. 2800VA; average: 2000VA max. 7700kJ; average: 5800kJ max. 6000kJ
packed
System footprint
Weights (dry / operational)
ML+ 320 ML+ 340 ML+ 520 ML+ 740 ML+ 220 ML+ 240 ML+ 120 ML+ 140
Mains voltage
Power consumption
Stray power
Ambient conditions Temperature
operational non-operational operational non-operational
+15o C to +30o C -25o C to +60o C 30% to 75% (not condensing) 10% to 90% (not condensing) max. 1000 Lux
Humidity
Master Lab / Master Lab+
Ambient light Noise level operational standby length diameter air flow rate
max. 70dB(A) max. 60dB(A) max. 2.5m (8.2ft.) 50mm (1.97) 1.6m3 / min1)
Exhaust tube
Exhaust fan
,W LV DEVROXWHO\ QHFHVVDU\ WKDW WKH YDSRUV IURP WKH FKHPLFDOV DUH OHG WR WKH RXWVLGH RI WKH URRP )RU GHWDLOV VHH FKDSWHU
Service Manual
31
Equipment Description
3ULQWHU SDUW
98.22.56 Edition 3 Master Lab / Master Lab+
Negative formats
ML+ 320 / 340 ML+ 520 / 740 ML+ 220 / 240 ML+ 120 / 140 ML+ 320 / 340 ML+ 520 / 740 ML+ 220 / 240 ML+ 120 / 140 ML+ 320 / 340 ML+ 520 / 740 ML+ 220 / 240 ML+ 120 / 140
135 only 135, 110, 126, 120, 220, Disc, APS 135, 110, 126, 120, 220, Disc, APS 135 only 4 only 3.5, 4, 5, 6, 7, 8, 8.25 3.5, 4, 5, 6, 7, 8, 8.25 4 only 4 x 6 only 3.5 x 3.5 to 8.25 x 12 Panorama. Passport 3.5 x 3.5 to 8.25 x 12 Panorama. Passport 4 x 6 only 200 (4) 400 (4) 225 (3.5), 200 (4), 160 (5), 100 (8) 450 (3.5), 400 (4), 160 (5), 100 (8) Daylight cassette for 175m paper rolls Automatic paper loading
Paper size
Print size
Capacity (prints / hour)
ML+ 320 / 120 ML+ 340 / 140 ML+ 520 / 220 ML+ 740 / 240
Paper loading
Film transport
135 110 126 120 / 220 Disc APS
Automatic with DX-Code reader Automatic Manual Manual Semi automatic Automatic with DX-Code and MOF reader Halogen lamp 24V / 250W Additive filter system
Light system
Lens system
ML+ 120 / 140 ML+ 320 / 340 ML+ 520 / 740 ML+ 220 / 240
Fix lens Fix lens Zoom lens (motor driven), single lenses optional Zoom lens (motor driven), single lenses optional True color scanner Approx. 96 pixels x 3 colors (135 FF) Densitometer (D188/D19C) Line printer Modem Auxiliary 1, 2 Memory card (RAM-card) 32kBytes
Measuring system
Serial interface for
Data backup
32
Service Manual
Equipment Description
98.22.56 Edition 3
:HW SDUW ILOP SURFHVVRU LI DSSOLFDEOH
Chemical process Transport system Film formats Processing time (dry to dry) Processing speed Processing capacity Replenishment system C-41 RANP Short leader (by leader cards) 110, 126, 135, 120, 220, APS 8 minutes 40 seconds (135 film, 24 exposures) 478mm / minute 21 films / hour (135 film, 24 exposures) Automatic, from integrated tanks (external tanks optional) Automatic, from integrated water tank DEV BL FIX 1 FIX 2 STAB 1 STAB 2 DEV BL FIX STAB 11.84 L 2.60 L 2.69 L 2.58 L 2.70 L 2.58 L 1.95 L 0.45 L 2.77 L 3.36 L
Evaporation compensation Capacity of working tanks (racks installed)
Capacity of replenishment tanks
Film capacity of built-in replenish- 80 rolls (135 film, 24 exposures) ment tanks Power backup Backup-battery in case of power failure for the film transport.
Master Lab / Master Lab+
Service Manual
33
Equipment Description
:HW SDUW SDSHU SURFHVVRU
Chemical process Paper loading syst5em RA-4 NP Daylight cassette for 175m rolls automatic paper loading Single sheet transport 4 minutes 30 seconds 635mm / minute Automatic, from integrated tanks (external tanks optional) Automatic, from integrated tanks (external tanks optional) Automatic, from integrated water tank DEV BL STAB 1 STAB 2 STAB 3 5.49 L 5.59 L 4.47 L 4.38 L 4.38 L
98.22.56 Edition 3 Master Lab / Master Lab+
Paper transport system Processing time (dry to dry) Processing speed Replenishment system
Replenishment system
Evaporation compensation Capacity of working tanks (racks installed)
Capacity of replenishment and recovery tanks (RA-4)
ML+ 320 to 740
DEV BL STAB DEV BL STAB
3.40 L 4.40 L 7.40 L 13.5 L 13.5 L 13.5 L
ML+ 120 and 240
Capacity of replenishment and recovery tanks (PRIME)
ML+ 320 to 740
DEV BL STAB
4.50 L 3.00 L 10.0 L
Print capacity of built-in replenishment tanks
ML+ 320 to 740 ML+ 220 and 240 ML+ 120 and 140
1700 prints (3.5 x 5) DEV (print size 3.5 x 5) 6800 prints BL (print size 3.5 x 5) 5200 prints STAB (print size 3.5 x 5) 3100 prints Backup-battery in case of power failure for the paper transport.
Power backup
34
Service Manual
Equipment Description
98.22.56 Edition 3
6KLSSLQJ NLW
The shipping kit is included with every delivered machine. There is a separate shipping kit for each part:
q q
one for the printer part one for the wet part
It contains all necessary consumables and other helpful items
3ULQWHU SDUW
3DUW
Exposure lamp 24V / 250W Fuse 5A (5 x 20mm) Fuse 2A (5 x 20mm) Hex key 1.5mm Hex key 2.5mm Testfilm 135 film (Kodak Gold 100-6) Memory card
2UGHU QXPEHU 11.61.46 20.94.12 11.21.21 13.55.65 20.90.45 34.91.33 11.62.70
4XDQWLW\ 5 10 10 1 1 1 1
1RWH
)RU WKH SDUWV OLVW FRQFHUQLQJ WKH EDVLF FRQILJXUDWLRQ UHIHU WR WKH SULFH OLVW
Master Lab / Master Lab+
Service Manual
35
Equipment Description
:HW SDUW
98.22.56 Edition 3 Master Lab / Master Lab+
3DUW
Splice tape Washing bottle Graduated cylinder, 100ml Manual film puller Hose clamp SNP14 Twincheck labels Fuse 1.25A (5 x 20mm) Fuse 2A (5 x 20mm) Fuse 10A (5 x 20mm) Fuse 1A (6.3 x 32mm) Fuse 25A (6.3 x 32mm) Fuse 2A (6.3 x 32mm) Fuse 2.5A (6.3 x 32mm) Fuse 4A (6.3 x 32mm) Fuse 8A (6.3 x 32mm) Replenishment filter Manual tape dispenser 5 lt. container tank Extension hose Tube 14 x 19 Film loading cassette Tools Hook for cylinder Splash shield Developer rack tray 126 film box 110 film box 120 film box 135 film adapter Seeger Seeger Seeger Seeger Air filter Chemical filter Air filter Film loading caps Film leader Rack tray Dripping tray Film preparation station O-ring kit Print collector Film loading Paper panel
2UGHU QXPEHU 00GSM2300 00GSM7555 0021-101-03 0021-906-84 0026-480-07 0028-493-03 0028-758-11 0028-758-13 0028-751-27 0028-759-75 0028-755-42 0028-759-78 0028-759-79 0028-759-81 0028-759-85 0029-100-23 0029-230-09 0029-302-11 0029-302-12 0034-411-06 14221-155-0 14991-009-2 15160-127-0 15410-180-0 15605-421-1 15615-075-0 15615-076-0 15615-088-0 16245-449-1 16315-009-0 16315-017-1 16315-019-1 16315-020-0 16445-137-1 16445-139-0 16445-517-0 0025-514-02 16555-211-0 16605-051-1 16605-057-2 18582-112-0 18988-460-0 16615-256-0 14211-036-0 15425-087-4
4XDQWLW\ 1 1 4 1 5 1 5 5 5 5 5 5 5 5 5 1 1 1 1 1 2 1 4 1 1 2 2 2 2 10 10 10 10 1 22 1 2 10 1 1 1 4 1 1 1
36
Service Manual
Equipment Description
98.22.56 Edition 3
$YDLODEOH RSWLRQV
More details about the following options as well as other information concerning service aspects are found in chapter 14.
)LOP FOHDQHU
Cleans the film with brushes and discharges any electrostatic with ionized air.
5HPRWH FRQWURO LQWHUIDFH
This interface plus the corresponding software allows the control of quality via a modem.
3DVVSRUW DQG ZDOOHW OHQV
Allows either four (passport) or two (wallet) prints on the same 3.5 paper.
([WHUQDO UHSOHQLVKPHQW FRQVROH
Provides larger replenishment tanks.
/LQH SULQWHU
Allows certain statistics and calculation data to be printed.
*UHHWLQJ FDUG DWWDFKPHQW
Prints an additional subject to the regular print.
9DULRXV FRQYHUVLRQ NLWV
Improving and upgrading the machine, such as
q Master Lab / Master Lab+ q q q q q q q q
Enlargement kit E1 Speed-up kit I Speed-up kit II Digital upkit Film processor upkit Automatic densitometer Lamp house upkit APS / Index kit Customizer 37
Service Manual
38
98.22.56 Edition 3
Equipment Description
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
,QVWDOODWLRQ
,QWURGXFWLRQ
,03257$17
,QVWDOODWLRQ RI D 0DVWHU /DE VKRXOG RQO\ EH PDGH E\ D WUDLQHG WHFKQLFLDQ This chapter contains procedures for unpacking and installing a Master Lab+ therefore: 5HDG WKLV FKDSWHU FDUHIXOO\ EHIRUH XQSDFNLQJ DQG LQVWDOOLQJ WKH 0DVWHU /DE WR IDPLOLDUL]H \RXUVHOI ZLWK WKH SURFHGXUH The chapter is organized as follows: 2.2 2.3
Master Lab / Master Lab+
Pre-Installation requirements Unpacking the Master Lab+ Installation Checking the system
2.4 2.5
Service Manual
39
Installation
3UH,QVWDOODWLRQ UHTXLUHPHQWV )ORRU VSDFH UHTXLUHPHQWV
saml02001a
Replen. Console (Optional)
100
800
1226
600
780
745
All measurements in Millimeter
Please note:
)ORRU VSDFH
q
at least 500mm (approx. 20) are required at the rear of the machine if the replenishment tanks are placed behind the machine. If there are no external replenishment tanks at the rear of the machine, leave at least 50mm (approx. 2) to guarantee sufficient air circulation. The 745mm (approx. 29) on the right-hand side are used to allow the electronic rack to be drawn out for service purposes.
40
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
0..500
Installation
5RRP KHLJKW
98.22.56 Edition 3
5RRP KHLJKW
A minimal room height of 2250mm (7.38ft.) is required to allow the film and/or paper dryer to be lifted.
saml02002a
2250
Repl. Console
All measurements in Millimeter
)ORRU ORDG
The floor in the Master Lab+ working area must be capable of supporting at least 410kg/m2.
)ORRU ORDG
Max. net weight of the Master Lab+ Max. operating weight (with chemistry)
355kg (7.82cwt.sh.) 407kg (9cwt.sh.)
Master Lab / Master Lab+
3OHDVH QRWH q 7KH QHW ZHLJKW RI D 0DVWHU /DE ZLWKRXW ILOP SURFHVVRU LV DERXW NJ VW OLJKWHU q 7KH RSHUDWLQJ ZHLJKW RI D 0DVWHU /DE ZLWKRXW D ILOP SURFHVVRU LV DERXW NJ VW OLJKWHU
6LWH LOOXPLQDWLRQ
Observe the following:
q
Keep a constant light intensity. Avoid direct sun light or spot light onto the operator side. Use diffused light from the ceiling such as daylight neon tubes. The light intensity in the film deck area should not exceed 1000 Lux.
q q
Service Manual
(Optional)
41
Installation
5RRP WHPSHUDWXUH DQG KXPLGLW\
q q q
Operate the machine at a room temperature between +15o C and +30o C. The maximum relative humidity (not condensing) is 75%. For the minimum permissible relative air humidity consult the specifications from the paper manufacturer (about 30%)
98.22.56 Edition 3 Master Lab / Master Lab+
$LU FRQGLWLRQLQJ
It is advisable to install a room temperature cooling system. The Master Lab+ produces an average heat of 5800kJ (max. 7700kJ).
([KDXVW
The Master Lab+ is equipped with an exhaust fan. The outlet is near the top right corner of the machine. The inner diameter of the exhaust tube is 50mm. The air flow rate of the exhaust is 1.6m3/min.
saml02003a
Exhaust tube 50mm
:$51,1*
+D]DUGRXV YDSRUV ,W LV DEVROXWHO\ QHFHVVDU\ WR GLVFKDUJH WKH H[KDXVW YDSRUV WR WKH RXWVLGH .HHSLQJ WKHP LQ WKH URRP FDQ FDXVH D VHULRXV KHDOWK KD]DUG DQG OHDG WR FRUURVLRQ RI PHWDOOLF SDUWV
42
Service Manual
Installation
With the built-in fan the maximum length of the additional exhaust tube is 2.5m (2.7yd.) For longer tubes an additional external exhaust fan must be installed. It is the duty of the customer to provide this fan. The capacity must be large enough to guarantee an air flow rate of 1.6m3/min.
98.22.56 Edition 3
5RRP DHUDWLRQ
Apart from discharging the exhaust vapors to the outside, the room in which the machine is to be installed, must be sufficiently ventilated to avoid concentrations of chemical vapors. In addition, please observe the regulation concerning room aeration given by the chemistry supplier, also see bibliography in chapter 15.1
0DLQV
0DLQV VRFNHW
The customer has to provide either a 1-phase or a 3-phase Mains socket (for details see chapter 2.4.4) The Mains socket must be installed close to the machine. The Mains socket must always be easily accessible. During operation, the access to the Mains socket shall not be obstructed by objects placed in front of it or by the machine itself. The Mains socket and its installation have to comply with the local safety standards and must be capable of carrying the maximum machine current (see technical specification in chapter 1.4). The customer has to ensure that the Mains socket has a good and reliable grounding connection.
,QVXUDQFH
8QSDFNLQJ WKH 0DVWHU /DE &KHFNLQJ IRU VKLSSLQJ GDPDJHV
GRETAG IMAGING AG takes out a transport insurance when a machine is shipped. The customer is invoiced for the insurance and transport costs.
Master Lab / Master Lab+
,03257$17
&KHFN GHOLYHU\ IRU VKLSSLQJ GDPDJHV 5HSRUW DQ\ WUDQVSRUW GDPDJHV WR *5(7$* ,0$*,1* $* RU WKH QHDUHVW UHSUHVHQWDWLYH 'R QRW GLUHFWO\ FRQWDFW WKH LQVXUDQFH RU VKLSSLQJ FRPSDQ\ *5(7$* RU WKH UHSUHVHQWDWLYH ZLOO XQGHUWDNH WKH QHFHVVDU\ VWHSV
Service Manual
43
Installation
7UDQVSRUW WR LQVWDOODWLRQ VLWH
To transport the packed Master Lab+ close to the installation site, you need a pallet trolley. The shipping weight is approx. 440kg (9.7cwt.sh.)
7RROV UHTXLUHG IRU LQVWDOODWLRQ
1RWH $OO WRROV UHTXLUHG IRU WKH LQVWDOODWLRQ RI D 0DVWHU /DE DUH RI WKH PHWULF V\VWHP
7RROV UHTXLUHG IRU LQVWDOODWLRQ
Most tools required are the standard tools in any Service Technicians tool box. All special tools required for the installation however are contained in a tool kit included in the shipment (Tool kit P/N SM 14991-009-1) o 1 spanner 7mm and 8mm o 1 spanner 10mm and 11mm o 1 spanner 16mm and 17mm o 1 screw driver 4mm (No. 2) o 1 Phillips screw driver (No. 1) o 1 hex key 3mm o 1 hex key 4mm
8QSDFNLQJ WKH 0DVWHU /DE
To unpack the Master Lab+ follow the given procedure:
saml02004a
Cut the straps that fasten the cover. Remove the top cover.
saml02005a
Unscrew the five big fasteners on the side by hand. In case they are too tight, use a pair of snipe nose pliers.
44
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Installation
saml02006a
98.22.56 Edition 3
Remove the cardboard packing.
Remove the wooden planks behind the machine. Remove the plastic covering the entire machine. Remove all the boxes packed on top of the working area. Check the whole shipment for completeness. A parts list is included in every shipment showing what parts should have been supplied. Remove the polystyrene foam block, located under the sorter.
Remove the dripping tray from underneath the machine. Remove all side panels of the Master Lab+.
saml02007a
Lower the four feet until they rest on the pallet (use the spanner size 17mm from the tool kit).
Master Lab / Master Lab+
saml02008a
Remove the four Z-shaped steel brackets (the counter nut is for additional security).
Turn the four feet upward until the machine rests on the four wheels.
Service Manual
45
Installation
saml02009a
&$87,21
7KH PDFKLQH LV YHU\ KHDY\ &DUHIXOO\ JXLGH WKH PDFKLQH GRZQ WKH UDPS 1HYHU WU\ WR OLIW LW RII WKH SDOOHW \RX PD\ GDPDJH \RXU EDFN
&$87,21
1HYHU SXVK WKH PDFKLQH GRZQ ZLWK WKH IURQW ILUVW <RX ZLOO GDPDJH WKH IURQW SDQHO VXSSRUW 3XVK LW GRZQ VLGHZLVH RQO\
saml02010a
Push the machine down the ramp until it is off the pallet.
Move the Master Lab+ to its final installation place. Lower the feet until the wheels are off the ground. Is the ground to uneven, you may have to place small wooden blocks under the feet to achieve the necessary stability.
46
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Make a ramp by nailing the two planks provided to the pallet with two nails each.
Installation
,QVWDOODWLRQ
As soon as the Master Lab+ is positioned at its definite place you can start the actual installation. Level the Master Lab+. Use a spirit level, place it on the wet part and turn the feet up- or downward until the machine is leveled. Place the dripping tray under the machine. Close all drain taps.
98.22.56 Edition 3
)LOP SURFHVVRU WDQNV QRW YDOLG IRU 0/ WR 0/
If your machine does not have a film processor, skip this chapter and proceed with the next one.
:$51,1*
:KHQHYHU \RX ZRUN ZLWK FKHPLFDOV ZHDU SURWHFWLYH JORYHV DQG JRJJOHV ,W LV DOVR DGYLVDEOH WR ZHDU D UXEEHU DSURQ WR SURWHFW \RXU FORWKHV
saml02011a
Remove the replenishment tanks from the film processor.
Master Lab / Master Lab+
saml02012a
Open the screw caps of the replenishment tanks.
Rinse the replenishment tanks with warm water.
Service Manual
47
Installation
&$87,21
98.22.56 Edition 3 Master Lab / Master Lab+
:KHQ \RX ILOO WKH WDQNV HQVXUH WKDW WKH FKHPLFDOV DQG WKH WDQN PDWFK 2WKHUZLVH FRQWDPLQDWLRQ ZLOO RFFXU ZKLFK PDNHV FKHPLFDOV ZRUWKOHVV Fill the replenishment tanks for the film processor with the corresponding chemicals. A color dot indicates which chemicals belongs into which replenishment tank: o Blue dot = developer o Red dot = bleach o Green dot = fixer o Yellow dot = stabilizer Close all screw caps so no chemicals are spilled when the tanks are moved.
saml02013a
Reinsert the full replenishment tanks. Open the screw caps.
saml02014a
Pull the draw-off unit from the filling unit.
saml02015a
Insert it into the replenishment tanks.
48
Service Manual
Installation
&$87,21
98.22.56 Edition 3
:KHQ \RX ILOO WKH ZRUNLQJ WDQNV HQVXUH WKDW WKH FKHPLFDOV DQG WKH WDQN PDWFK 2WKHUZLVH FRQWDPLQDWLRQ ZLOO RFFXU ZKLFK PDNHV WKH FKHPLFDOV ZRUWKOHVV Fill the working tanks of the film processor with the corresponding chemicals. A color dot indicates which chemicals belongs into which working tank: o Blue dot = developer o Red dot = bleach o Green dot = fixer o Yellow dot = stabilizer Check the working tanks for leaks. ,I D OHDN LV GHWHFWHG GUDLQ WKH WDQN LPPHGLDWHO\ 7KH OHDN FDQ EH UHSDLUHG ZLWK 6&27&+:(/' '3 8VH WKH VWUXFWXUDO DGKHVLYH WR GLUHFWLRQ ZULWWHQ RQ WKH SDFNDJH
1RWH
Ensure that the filling unit of the overflow tanks of the film processor is pushed down properly. Fill the top-off tank with water.
)LOOLQJ WKH SDSHU SURFHVVRU WDQNV
:$51,1*
:KHQHYHU \RX ZRUN ZLWK FKHPLFDOV ZHDU SURWHFWLYH JORYHV DQG JRJJOHV ,W LV DOVR DGYLVDEOH WR ZHDU D UXEEHU DSURQ WR SURWHFW \RXU FORWKHV
Master Lab / Master Lab+
saml02016a
Remove the replenishment tanks from the paper processor
Service Manual
49
Installation
saml02017a
Open the screw caps of the replenishment tanks.
Rinse the replenishment tanks with warm water.
&$87,21
:KHQ \RX ILOO WKH WDQNV HQVXUH WKDW WKH FKHPLFDOV DQG WKH WDQN PDWFK 2WKHUZLVH FRQWDPLQDWLRQ ZLOO RFFXU ZKLFK PDNHV WKH FKHPLFDOV ZRUWKOHVV Fill the replenishment tanks for the paper processor with the corresponding chemicals. A color dot indicates which chemicals belongs into which replenishment tank: o Blue dot = developer o Red dot = bleach / fix o Yellow dot = stabilizer Close all screw caps so no chemicals are spilled when the tanks are moved.
saml02018a
Reinsert the full replenishment tanks. Open the screw caps.
Master Lab / Master Lab+
saml02019a
Pull the draw-off unit from the filling unit.
50
Service Manual
98.22.56 Edition 3
Installation
saml02020a
98.22.56 Edition 3
Insert it into the replenishment tanks.
&$87,21
:KHQ \RX ILOO WKH ZRUNLQJ WDQNV HQVXUH WKDW WKH FKHPLFDOV DQG WKH WDQN PDWFK 2WKHUZLVH FRQWDPLQDWLRQ ZLOO RFFXU ZKLFK PDNHV WKH FKHPLFDOV ZRUWKOHVV Fill the working tanks of the paper processor with the corresponding chemicals. A color dot indicates which chemicals belongs into which working tank: o Blue dot = developer o Red dot = bleach o Yellow dot = stabilizer Check the working tanks for leaks. ,I D OHDN LV GHWHFWHG GUDLQ WKH WDQN LPPHGLDWHO\ 7KH OHDN FDQ EH UHSDLUHG ZLWK 6&27&+:(/' '3 8VH WKH VWUXFWXUDO DGKHVLYH WR GLUHFWLRQ ZULWWHQ RQ WKH SDFNDJH
1RWH
Ensure that the filling unit of the overflow tanks of the paper processor is pushed down properly. It not already done, fill the top-off tank with water.
Master Lab / Master Lab+
0HFKDQLFDO FRQILJXUDWLRQ
The mechanical configuration consists of installing and connecting equipments removed for transport.
saml02021a
Install the fix lens for Master Lab+ 320, 340, 120 and 140.
Service Manual
51
Installation
saml02022a
saml02023a
Install the film deck.
saml02024a
Install the light shaft.
9ROWDJH VHWXS
,03257$17
7KH VWDQGDUG FRQILJXUDWLRQ DV WKH PDFKLQH OHDYHV WKH IDFWRU\ DQG LV VKLSSHG LV 9 VLQJOH SKDVH After the Master Lab+ is mechanically prepared, connect the power to the machine. There are three possibilities of power connection: o single phase 230V with protective Ground (200 ... 240V) o three phase 230V with protective Ground (200 ... 240V) o three phase 380V with protective Ground (376 ... 415V)
0DLQV FDEOH
Mains cable and mains plug are not provided with the machine as they have to comply with local regulations. They have to be provided by the customer. Preparation of the cable has to be made prior to the connection of the machine to the Mains.
52
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Install the zoom lens for Master Lab+ 520, 740, 220 and 240.
Installation
98.22.56 Edition 3
o o o o
The type of plug has to comply with local safety standards and has to be capable of carrying the maximum power required by the machine (for details see chapter 1 Technical specification). The type of cable has to comply with local safety standards and has to meet at least the following diameter requirements: for single phase 230V AWG 14 (2mm2) for three phase 230V AWG 16 (1mm2) for tree phase 380V AWG 18 (0.75mm2) The isolation of the grounding wire must have the color yellow/green or green or yellow. The plug should meet the standard for industrial use according IEC 320. In Europe use cables of the type H05RR-F, H05VV-F or H05H2-F (specifications according VDE 0281, 0282, 0292) In USA use cables of the type S, SO, ST or STO (specifications according UL-CSA)
3UHSDULQJ WKH FDEOH
The power cable has to be prepared as shown before it is thread into the machine.
saml02025a
0.5D
Cable diameter D
min. 60mm (2.4") max. 90mm (3.5")
ye
llo
9mm
/g
re
en
Strain relief
Master Lab / Master Lab+
&RQQHFWLQJ WKH FDEOH
'$1*(5
0DNH VXUH WKDW WKH LQFRPLQJ FDEOH LV 127 FRQQHFWHG WR RU SOXJJHG LQWR WKH 0DLQV EHIRUH \RX VWDUW FRQQHFWLQJ WKH ZLUHV (OHFWULF VKRFN KHDYLO\ HQGDQJHUV \RXU OLIH LW PD\ HYHQ NLOO \RX
Service Manual
53
Installation
Thread the cable into the machine and through the strain relief. Tighten the strain relief.
98.22.56 Edition 3
saml02026a
Line filter
Connect the incoming cable to the terminal block X3.
X3
XZ
The connections for the various types of mains supplies are shown in the next figure.
saml02027a
X 3
200 - 240V /1 Phase
-YG-1-2-3-4Phase 1 L1 L2 1 2 3 4
-YG3-1- Black -4- Black -3- Black XZ -2- Black
-173-174-175-176-YG-
Mains cable Ph 2/Neutral Ground
L3 MP
200 - 240V/3 Phase
X 3
-YG-1-2-3-4Phase 1 Phase 2 L1 L2 L3 MP Ground 1 2 3 4 -YG3-1- Black -2- Black -3- Black -4- Black -173-
Mains cable
Phase 3
-175-176-YG-
X 3
376 - 415V/3 Phase
-YG-1-2-3-4Phase 1 Phase 2 L1 L2 L3 MP 1 2 3 4
-YG3-1- Black -2- Black -3- Black -4- Black -173-174-175-176-YG-
Mains cable
Phase 3 Neutral Ground
54
Service Manual
Master Lab / Master Lab+
-174-
Installation
saml02028a
200-240V/3phase 200-240V 1 Phase 376-415V/3phase
-1-
-4-
-1-
-4-
-3-
98.22.56 Edition 3
-2-
L1'
L2'
-2-
N'
L3'
L1'
L2'
N'
L3'
-3-
LOAD
LOAD
With three phase 230V or 380V disconnect the wire bridges (jumper) on the filter Z.
LINE
LINE
L1
L2
L3
L1
L2
L3
-176-
-174-
-173-
-173-
-174-
-176-
-YG-
-YG-
-175-
X = Remove
-175-
saml02029a
XT Transformer
X2
saml02030a
200-240V/1Phase 200-240V/3 Phase 376-415V/3 Phase
%
"
%
%
"
Master Lab / Master Lab+
"
106
%
"
!
106
With three phase 230V or 380V you have to connect the bridge (jumper) on terminal block X2 between terminal 2 and 3.
172
106
106
172
Set the bridges (jumpers) on terminal block XT according to the incoming voltage. In case of three phase 230V disconnect wire # 172
Service Manual
55
Installation
saml02031a
200-240V/1 Phase 200-240V/3 Phase
376-415V/3 Phase
' ' ' &
' ' ' &
' ' ' &
172
172
172
! ! % % # #
! ! % % # #
saml02032a
# 103
220V~ # 1 11
0V 0V 200V 208V 220V 230V 240V
Check the connection on the autotransformer for the right voltage. Change if necessary.
9ROWDJH FXUUHQW UDWLQJV
7ULDQJOH 9.2A 9.3A 9.5A 9.6A 9.8A 5.2A 5.3A 5.4A 6WDU
9ROWDJH 200V 208V 220V 230V 240V 380V 400V 415V
6LQJOH SKDVH 14A 14.2A 14.5A 14.8A 15.2A
! ! % % # #
56
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Installation
&KHFNLQJ WKH V\VWHP &KHFN WKH 3ULQWHU
Load the first paper cassette with paper. On the paper cassette, set the magnet code for the paper memory as required by the customer. Insert the prepared paper cassette.
98.22.56 Edition 3
saml01001a
POWER
ATS
Switch ON the Master Lab+ with the main circuit breaker.
saml02033a
Pull out the drawer.
Master Lab / Master Lab+
Connect a voltmeter to the 24V backup battery on the right-hand side of the transformer. Test the voltage of the battery. The Master Lab+ changes during start-up from mains supply to battery supply. If the voltage is approx. 27Vdc, the battery is charged. If the voltage falls rapidly down to 24Vdc under load, then the Master Lab+ runs on the standby-battery. If the battery voltage drops below 21V, turn ON the Master Lab+ to charge the battery for at least one day and test it again. If the test fails, replace the battery. Check for smooth transport in all racks. If the Master Lab+ is equipped with a film processor, feed several leader cards through the film processor. Check all fans for proper operation. Location and direction of air flow are given in the following drawing.
Service Manual
57
Installation
saml02034a
"
98.22.56 Edition 3 Master Lab / Master Lab+
1 2 3 4 5
Pump cooling fan (blows into the machine) Wet part electronic cooling fan (blows into the machine) Printer part electronic fan (blows up into the machine) Exhaust fan (blows fume out of the machine) Lamp cooling fan (blows out of the lamp house)
&KHFN WKH ILOP SURFHVVRU
If the Master Lab+ is not equipped with a film processor, simply skip this section and proceed with the paper processor. Check that the temperatures in the film processor tanks rise with the following procedure: Press &200!. A softkey menu is displayed Press the key below )352&. Press the key below ',63703. The actual temperatures in the various tanks are displayed.
saml02035a
100:1 in 20 C ml
100 90 80 70 60 50
100:1 in 20 C ml
100 90 80 70 60 50
100:1 in 20 C ml
100 90 80 70 60 50
100:1 in 20 C ml
100 90 80 70 60 50
Check the replenishment rates with four graduated plastic cylinders supplied by placing the replenishment tubes into the cylinders.
Press &200!. A softkey menu is displayed. Press the key below )352&.
58
Service Manual
Installation
Press the key below 0$15(3/. The nominal replenishment quantities of the various tanks are displayed. Press the key below 7(67. An amount equal to 20 strokes is pumped into the cylinders.If the quantity is not correct the first time, repeat the procedure a few more times to deaerate the tubes. Is the quantity still wrong afterwards, adjust it as described in the chapter 11.8.2
98.22.56 Edition 3
After the operating temperatures have been reached (about 1 hour after switching ON) check the temperatures with an accurate mercury or electronic thermometer. The procedure is as follows:
saml02036a
Remove the lid of the film processor.
saml02037a
Lift the cover of the film dryer Remove the light shield covering the tanks.
Press &200!. A softkey menu is displayed. Press the key below )352&.
Master Lab / Master Lab+
Press the key below ',63703. The actual temperatures in the various tanks are displayed.
,03257$17
7KH WHPSHUDWXUH RI WKH IL[HU DQG WKH VWDELOL]HU PXVW EH PHDVXUHG LQ WKH VHFRQG WDQN RI WKH FRUUHVSRQGLQJ EDWK
Service Manual
59
Installation
saml02038a
L L LLLLLLL LLL
L LLLLL LLL LLL
L LLLLLL LL LLL
LLL L LLLL LLL
L LL LLLLL LLL
L L LLLLLL LLL
L L LLLLLL LLL
L LL LLLLL LLL
L L LLLLLL LLL
L LL LLLLL LLL
LLLLL LLL LLL
L LLLLL LL LLL
If the actual value deviates more than the permissible tolerance from the nominal value, a recalibration is necessary. Proceed as described in chapter 11.8.1
saml02039a
When the temperature measurement is finished, place the light shield back over the tanks. Lower the cover of the film dryer.
saml02040a
Remount the lid of the film processor.
&KHFNLQJ WKH SDSHU SURFHVVRU
Check that the temperatures in the paper processor tanks rise with the following procedure: Press &200!. A softkey menu is displayed. Press the key below 3352&. Press the key below ',63703. The actual temperatures of the various tanks are displayed.
60
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Insert an accurate thermometer into the tank right by the temperature sensor and compare the measured value with the value displayed.
L LLLLLL LL LLL
L LL LLLLL LLL
L LL LLLLL LLL
LLL L LLLL LLL
L L LLLLLLL LLL
L LLLLL LL LLL
L L LLLLLLL LLL
LLLLLLLLL LLL
L LL LLLLL LLL
L LLLLL LL LLL
LLLLLLLL LLL
L LLLL L LL LL
Installation
saml02041a
98.22.56 Edition 3
100:1 in 20 C ml
100 90 80 70 60 50 40 30 20 10
100:1 in 20 C ml
100:1 in 20 C ml
100 90 80 70 60 50 40 30 20 10
100 90 80 70 60 50 40 30 20 10
Check the replenishment rates with three graduated plastic cylinders supplied by placing the replenishment tubes into the cylinders.
Press &200!. A softkey menu is displayed. Press the key below 3352&. Press the key below 0$15(3/. The nominal replenishment quantities of the various tanks are displayed. Press the key below 7(67. An amount equal to 20 strokes is pumped into the cylinders. If the quantity is not correct the first time, repeat the procedure a few more times to deaerate the tubes. Is the quantity still wrong afterwards, adjust the quantity as described in chapter 12.9.2.
After the operating temperatures have been reached (about 1 hour after switching ON) check the temperatures with an accurate mercury or electronic thermometer. The procedure is as follows:
saml02042a
Remove the lid of the paper processor.
saml02043a
Master Lab / Master Lab+
Lift the cover of the paper dryer. Make sure the cover locks on both sides.
Service Manual
61
Installation
saml02044a
saml02045a
Unlock the lower part of the dryer with the two knurled screws and tip it up.
Press &200!. A softkey menu is displayed. Press the key below 3352&. Now press the key below ',63703. The actual temperatures of the various tanks are displayed.
,03257$17
7KH WHPSHUDWXUH RI WKH VWDELOL]HU PXVW EH PHDVXUHG LQ WKH ODVW WDQN
saml02046a
Insert an accurate thermometer into the tank right by the temperature sensor and compare the measured value with the value displayed.
saml02047a
When the temperature measurement is finished, lower the lower part of the dryer and lock it.
62
Service Manual
Master Lab / Master Lab+
If the actual value deviates more than the permissible tolerance from the nominal value, a recalibration is necessary. Proceed as described in chapter 12.9.1.
saml02046a
98.22.56 Edition 3
Turn both fasteners on the crossover unit left, then lift the unit and remove it.
Installation
saml02048a
98.22.56 Edition 3
Remount the crossover unit and turn the fasteners right until they lock.
saml02049a
Lower the cover of the dryer.
saml02050a
Remount the lid of the paper processor.
&RQFOXGLQJ FKHFNV
Check the chemicals of the film processor and the paper processor by means of control strips. Refer to the Operating Manual Setup. Check the code of the reference paper. If necessary, modify it according to the customer requests, otherwise proceed with step 10. Press 6(7!. Enter the password. (default is 3340) and confirm with (17(5!. A softkey menu is displayed. Press the key below 35,17(5. Press the key below 0$67(5. Press the key below ',5(&7 and change the code for the reference paper. Confirm with (17(5!. Press any menu key to exit the present menu
Master Lab / Master Lab+
Service Manual
63
Installation
Now, insert a film strip and place the first negative in the viewing window. Press &200!. A softkey menu is displayed.
98.22.56 Edition 3
Press the key below 35,17(5. Press the key below 6(7/(16. Press the key below 6(7=220. Press the key below 67$57. The negative is now transported into the exposure position, paper is cut and brought into the exposure position on the paper deck.
saml02051a
Crown Gear
The projected image may overlap the paper by maximum 2mm (0.08). Should this not be the case, adjust the zoom by turning the crown gear until the proper overlap is achieved.
CW
CCW
Confirm with (17(5!. Press any menu key to exit the present menu
:$51,1*
,W LV YHU\ LPSRUWDQW WKDW \RX H[DFWO\ IROORZ WKH VWHSV WR IRU DGMXVWLQJ WKH ILOP WUDFN RWKHUZLVH IDXOW\ H[SRVXUHV PD\ RFFXU
Master Lab / Master Lab+
Load a film strip with the
key. and
Position the negative in the viewing window with the arrow keys . Press 0$,17!. Enter the password (default is 7890) and confirm with (17(5!. Press the key below 35,17(5. Press the key below ),75$&.. Press the key below ,1,7.
64
Service Manual
Installation
Press the key below $'-(;3 to adjust the exposure position. Press the key below 67$57. This transports the negative from the viewing window into the exposure position, a paper is cut and positioned on the paper deck. Position the negative exactly in the middle of the paper with the keys just below the signs < and > shown in the display. Confirm the final position with (17(5!. The film strip is then removed from the film deck. Press any menu key to exit the present menu. Load the test negative #6 in the viewing window with the Press 0$,17!. Enter the password (default is 7890) and confirm with (17(5!. Press the key below 35,17(5. Press the key below ),75$&.. Press the key below ,1,7. Press the key below $'-9,(:. Position the negative exactly in the viewing window with the keys just below the signs < and > shown in the display. Confirm the final position with (17(5!. Press any menu key to exit the present menu. key.
98.22.56 Edition 3
Master Lab / Master Lab+
6HWWLQJ WKH ZDNHXS WLPHV
Press 6(7! and proceed as follows to set the 7-day timer. Enter the password (default is 3340) and confirm with (17(5!. Press the key below 6<67(0. Press the key below :$.(83 and enter the on/off times.
<SET> Monday [24:00] ON [24:00] OFF SYSTEM WAKEUP Set any Time to 24:00 for disable
1RWH
6HWWLQJ WKH 21 2)) WLPH WR GLVDEOHV WKH ZDNHXS IXQFWLRQ IRU WKDW GD\
Service Manual
65
Installation
Repeat this step for every day of the week. At the end press any menu key to exit the present menu.
98.22.56 Edition 3 Master Lab / Master Lab+
6HWWLQJ WLPH DQG GDWH
Press 6(7! and proceed as follows to set the actual time and date. Enter the password (default is 3340) and confirm with (17(5!. Press the key below 6<67(0. Press the key below '$77,0 and enter the correct date and time.
<SET> SYSTEM DATTIM Actual Date and Time 1999 Year 6 Month 17 Day 13:25 Time
Remount all removed side panels.
0DVWHU VHWXS
Press 6(7! and proceed as follows to set the reference film. Enter the password (default is 3340) and confirm with (17(5!. Press the key below 35,17(5. Press the key below 0$67(5 Press the key below 7(676(7'(1 until the aim values are reached (refer to the Operating Manual SETUP). Press any menu key to exit the present menu
6DYLQJ WKH GDWD RI WKH LQLWLDO VHWXS
saml02052a
Insert the memory card
Press &200!. A softkey menu is displayed.
66
Service Manual
Installation
98.22.56 Edition 3
Press the key below 6<67(0. Press the key below 6$9(. Press the key below 67$57 to save the parameters. Remove the memory card as soon as the saving procedure is finished.
Master Lab / Master Lab+
Service Manual
67
68
98.22.56 Edition 3
Installation
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
6HUYLFH PHQX
7KH V\VWHP
Before entering values or reading data you have to address the corresponding location in the menu system. The following figure shows the keys used to navigate through the menu system.
saml03001a
Standard Display
Corresponding Menu Key <MAINT>
Menu 1. Level (1. line of Display) Any Menu Key 2. Level n. Level
SOFTKEY SOFTKEY SOFTKEY
Master Lab / Master Lab+
Last Level Screen # 1
Menu Last Level Screen # 2 <ENTER> Menu Last Level Screen # n <ENTER> Menu Last Level Last Screen
Service Manual
69
Service menu
0DLQWHQDQFH 0HQX IRU WKH 3ULQWHU
'HVLJQDWLRQ 0HQX OD\HU 0$,17! PRINTER PATRACK INIT ADJUST ADJUST ALL DISTR TRANSP ADVANCE FETCH LEAVE FEED TURN DISTR CASS Display paper end, splice detector Display magnet settings & cassette code EXTRACT Activates paper extractor-motor (without a cassette only) FORW Extracting forward BACKW Extracting backward STOP Stop extracting KNIFE Move knife, display light barrier CUTLFT Move knife left CUTRGHT Move knife right PDECK Select paper deck MOVE Move paper deck transport 100mm/ cont. FORW Move paper 100mm/cont. forward BACKW Move paper 100mm/cont. backward STOP Stop FAN VACUUM Vacuum fan ON/OFF EXIT SENS Display light barriers feeder FEEDER Turn feeder and display light barriers TURNPRI Turn feeder into printer position and display light barriers TURNPRO Turn feeder into processor position and display light barriers. continued on next page SENS CODE Regular paper transport Move paper from cassette to paper deck Move paper from paper deck to processor Move paper from paper deck to 7KHVH PHQXV DUH feeder RQ WKH QH[W Turn feeder to processor / distribuVFUHHQ tor Move paper from distributor to processor Enter the maintenance menu (Password) Select printer functions Select paper track Initialize paper track Adjust exposure position Enter exposure position in (mm) and confirm with (17(5! Overall initialization of paper transport Reset of distributor )XQFWLRQ
70
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Service menu
'HVLJQDWLRQ 0HQX OD\HU 98.22.56 Edition 3 0$,17! PRINTER PATRACK EXIT DISTR START RESET FITRACK INIT FDECK ADJEXP START <-> ADJVIEW <->
)XQFWLRQ
Enter the maintenance menu (Password) Select printer functions Select film track Start distributor, reset, display error Start transport in distributor, display error Reset distributor Initialize film track Press (17(5! to init software (after changing a film deck) Adjust exposure window with softkeys Move the film to exposure position Move film left, confirm with (17(5! Move film right, confirm with (17(5! Adjust viewer window with soft keys Move film left, confirm with (17(5! Move film right, confirm with (17(5! Adjust sensors Move film, calibrate, display photo sensors o PosDiode: density, absolute, offset o -DxData: density, absolute, offset o DxClock: density, absolute, offset o STC Data: density, absolute, offset (Fuji frame number) Number of steps to move film Move film forward (number of steps) Move film backward (number of steps) Calibration of photo diodes Move film, display microswitch viewer and exposure Number of steps to move film Move film forward (number of steps) Move film backward (number of steps) continued on next page
SENS A135
Master Lab / Master Lab+
STEPS FORW BACKW CALIB A110 STEPS FORW BACKW
Service Manual
71
Service menu
'HVLJQDWLRQ 0HQX OD\HU 0$,17! PRINTER FITRACK SENS UNI STEPS FORW BACKW
)XQFWLRQ
Enter the maintenance menu (Password) Select printer functions Select film track Adjust sensors Move film, display light barrier home-position Number of steps to move film Move film forward (number of steps) Move film backward (number of steps) Display DX and MOF signals Number of steps to move film Move film forward (number of steps) Move film backward (number of steps) Dark calibration Display film deck code and mask code Forward, backward, stop motor ON/ OFF Move film continuously forward Move film continuously backward Stop film movement Motor ON/OFF Position LED, clamp, viewer lamp Activate negative mask Position LED ON/OFF Viewer lamp ON/OFF
ATAPS STEPS FORW BACKW CALIB CODE
MOVE FORW BACKW STOP MOTOR ACTUAT CLAMP POSLED VIEWER EXPSYS FIXTIME
LAMPSYS MODE ATTEN TURN SENS CODE
Lamp voltage ON/OFF Swing attenuator Move attenuator in/out Display state of temperature switch Status light barrier and light shaft code continued on next page
72
Service Manual
Master Lab / Master Lab+
BLUE GREEN RED ATTEN FIXTIME
Allows to copy prints with user defined constant exposure times [ms] for tests. Scanner is OFF Enter the time for blue in [ms] Enter the time for green in [ms] Enter the time for red in [ms] Attenuator ON/OFF 2Q QH[W Set fixtime mode ON/OFF VFUHHQ
98.22.56 Edition 3
Service menu
'HVLJQDWLRQ 0HQX OD\HU 98.22.56 Edition 3 0$,17! PRINTER EXPSYS FWHEEL INIT EXPOSE START COLORS
)XQFWLRQ
Enter the maintenance menu (Password) Select printer functions Select exposure system Initialize filter wheel Exposure time 40ms for each color Start an exposure cycle of 40ms Turn dark > blue > green > red > dark > white > dark display home sensor. Start the test cycle Turn continues Start rotating the filter wheel Stop rotating the filter wheel Swing shutter, display light barriers Turn shutter in/out Temperature correction Density correction yellow Density correction magenta Density correction cyan
TURN CONT START STOP SHUTTER TURN TEMPCOR YELLOW MAGENTA CYAN MEASYS SENS SCANLIN
START GAIN
Display temperature in measuring system Measure and display one scan line (12 diodes), gain, offset, absolute of blue, green, red. (Diode 1 ... 10 Scan diodes Diode 11 Reference diode) Scan one line of negative Enter value for gain See results with
T-CALIB AUTO Master Lab / Master Lab+ MAN AIM OTHER OPTICS CODE ZOOM GETPOS RELEASE De-energize zoom drive, move zoom by hand GETPOS Get actual zoom position in steps POSITION Display actual position in steps. continued on next page Read lens code (in home position only!) Measure calib. strip automatically (ADM) Measure calib. strip manually (D19C) Enter aim values
Service Manual
73
Service menu
'HVLJQDWLRQ 0HQX OD\HU 0$,17! PRINTER OTHER ZOOM GOPOS
)XQFWLRQ
Enter the maintenance menu (Password) Select printer functions
START Move zoom to specified position POSITION Enter position of zoom in [steps] ELECTR SENS Status of DIP-Switch 1 - 7 on CPU board, memory card, backup battery, software version of CPU board. Status of connected options, paper transport, wet part Initialize the backprinter Switch the ribbon motor ON/OFF Expose a grey print
SERIAL BACKPRI INIT RIBBON TEST_EX
0DLQWHQDQFH PHQX IRU WKH SDSHU SURFHVVRU
'HVLJQDWLRQ 0HQX OD\HU 0$,17! P.PROC TEMP CALTMP DEV BLEACH STAB DRYER STATUS Actual temperature in C in the developer Actual temperature in C in the bleachfix Actual temperature in C in the stabilizer Actual temperature in C in the dryer Actual temperature in comparison to the set temperature for developer, bleachfix, stabilizer and dryer Heater of developer ON/OFF Heater of bleachfix ON/OFF Heater of stabilizer 1 ON/OFF Heater of stabilizer 2 ON/OFF Heater of stabilizer 3 ON/OFF 2Q QH[W Heater of dryer ON/OFF VFUHHQ Continued on next page Enter the maintenance menu (Password) Select paper processor functions )XQFWLRQ
HEATER DEV BLEACH STAB1 STAB2 STAB3 DRYER
74
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Service menu
'HVLJQDWLRQ 0HQX OD\HU 98.22.56 Edition 3 0$,17! P.PROC TEMP PROBES
)XQFWLRQ
Enter the maintenance menu (Password) Select paper processor functions Condition of the temperature probes and heaters in developer, bleachfix, stabilizer and dryer
LIQUID CALPUMP DEV BLEACH STAB TEST PUMPS DEV BLEACH STAB REPL SENS Actual pump rate for 20 strokes and per m2 for the developer Actual pump rate for 20 strokes and per m2 for the bleachfix Actual pump rate for 20 strokes and per m2 for the stabilizer Execute 20 pump strokes Switch agitation and replenishment pumps Switch developer agitation pump ON/OFF Switch bleachfix agitation pump ON/ OFF Switch stabilizer agitation pump ON/ OFF Switch replenishment pumps ON/ OFF Display level condition in the working tanks, the replenishment and recovery tanks (optional console only). Displays status of flow/vacuum sensor. Switch fans ON/OFF Switch dryer fan ON/OFF Switch exhaust fan ON/OFF Switch cooling fan ON/OFF
AIR DRYER EXHAUST COOLING Master Lab / Master Lab+ TRANSP PAPER MOTOR
Switch paper transport motor ON/ OFF
SORTER MOVE LEFT RIGHT STOP STATUS SENS
Move sorter and shows position Move sorter to the left Move sorter to the right Stop sorter movement Status of the sorter Condition of light barriers, paper width and presence of sorter kit. Continued on next page
Service Manual
75
Service menu
'HVLJQDWLRQ 0HQX OD\HU 0$,17! P.PROC TRANSP STATUS SENS SYSTEM ON/OFF PROCESS DRYER DEVTIM SWITCH BUZZER 24VBAT ACPOW DCPOW STATUS SENS
)XQFWLRQ
Enter the maintenance menu (Password) Select paper processor Select transport Status of the paper processor Condition of the tacho light barrier Select system functions Switch paper processor ON/OFF Switch dryer ON/OFF Developer time in seconds Switch buzzer ON/OFF Switch 24V ON/OFF Switch AC-Power OFF Switch DC-Power ON/OFF Display the various status of the paper processor Displays status of various sensors of the system
0DLQWHQDQFH PHQX IRU WKH ILOP SURFHVVRU
(Valid for machines with film processor only!)
'HVLJQDWLRQ 0HQX OD\HU 0$,17! F.PROC TEMP CALTMP DEV BLEACH FIX STAB DRYER STATUS
)XQFWLRQ
Actual temperature in C in the developer Actual temperature in C in the bleach Actual temperature in C in the fixer Actual temperature in C in the stabilizer Actual temperature in C in the dryer Actual temperature in comparison to the set temperature for developer, bleach, fixer, stabilizer and dryer Continued on next page
76
Service Manual
Master Lab / Master Lab+
Enter the maintenance menu (Password) Select film processor functions
98.22.56 Edition 3
Service menu
'HVLJQDWLRQ 0HQX OD\HU 98.22.56 Edition 3 0$,17! F.PROC TEMP HEATER DEV BLEACH FIX1 FIX2 STAB1 STAB2 DRYER PROBES
)XQFWLRQ
Enter the maintenance menu (Password) Select film processor functions
Heater of developer ON/OFF Heater of bleach ON/OFF Heater of fixer 1 ON/OFF Heater of fixer 2 ON/OFF Heater of stabilizer 1 ON/OFF Heater of stabilizer 2 ON/OFF Heater of dryer ON/OFF Condition of the temperature probes and heaters in developer, bleach, fixer, stabilizer and dryer
LIQUID CALPUMP DEV BLEACH FIX STAB TEST PUMPS DEV BLEACH FIX STAB REPL SENS Master Lab / Master Lab+ Switch developer agitation pump ON/OFF Switch bleach agitation pump ON/ OFF Switch fixer agitation pump ON/OFF Switch stabilizer agitation pump ON/ OFF Switch replenishment pumps ON/ OFF Displays level condition in the working tanks, the replenishment and recovery tanks (optional console only). Displays status of flow sensors. Switch fans ON/OFF Switch dryer fan ON/OFF Switch air blower bleach ON/OFF Select film transport FILM MOTOR Switch film transport motor ON/OFF Continued on next page Actual pump rate for 20 strokes and per m2 for the developer Actual pump rate for 20 strokes and per m2 for the bleach Actual pump rate for 20 strokes and per m2 for the fixer Actual pump rate for 20 strokes and per m2 for the stabilizer Execute 20 pump strokes
AIR DRYER AIRBLEA TRANSP
Service Manual
77
Service menu
'HVLJQDWLRQ 0HQX OD\HU 0$,17! F.PROC TRANSP LOAD LOCK CUT STATUS SENS
)XQFWLRQ
Enter the maintenance menu (Password) Select film processor functions Select film transport Switch film loading Activate the knife when a film loading cassette is inserted. Status of the film processor and its various modules. Display the tacho light barrier and the film detecting sensor.
SYSTEM ON/OFF PROCESS DRYER DEVTIM SWITCH BUZZER 24VBAT ACPOW DCPOW STATUS SENS Switch buzzer ON/OFF Switch 24V ON/OFF Switch AC-Power OFF Switch DC-Power ON/OFF Display the various status of the film processor Displays status of various sensors of the system Switch film processor ON/OFF Switch dryer ON/OFF Developer time in seconds
78
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Service menu
0DLQWHQDQFH PHQX IRU WKH RWKHU V\VWHP SDUWV
'HVLJQDWLRQ 0HQX OD\HU 0$,17! OTHER SYSTEM LANG DEFAULT MEMCARD Enter the maintenance menu (Password) Select various other parts Select various system parts Load the default language (English) Load language from the language card )XQFWLRQ
98.22.56 Edition 3
PASSWD PASSWD SOFT
Enter new password Display software version of printer part, wet part, paper transport and keyboard, LCD etc. Automatic Densitometer
ADM MOVE REMHEAD
<0RYH UDVWHU
->
<0RYH HQG -> HOME
Move the measuring head and indicate the position of the head (right or left of the center position) Move the head one step to the left (One step is NOT equal to one raster segment) Move the head one step to the right (One step is NOT equal to one raster segment) Move the head to the left end position Move the head to the right end position Move the head to the center position (marked with an arrow on the raster segment).
TRANSP Master Lab / Master Lab+
Transport the strip Select the method of measurement (REM / TRANS) INDEX Distance the strip will be moved (not equal for REM and TRANS) FORW Transport the strip forward. BACKW Transport the strip backward STROUT Transport the strip out of the ADM TYPE
ACTUATE STRACC Enable / disable the function Strip access LAMP Lamp ON/OFF Continued on next page
Service Manual
79
Service menu
'HVLJQDWLRQ 0HQX OD\HU 0$,17! OTHER ADM TEST DARKMEA REM TRANS BRIMEA REM TRANS WHIMEA MIPOS RESET SENS
)XQFWLRQ
Enter the maintenance menu (Password) Select various other parts Automatic Densitometer Dark measurement Remission Densitometer Transmission Densitometer Bright measurement Remission Densitometer Transmission Densitometer White measurement Move head to center position Selftest of the ADM, reset all stored commands in the ADM Information about: o Transmission of the sensor for the raster segment o Transmission of the sensor for the strip detector o Sensor for the filter wheel (in the measuring head) Calibration of the ADM. Providing information about: o Measured and target values for white o Measured and target values for dark o Distance between the reference marks. o Max. number of measurements between reference marks for remission densitometer o Max. number of measurements between reference marks for transmission densitometer Measurement of a film strip Start the measuring process. Next measuring position Previous measuring position Measuring position (mm) Measurement of a paper strip Start the measurement Offset of the head from the center position (mm) Next measuring position Previous measuring position Measuring position (mm)
CALIB
MEAS FILM START 2Q QH[W VFUHHQ FORW BACKW DIST PAPER START HEAD<-> 2Q QH[W VFUHHQ FORW BACKW DIST
80
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Service menu
0DLQWHQDQFH PHQX IRU RSWLFDO LQGH[ SULQWHU
The following maintenance menu is only valid for software version 3.30
98.22.56 Edition 3
'HVLJQDWLRQ 0HQX OD\HU 0$,17! OTHER INDEX MOVE IDXUNIT HOME WORKPOS LOGO NEXT HOME
)XQFWLRQ
Enter the maintenance menu (Password) Select various other functions Select index functions for optical Indexprinter Activate the index unit Set index unit to home position Set index unit to work position
ZOOM
Movement of the logo turret Move to the next logo position Move to logo home position Move to index zoom magnification START Move to index zoom position HOME Move to index zoom home position POSITION Enter number of steps for zoom movement
TRANSL START Move to index translation position HOME Move to translation home position POSITION Enter number of steps for translator movement MIRRORS FDECK Turn film deck mirror LOGO Turn logo mirror EXPOSE FRAMENR EXPOSER Expose frame number for specified time TIME Set exposure time for frame number FORMAT EXP_C Expose format indicator C for specified time EXP_P Expose format indicator P for specified time TIME Set exposure time for format indicator TEXT EXPOSE Expose text for specified time TIME Set exposure time for text LOGO EXPOSE Expose logo for specified time TIME Set exposure time for logo Continued on next page
Master Lab / Master Lab+
Service Manual
81
Service menu
'HVLJQDWLRQ 0HQX OD\HU 0$,17! OTHER INDEX CALIB LEFT RIGHT UP DOWN CALTYP FMTWHL INT ADJUST NEXT -1 +1 FMTWHL ADJUST
)XQFWLRQ
Entering the maintenance menu (Password) Select various other functions Select index functions Move paper to the left Move paper to the right Move zoom translation up Move zoom translation down Selection of frame min./max. or logo With (17(5!, the format wheel id initialized
CHECKMIR NEUTRAL H-FMT P-FMT C-FMT FRAMENR YES/NO Confirmation for saving the data of the format wheel setting. EXPOSE EXPOSE TIME Expose frame number for specified time Set exposure time for frame number
0DLQWHQDQFH PHQX IRU &XVWRPL]HU
The following maintenance menu is only valid as of software version 5.xx
Master Lab / Master Lab+
'HVLJQDWLRQ 0HQX OD\HU 0$,17! OTHER SYSTEM ADM CCD LCD INDEX
)XQFWLRQ
Entering the maintenance menu (Password) These menu items are described in detail in the Service Manual Customizer Master Lab+ P/N 98.29.02
82
Service Manual
98.22.56 Edition 3
Service menu
'HEXJ PHQX
'HVLJQDWLRQ 0HQX OD\HU 0$,17! DEBUG INFO P.PROC F.PROC APS DEBUG TEST STRING TEST STRING TEST STRING For software development only! For software development only! For software development only! For software development only! For software development only! For software development only! FID (Test string) For software development only! Entering the maintenance menu (Password) )XQFWLRQ
98.22.56 Edition 3
0DLQWHQDQFH IXQFWLRQV RQ WKH $/0/3/86 ERDUG
A set of maintenance functions are provided on the ALMLPLUS board to check the pumps and sensors.
saml04007a
)65
green lamp
Make sure that the automatic topoff system is ON. The green light must be ON
Master Lab / Master Lab+
saml04008a
Turn the rotary switch SW1 from 0 upward. As soon as the position 0 is left, the MAIN LED indicates the maintenance mode. Test the pumps, various valves and switch SW2 and SW3 by stepping-up switch SW1 as given in the following tables:
MAIN LED
8 C 0 8 C 8 C
4
0
SW1 SW2 SW3
Service Manual
83
Service menu
3RVLWLRQ RI 6: 0 1 2 3 4 5 6 7 8 9 A B C D E F
7DE 3RVLWLRQ RI VZLWFK 6:
$FWLYDWHG IXQFWLRQ Maintenance OFF Pump and valve film developer (EV1) Pump and valve film bleach (EV2) Pump and valve film fixer 1 (EV3) Pump and valve film fixer 2 (EV4) Pump and valve film stabilizer 1 (EV5) Pump and valve film stabilizer 2 (EV6) Pump and valve paper developer (EV7) Pump and valve paper bleachfix (EV8) Pump and valve paper stabilizer 1 (EV9) Pump and valve paper stabilizer 2 (EV10) Pump and valve paper stabilizer 3 (EV11) Tank empty lamp (red lamp) Buzzer Checking switch SW2 as given in the next table Checking switch SW3 as given in the next table
saml13019a
EV1 EV2 EV3 EV4 EV5 EV6 EV7 EV8 EV9 EV10 EV1 1
8 8 8
ALAR +24V +5V ACT PUMP MAIN ON TANK BUZZ.
Manual switch activated (green lamp) Level empty (red lamp) Buzzer
84
Service Manual
Master Lab / Master Lab+
Electro valve film developer Electro valve film bleach Electro valve film fixer 1 Electro valve film fixer 2 Electro valve film stabilizer 1 Electro valve film stabilizer 2 Electro valve paper developer Electro valve paper bleach Electro valve paper stabilizer 1 Electro valve paper stabilizer 2 Electro valve paper stabilizer 3 Level phase alarm Power supply +24V Power supply +5V The board is running (flashing with 1Hz) Top-Of f pump Maintenance mode
98.22.56 Edition 3
Service menu
3RVLWLRQ 3RVLWLRQ $FWLYDWHG 6: 6: /(' 0 All LEDs OFF 1 EV1 2 EV2 3 EV3 4 EV4 5 EV5 6 EV6 7 EV7 E 8 EV8 9 EV7 A EV6 B EV5 C EV4 D EV3 E EV2 F EV1 Position of SW2
3RVLWLRQ 6:
3RVLWLRQ $FWLYDWHG 6: /(' 0 All LEDs OFF 1 EV1 2 EV2 3 EV3 4 EV4 5 EV5 6 EV6 7 EV7 8 EV8 9 EV7 A EV6 B EV5 C EV4 D EV3 E EV2 F EV1
98.22.56 Edition 3
Position of SW3
Master Lab / Master Lab+
Service Manual
85
86
98.22.56 Edition 3
Service menu
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
3UHYHQWLYH PDLQWHQDQFH
3UHYHQWLYH PDLQWHQDQFH GHVFULEHG LQ WKLV FKDSWHU LV D VHUYLFH WHFKQLFLDQV GXW\ DQG QR ORQJHU DQ RSHUDWRUV GXW\ $OO GXWLHV SHUIRUPHG E\ WKH RSHUD WRU DUH GHVFULEHG LQ WKH 2SHUDWLQJ 0DQXDO VXSSOLHG ZLWK HYHU\ PDFKLQH 7KLV PDLQWHQDQFH UHTXLUHV DQ LQGHSWK NQRZOHGJH RI WKH 0DVWHU /DE WHFKQRORJ\ HJ RSHUDWLQJ LQ WKH PDLQWHQDQFH PHQX
6WDQGDUG SUHYHQWLYH PDLQWHQDQFH
For the standard preventive maintenance which should be done every half year the following material is required:
3DUW QXPEHU 11.54.43 3ULQWHU SDUW Filter mat :HW SDUW Chemical filter Filter mat Filter mat Squeegee roller
'HVFULSWLRQ 1
4W\
Master Lab / Master Lab+
16445-139-0 16445-137-0 16445-145-0 15525-159-0
11 1 1 4
0029-100-22 0021-658-51 0021-658-56 0021-658-53 0021-658-62 0026-729-44
0DWHULDO IRU SUHYHQWLYH PDLQWHQDQFH Filter for replenishment pump Flap valve for replenishment pump Bellow 3/4 for bleach replenishment pump Bellow 1 for replenishment pump Bellow 1.5 for stabilizer pump Drain tap
7 7 1 5 1 1
Service Manual
87
Preventive maintenance
3DUW QXPEHU 20.66.98 14.20.88 35.37.28 18540-061-0
'HVFULSWLRQ $X[LOLDU\ PDWHULDO Lens cleaning tissues Lens cleaning liquid TRI-FLOW teflonbased lubricant Pure silicon oil Vacuum cleaner Brush Alcohol
4W\
*HQHUDO 3URFHGXUHV
Save all data on the memory card. Check the +5Vdc supply according to instructions in chapter 5.4.4
:$51,1*
$OZD\V VZLWFK RII WKH PDFKLQH EHIRUH FOHDQLQJ 1RWH FHUWDLQ DGMXVWPHQWV DQG IXQFWLRQDO WHVWV UHTXLUH WKH PDFKLQH WR EH RSHUDWLRQDO :LWK WKH H[FHSWLRQ RI WKH FRYHUHG SDUW RI WKH FRQWURO XQLW PDUNHG ZLWK WKH IODVK V\PERO WKH SULQWHU SDUW RQO\ RSHUDWHV ZLWK YROWDJHV EHORZ 9 KRZHYHU ZKHQ VHUYLFLQJ D OLYH PDFKLQH PDNH VXUH WR XVH QRQFRQGXFW LQJ WRROV Shut down the machine.
,03257$17
Master Lab / Master Lab+
'RQW XVH FRPSUHVVHG DLU IRU FOHDQLQJ EHFDXVH LW GLVWULEXWHV WKH GXVW LQ VWHDG RI HOLPLQDWLQJ LW %UXVKHV RI YDULRXV VL]HV DQG D KDQGKHOG YDFX XPFOHDQHU DUH UHFRPPHQGHG IRU FOHDQLQJ SXUSRVHV Dust the control panel with a brush and a vacuum-cleaner. Clean the control unit (electronics) with a brush and a vacuum-cleaner. Open the test cassette for paper processor control strips and dust it with a brush and a vacuum-cleaner.
88
Service Manual
98.22.56 Edition 3
Preventive maintenance
3ULQWHU SDUW 2SWLFDO V\VWHP
saml04001a
98.22.56 Edition 3
! " # $ % & '
1 2 3 4 5 6 7 8 9 10 11* 12* 13* 14* 15* 16 17
! " # $ %
Lamp IR filter (coated side up) Correction filter (coated side up) Test filter Filter wheel (blue/green/red color filters, coated side up) Filter wheel motor Fixed light cone Exchangeable light shaft Film deck Shutter Lens turret Turret lock Lens code reader Zoom lens motor Zoom lens Paper Paper deck
* = ML+ 220 / 240 / 520 / 740 only!
Master Lab / Master Lab+
Shut down the machine with the main switch. Dust the lamp house with a brush and a vacuum-cleaner. Use lens cleaner to clean the IR filter, the correction filter, the test filter and the color filters. 5HPRXQW WKH ILOWHUV LQ WKH FRUUHFW VHTXHQFH DQG PDNH VXUH WKDW WKH FRDWLQJ LV RQ WKH ULJKW VLGH q ,5 ILOWHU FRDWHG VLGH XS q &RUUHFWLRQ ILOWHU FRDWHG VLGH XS q 7HVW ILOWHU QR FRDWHG VLGH q &RORU ILOWHUV FRDWHG VLGH XS
1RWH
Use a brush to dust the outside of all light shafts. Clean both sides of the respective diffusers with lens cleaner. Thoroughly dust all film decks with a brush.
Service Manual
89
Preventive maintenance
Clean the conveyer rollers and the reader unit with alcohol. Check the tension of the toothed belt (see chapter 9.6.4)
98.22.56 Edition 3 Master Lab / Master Lab+
Clean the table of the printer part with a damp cloth. Clean the film deck seat with a brush and a vacuum-cleaner.
Clean the front surface of all lenses using lens cleaner. )RU 0/ DQG RQO\ Unlock the lens turret and check that it runs smoothly and without effort. The turret shall not jam in any position!
Switch on the machine. Open the lamp house.
Check the lamp voltage in normal operation, adjust if necessary (refer to chapter 5.4.5.) Check the function of the thermostat in the lamp house with the following procedure: Cover the lamp cooling fan (e.g. with an aluminum plate). Close the lamp house cover. Ensure that the lamp is on. Wait approx. 10 minutes, the lamp should now be switched off Does this not happen, replace the sensor.
Operate the test filter with the menu 0$,17! ),75$&. (;36<6 /$036<6 $77(1 Press the key below 7851 and check the evenness of movement. The test filter shall not touch the filter wheel and the fixed light cone. Check the sequence of the color filters with the menu 0$,17! ),75$&. (;36<6 ):+((/ &2/256 )RU 0/ DQG RQO\ Check the movement of the shutter, at least 20 times with the menu 0$,17! ),75$&. (;36<6 6+877(5 Press the key below 7851
90
Service Manual
Preventive maintenance
0HDVXULQJ V\VWHP
saml04002a
98.22.56 Edition 3
& % ! "
$
#
"
% ! &
'
1 3 5 7 9 11 13 15 17
Master Lab / Master Lab+
Lamp Test filter Light shaft Photo diode Measuring box Measuring lens Deviation mirror Lower diffuser Correction filter
2 4 6 8 10 12 14 16 18
Lamp house Filter wheel Film Measuring board (MESY) Measuring filter Optical box Film deck Upper diffuser IR-filter
Clean the test filter in the lamp house Clean the measuring filter of the measuring box with lens cleaner.
saml04003a
"
1 2 3 4
Measuring lens Deflection mirror Fibre optic Magnets
! "
Use a brush to dust the inside and outside of the optical box
Service Manual
91
Preventive maintenance
Clean the deflection mirror and the measuring lens with lens cleaner Check if both ends of the fibre optic are properly seated. Before remounting the cover, ensure that the coated side of the deflection mirror faces down and that it is positioned in a 45o angle to the light path. Check if the four holding magnets are in place (optical box for universal film deck only!).
98.22.56 Edition 3 Master Lab / Master Lab+
3DSHU SDWK
saml04004a
! " ' % $ #
& "
)LJ
3DSHU SDWK DVVHPEOLHV
1 3 5 7 9 11 13
Paper cassette Paper extractor front panel Paper extractor motor Paper deck transport motor Feeder pivot drive motor Paper distributor (ML+ X40 only!) Paper distributor carriage motor
2 4 6 8 10 12 14
Light trap PAMID board Knife motor Paper deck Feeder Drive shaft of paper processor Paper distributor motor
92
Service Manual
Preventive maintenance
saml04005a
%
98.22.56 Edition 3
&
'
& ' $
% $ # " !
!
" # $ !
)LJ
'ULYH DQG PRQLWRULQJ V\VWHP
1 3 5 7 9 11 13 15 17 19 21
Paper cassette Detection of knife position Paper deck Feeder Paper detector of feeder Paper cassette code detection Paper splice sensor Knife drive DC motor Paper distributor Distributor carriage stepper motor Paper path sensors
2 4 6 8 10 12 14 16 18 20
Paper extractor and knife unit Vacuum fan Detection of feeder position Paper width detector Feeder pivot drive motor Paper present detector Paper deck drive stepper motor Paper extractor stepper motor Paper transport stepper motor Detection of carriage position
The paper path needs the following maintenance:
Master Lab / Master Lab+
Shut down the machine with the main switch. Dust the paper cassette and the paper path from the paper inlet to the paper distributor.
Service Manual
93
Preventive maintenance
saml04006a
)
98.22.56 Edition 3
Check the fasteners ($) of all paper cassettes for correct function. Replace defective fasteners
Check the belt tension of the knife, the feeder and the paper distributor. (For details refer to chapter 10). Replace defective or worn parts, such as: o Fasteners of the light trap. o Tension and pressure springs of the paper inlet and the knife unit. o Rollers of the feeder and the paper distributor.
:$51,1*
2QO\ XVH DOFRKRO IRU FOHDQLQJ WKH UROOHUV 7KH XVH RI DQ\ RWK HU FOHDQLQJ DJHQW LV VWULFWO\ SURKLELWHG ,W GDPDJHV WKH UXEEHU RI WKH UROOHUV
Master Lab / Master Lab+
Use alcohol to clean the paper inlet rollers and the transport rollers of the paper deck. Replace the air filter below the electronic rack. Check the play between the driving mechanism of the paper processor and the paper distributor outlet. The paper distributor shall not touch the motor shaft of the paper processor. Lubricate both drive sprockets with TRI-FLOW (teflonbased lubricant).
Check the play between the driving mechanism of the paper distributor and the feeder.
94
Service Manual
Preventive maintenance
Check the play between the driving mechanism of the paper deck and the feeder.
98.22.56 Edition 3
Switch the machine on and check the function of all paper path assemblies during initialization. Execute 30 exposures with a paper size of 3.5 x 3.5 or 4 x 4 and check the parallelism of the paper path from paper deck to paper distributor. Expose several gray prints with the menu: 0$,17! 35,17(5 27+(5 7(67B(;3 Check the prints for the following criteria: o how has the print been cut, it must be a clean cut. o that no edges are damaged. o that no pressure marks are on the prints o that all prints have the same length (+/- 0.2mm) Check the paper position (X-Y adjustment) on the paper deck and readjust if necessary (for details refer to chapter 10). Trigger three paper feeds of each paper type used during daily production and check the edges of the prints for damages. Check if the detection of the paper cassette code works correct. (Instruction about cassette coding is given in chapter 10).
:HW SDUW *HQHUDO
:$51,1*
:KHQ HYHU \RX KDYH WR KDQGOH FKHPLFDOV SURWHFW \RXUVHOI ZLWK JORYHV DQG JRJJOHV
Master Lab / Master Lab+
1HJOHFWLQJ WKLV SUHFDXWLRQ FRXOG OHDG WR VHYHU VNLQ LUULWDWLRQ DQGRU GDPDJHV WR \RXU H\HV ,Q WKH ZRUVW FDVH OHDGLQJ WR ORVV RI H\HVLJKW It is advisable to do the following maintenance at least every half year. It is further assumed that the daily, weekly and monthly maintenance have been done on a regular basis. Unlike the maintenance in the printer part, the maintenance in the wet part mainly include functional checks, verifying of values and inspection of various parts. Cleaning is only covered to some extent as this is a duty which has to be done much more frequently.
Service Manual
95
Preventive maintenance
)LOP SURFHVVRU
saml04009a
! $ # " #
$ % &
"
!
'
1 3 5 7 9 11 13 15
Exhaust fan Temperature sensor dryer Dryer fan Speedometer of transport motor Stabilizer 2 Fixer 2 Bleach Transport safety switch
2 4 6 8 10 12 14 16
Dryer Dryer heating Squeegee roller Transport motor Stabilizer 1 Fixer 1 Developer Film collecting bin
Develop a chemistry test strip. Evaluate the developed test strip. Shut down the machine with the main switch. Replace the four squeegee rollers of the last stabilizer rack. Remove the dryer rack. Clean it with a vacuum cleaner. Lubricate all bearings of the dryer with pure silicon oil (P/N 18540.061.0)
Master Lab / Master Lab+
96
Service Manual
98.22.56 Edition 3
Preventive maintenance
,03257$17
98.22.56 Edition 3
'RQW XVH 75,)/2: WR OXEULFDWH WKH EHDULQJV RI WKH GU\HU 7KLV ZLOO OHDG WR WKH GHVWUXFWLRQ RI WKH UROOHUV Check all racks for possible mechanical damages and wear. Replace defective parts. Check and ensure that all racks are transporting smoothly
Lubricate the bearings in all processor racks with TRI-FLOW
,03257$17
75,)/2: PXVW EH XVHG IRU WKH UDFNV LQ WKH SURFHVVRU EXW 1(9(5 IRU WKH GU\HU UDFNV Clean the film outlet station and the dryer housing with a brush and a vacuum cleaner.
saml04010a
"
$
1 3 5 Pulley 30T Toothed belt Ball bearing
$
2 4 6
$
Pulley 15T Friction bearing Worm gears
#
Master Lab / Master Lab+
Check the condition of the worm gears on the main drive shaft. Use TRIFLOW to lubricate the worm gears, the ball bearings and the friction bearings. If a worm gear or a bearing has to be replaced, refer to chapter 11
Service Manual
97
Preventive maintenance
saml04011a
5N
Replace the air filters for the wet part electronics and the pump cooling fans. Remove the cover of the tank heaters and temperature/level sensors. Clean the frame located underneath by removing all chemical residues (furring) Check chemical tanks, pumps and hoses for possible leaks. Open all filter housings in the replenishment tubes. Clean the filters under running water. 1RWH %H FDUHIXO QRW WR ORVH WKH 2ULQJV
Remove the suction tube of the automatic top-off tank.
&$87,21
'RQW VZLWFK 21 WKH PDFKLQH DV ORQJ DV WKH UDFNV DUH UH PRYHG DQG WKH VXFWLRQ WXEH LV VWLOO LQ WKH DXWRPDWLF WRSRII WDQN 7KH DXWRPDWLF WRSRII V\VWHP ILOOV XS WKH WDQNV ZLWK ZDWHU DQG WKH FKHPLVWU\ ZRXOG EH GLOXWHG DQG XVHOHVV Switch ON the machine with the main switch.
Master Lab / Master Lab+
Visually check circulation of the liquid in each working tank. Visually check the agitation in the developer. Visually check the air pump in the bleach. Switch OFF the machine again. Before reinserting the racks, check the results of the evaluated test strip, if necessary fill new chemistry into the tanks. 1RWH &OHDQ WKH WDQNV EHIRUH UHILOOLQJ ZLWK QHZ FKHPLVWU\
98
Service Manual
98.22.56 Edition 3
5 mm
Check the belt tension of the main drive and adjust if necessary.
Preventive maintenance
saml04011a
98.22.56 Edition 3
Remove the film loading station.
&$87,21
C A U T I O N S H A R P B L A D E
%HORZ WKH FRYHU RI WKH ILOP ORDGLQJ VWDWLRQ LV WKH ILOP FXWWLQJ NQLIH :KHQ UHPRYLQJ WKH FRYHU EH FDUHIXO RWKHU ZLVH \RX PD\ FXW \RXU ILQJHUV
saml04013a
Remove the screws marked (A) and open the film loading station. Check the blade of the knife for a sharp edge. Exchange a damaged or unsharp knife. Clean the rollers of the film loading station with alcohol.
Sensor board
M805
Check all pressure and tension springs. Lubricate the outside of the guide rails (for the film loading cassette) and the gears with silicon oil. Check the cassette locking and the knife solenoid for smooth movement and if necessary lubricate with very little TRI-FLOW to prevent films from getting dirty.
A
Master Lab / Master Lab+
A A
Service Manual
99
Preventive maintenance
saml04014a
Close the film loading station and reinstall it Insert the racks into the working tanks. Switch ON the machine with the main switch. Check the film transport from the film loading through to the film collecting bin. Process at least two to three films and check them for scratches. Check the temperature of the chemicals and the dryer (see chapter 11). Check the replenishment rates (see chapter 11). Make sure the pumps are self-priming, otherwise change the valves. Check the bellows and the valves for possible leaks. Check the volume of the remaining chemicals in the replenishment tanks to see whether they are in proportion to each other. Select the menu: 0$,17! 3352& $,5 (;+$867 Switch the exhaust fan OFF and ON again and check the air flow of the fan.
Master Lab / Master Lab+
Check the transport speed by inserting an HPSW\ leader card into the Master Lab+. Start a stop watch when the front of the leader card enters the developer rack. Stop the time when the leader card enters the bleach rack. The time should be 3min. 15sec. (195s). If necessary, adjust the time with the menu: 0$,17! )352& 6<67(0 '(97,0 Close all covers of the film processor and the dryer.
100
Service Manual
98.22.56 Edition 3
Check the contact resistance of both micro switches with an Ohmmeter. Activate the switches several times by hand. The resistance must be below 1Ohm
Preventive maintenance
3DSHU SURFHVVRU
saml12001a
98.22.56 Edition 3
! " # $ % & "
#
$ ' !
1 3 5 7 9 11 13 15
Dryer Dryer heating 1 (230V / 450W) Dryer heating 2 (230V / 450W) Speedometer of transport motor Stabilizer tank 3 Stabilizer tank 1 Developer tank Print collector
2 4 6 8 10 12 14 16
Temperature sensor of dryer Dryer fan 1 Dryer fan 2 Transport motor Stabilizer tank 2 Bleachfix tank Transport switch Water tank (auto top-off system)
saml04015a
Master Lab / Master Lab+
"
1 3 5
Sorter transport motor Sensor, sorter right Sensor, sorter end
2 4
Large print detection (5 and up) Sensor, sorter left
Service Manual
101
Preventive maintenance
Develop a chemistry test strip. Evaluate the developed test strip. Switch OFF the machine with the main switch. Remove the dryer rack. Clean the dryer rack with a vacuum cleaner. Lubricate all bearings of the dryer with pure silicon oil (P/N 18540.061.0)
98.22.56 Edition 3
saml04016a
,03257$17
'RQW XVH 75,)/2: WR OXEULFDWH WKH EHDULQJV RI WKH GU\HU 7KLV ZLOO OHDG WR WKH GHVWUXFWLRQ RI WKH UROOHUV Check all racks for possible mechanical damages and wear. Replace defective parts. Check and ensure that all racks are transporting smoothly. Lubricate the bearings in all processor racks with TRI-FLOW.
,03257$17
75,)/2: PXVW EH XVHG IRU WKH UDFNV LQ WKH SURFHVVRU EXW 1(9(5 IRU WKH GU\HU UDFNV Clean the paper outlet station and the dryer housing with a brush and a vacuum cleaner.
$ $ $ #
"
1 3 5
Pulley 18T Toothed belt Ball bearing
2 4 6
Pulley 15T Friction bearing Worm gears
Check the condition of the worm gears on the main drive shaft. Use TRIFLOW to lubricate the worm gears, the ball bearings and the friction bearings. If a worm gear or a bearing has to be replaced, refer to chapter 12 Service Manual
102
Master Lab / Master Lab+
Preventive maintenance
saml04017a
5 mm
98.22.56 Edition 3
5N
Check the belt tension of the main drive and adjust if necessary.
Remove the cover of the tank heaters and temperature/level sensors. Clean the frame located underneath by removing all chemical residues (furring) Check chemical tanks, pumps and hoses for possible leaks. Open all filter housings in the replenishment tubes. Clean the filters under running water. 1RWH %H FDUHIXO QRW WR ORVH WKH 2ULQJV
Remove the suction tube of the automatic top-off tank.
&$87,21
'RQW VZLWFK 21 WKH PDFKLQH DV ORQJ DV WKH UDFNV DUH UH PRYHG DQG WKH VXFWLRQ WXEH LV VWLOO LQ WKH DXWRPDWLF WRSRII WDQN 7KH DXWRPDWLF WRSRII V\VWHP ILOOV XS WKH WDQNV ZLWK ZDWHU DQG WKH FKHPLVWU\ ZRXOG EH GLOXWHG DQG XVHOHVV Switch ON the machine with the main switch. Visually check circulation of the liquid in each working tank.
Master Lab / Master Lab+
Visually check the agitation in the developer. Visually check the air pump in the bleach. Switch OFF the machine again. Before reinserting the racks, check the results of the evaluated test strip, if necessary fill new chemistry into the tanks. 1RWH &OHDQ WKH WDQNV EHIRUH UHILOOLQJ ZLWK QHZ FKHPLVWU\
Switch ON the machine. Insert a test negative into the film deck.
Service Manual
103
Preventive maintenance
Expose the negative several times. Check the prints, they must have a clean surface, be without scratches and the edges must be free of notches. Check the temperature of the chemicals and the dryer (see chapter 12). Check the replenishment rates (see chapter 12). Make sure the pumps are self-priming, otherwise change the valves. Check the bellows and the valves for possible leaks. Check the volume of the remaining chemicals in the replenishment tanks to see whether they are in proportion to each other. Check the transport speed by exposing a print. Start a stop watch when the leading edge of the print enters the developer rack. Stop the time when the print enters the bleachfix rack. The time should be 45s. If necessary, adjust the time with the menu: 0$,17! 3352& 6<67(0 '(97,0 Close all covers of the film processor and the dryer. Lubricate the guide rails of the sorter with vasoline.
98.22.56 Edition 3 Master Lab / Master Lab+
saml04018a
8 mm
Check the belt tension. Adjust if necessary.
2.5 N
&RQFOXGLQJ SURFHGXUHV
Check and calibrate the Densitometer. Clean the printer table and all covers with a damp piece of cloth. To ensure proper operation of the machine carefully watch it during the first hour of production. Check all further Master Lab+ peripherals (options supplied by GRETAG IMAGING)
104
Service Manual
98.22.56 Edition 3
3RZHU VXSSO\
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ
The entire Master Lab+ is powered from the wet part.
In the wet part is a transformer with input coils from 200Vac to 240Vac producing output voltages of 220Vac / 780VA, 19,5Vac / 450VA and 32Vac / 1000VA. The 19.5Vac and 32Vac are rectified and filtered by the main power supply. The resulting 5Vdc, 24Vdc and 45Vdc are fed to the DC load circuits of the wet part and the printer part. All supplies for the printer part are led to the 32wer ',6tributor (PODIS) from where they are distributed throughout the printer part. The printer electronics is grounded in the wet part via the 24VGND and the 45VGND, no grounding is provided inside the printer part. The 45Vdc is not for direct use in the printer part but is used as input for: o the lamp power supply, produces a stable 20Vdc for the exposure lamp o the 34V regulator supplying the stepper motor drivers of the paper path and the filter wheel o the 26V switching regulator for the paper path fan (on CBO). The 24Vdc supplies all other stepper motor drivers, motors, solenoids, fans and lamps of the printer part.
Master Lab / Master Lab+
Service Manual
105
Power supply
saml05001a
Battery low Battery charger Power fail
BLOW +24V DC / DC 5V +5V GND PF +24V Printer power on / off +45V GND Printer Wet section
3RZHU VXSSO\ ZHW SDUW :LULQJ
The Mains connection starts at the connector block located in the rear part of the electrical panel, under the connector for the modem. Thereafter it leads to the line filter, then to the main switch, to the voltage selector and finally to the transformer. For the setup of the transformer to the different voltages refer to chapter 2.4.4.
%DFNXS EDWWHULHV
Two Pb-batteries 12V / 1.9Ah connected in series are installed in the Master Lab+. In case of a power fail the batteries are used to finish a pending work cycle in the film- and/or paper processor. During start-up of the machine, the batteries are tested under load-condition. The power supply switches both transport motors to the batteries for about 20 seconds and monitors the voltage. If the voltage of the batteries falls below 21V, the message BATTERY OF TRANSPORT IS LOW appears on the screen. The error message remains until the machine has been restarted and the batteries had time to recharge. The charging voltage is between 26V and 27V. The charging current is between 10mA and 200mA depending on the charging level. The batteries are on trickle charge as long as the machine is not switched off by the main switch.
)XVHV LQ WKH SRZHU VXSSO\
The power supply board and the battery charger board contain fuses.
106
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Power supply
2OG YHUVLRQ
saml05002a
98.22.56 Edition 3
+ -
F1 Battery Charger Board
F1 F2 F3
F4 Power Supply
F5
Power supply board
)XVH F1 F2 F3 F4
9DOXH 7\SH >$@ 25 25 25 25 T T T T
'LPHQ VLRQV 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32
31 0028-755-42 0028-755-42 0028-755-42 0028-755-42
3URWHFWHG SDUW 19.5Vac of the main transformer 19.5Vac of the main transformer 32Vac of the main transformer 32Vac of the main transformer 24Vdc Analog section of the MCB Sorter Motor Transport motor paper processor Transport motor film processor Knife solenoid Film loading cassette locking solenoid
F5
10
5 x 20
13.58.28
Master Lab / Master Lab+
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
Battery charger board
)XVH F1
9DOXH 7\SH >$@ 10 T
'LPHQ VLRQV 5 x 20
31 13.58.28
3URWHFWHG SDUW 24Vdc Backup battery
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
Service Manual
107
Power supply
1HZ YHUVLRQ
saml05003a
+ -
F6
F1 F2
F3 F4
F5
Power Supply
)XVH F1 F2 F3 F4
9DOXH 7\SH >$@ 25 25 25 25 T T T T
'LPHQ VLRQV 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32
31 0028-755-42 0028-755-42 0028-755-42 0028-755-42
3URWHFWHG SDUW 19.5Vac of the main transformer 19.5Vac of the main transformer 32Vac of the main transformer 32Vac of the main transformer 24Vdc Analog section of the MCB Sorter Motor Transport motor paper processor Transport motor film processor Knife solenoid Film loading cassette locking solenoid 24Vdc Backup battery
F5
10
5 x 20
13.58.28
F6
10
5 x 20
13.58.28
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
108
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Power supply
3RZHU VXSSO\ SULQWHU SDUW (OHFWURQLF SRZHU VXSSO\
The electronics power supply consists of a primary switched, isolated AC/DC converter. The input voltage range is 85Vac to 260Vac and the output voltages are +5Vdc / 5A, +12Vdc / 1A and -12Vdc / 1A. The +5Vdc is used for the logical circuits while the +/- 12Vdc supplies the RS232 drivers on the main board.
98.22.56 Edition 3
/DPS SRZHU VXSSO\
The lamp power supply is a switched, non-isolated DC/DC converter. The input voltage range is 10V to 60V and the output voltage is adjustable between 4.5V and 30V. For operation, the output voltage must be set to 20.0V (with the 25W exposure lamp) and the input voltage must be at least 3V higher than the output voltage.
9 7HUPLQDO UHJXODWRU
The stepper motor drivers for the paper path and the filter wheel are specified for a maximum input voltage of 42V. Because the supply with 45V would be too risky, this regulator serves as an overvoltage protection and is supplied with 45V. The power dissipation of the regulator is limited, i.e. if the product of the voltage over the controller and the current through the controller exceeds the specified limit, the regulator is switched off. The same happens when a short-circuit occurs. In this case the unit must be switched OFF and ON again for the regulator to recover.
Master Lab / Master Lab+
Service Manual
109
Power supply
)XVHV LQ WKH SRZHU VXSSO\ 5DFN ZLWK ROG 32',6
saml05004a
Electronics Power Supply
RET +OUT
Power Distributor PODIS
F1
Lamp Power Supply F1
IN
PODIS
)XVH
9DOXH 7\SH >$@
'LPHQ VLRQV
31
3URWHFWHG SDUW +24Vdc Attenuator solenoid Zoom drive stepper motor Shutter motor Knife motor Feeder motor Film deck stepper motor Viewing window lamp (f-deck) Pressure mask solenoid (f-deck) Distributor stepper motor Distributor clutches
F1
5 x 20
13.54.62
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
Electronics power supply
Master Lab / Master Lab+
)XVH
9DOXH 7\SH >$@ 2 F
'LPHQ VLRQV 5 x 20
31 11.21.09
3URWHFWHG SDUW 5Vdc CPU CBO / CBO2
F1
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
110
Service Manual
98.22.56 Edition 3
Power supply
5DFN ZLWK QHZ 32',6
saml05005a
98.22.56 Edition 3
Electronics Power Supply
RET +OUT
Power Distributor PODIS F1 F5 F4
F1
Lamp Power Supply
IN
PODIS
)XVH
9DOXH 7\SH >$@
'LPHQ VLRQV
31
3URWHFWHG SDUW +24Vdc Attenuator solenoid Zoom drive stepper motor Shutter motor Knife motor Feeder motor Film deck stepper motor Viewing window lamp (f-deck) Pressure mask solenoid (f-deck) Distributor stepper motor Distributor clutches +34Vdc Stepper motor filter wheel Stepper motor extractor Stepper motor paper deck +42Vdc Exposure lamp power supply Vacuum fan paper deck.
F1
6.3
5 x 20
11.21.24
F4
6.3
5 x 20
11.21.24
F5
6.3
5 x 20
11.21.24
Master Lab / Master Lab+
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
Electronics power supply
)XVH
9DOXH 7\SH >$@ 2 F
'LPHQ VLRQV 5 x 20
31 11.21.09
3URWHFWHG SDUW 5Vdc CPU CBO / CBO2
F1
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
Service Manual
111
Power supply
)XVH ERDUG
saml05006a
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14
)XVH F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14
9DOXH 7\SH >$@ 1 1 1 1 1 2.5 2.5 2 1 1 1 1 1 4 F F F F F F F F F F F F F F
'LPHQ VLRQV 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32 6.3 x 32
31 13.59.35 13.59.35 13.59.35 13.59.35 13.59.35 0028-759-79 0028-759-79 14.04.34 13.59.35 13.59.35 13.59.35 13.59.35 13.59.35 0028-759-81
3URWHFWHG SDUW Heater developer, paper Heater bleach, paper Heater stabilizer 1, paper Heater stabilizer 2, paper Heater stabilizer 3, paper Heater dryer 1, paper Heater dryer 2, paper Heater developer, film2) Heater bleach, film2) Heater fixer 1, film2) Heater fixer 2, film2) Heater stabilizer 1, film2) Heater stabilizer 2, film2) Heater dryer, film2)
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow) 2) These fuses are not used in machines without film processor and may be used as spares.
112
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Power supply
,QGLFDWRUV LQ WKH SRZHU VXSSO\
2OG YHUVLRQ
saml05007a
98.22.56 Edition 3
1HZ YHUVLRQ
saml05008a
," ,$ ,& ,
D4 D2 D1
The LEDs indicate the following when li up:
2OG YHUVLRQ D1 Board receives +24Vdc Fuse F1 is good D2 Board receives +42Vdc D4 Regulator produces +34Vdc D2 D4 D6 D8
Master Lab / Master Lab+
1HZ YHUVLRQ +24Vdc Fuse F1 is good Board receives +24Vdc Regulator produces +34Vdc +42Vdc Fuse F5 is good Board receives +42Vdc
D10
Service Manual
113
Power supply
6HUYLFLQJ :HW SDUW SRZHU VXSSO\
There are no adjustments necessary. To access the power supply:
saml01001a
POWER
Switch OFF the Master Lab+ with the main switch and disconnect the power cable. Loosen the cap screw on the drawer.
ATS
saml05009a
Pull the drawer out. 1 Power supply 2 Batteries 3 Transformer
The batteries may be checked with the following procedure: Switch OFF the Master Lab+ with the main switch. Disconnect both cables from the batteries. Disconnect the cable between both batteries. 'R QRW PHDVXUH WKH EDWWHULHV FRQQHFWHG LQ VHULHV ,Q WKLV FDVH \RX FDQQRW UHFRJQL]H D IDXOW\ EDWWHU\
1RWH
Connect a load of 2A .. 5A (e.g. spare exposure lamp) to each battery.
114
Service Manual
Master Lab / Master Lab+
&KHFNLQJ WKH EDFNXS EDWWHULHV
98.22.56 Edition 3
Power supply
&$87,21
98.22.56 Edition 3
%H DZDUH WKDW WKH ODPS XVHG DV ORDG JHWV YHU\ KRW 'RQW WRXFK LW ZLWK \RXU ILQJHUV \RX PD\ EXUQ \RXUVHOI Measure the voltage of the battery: o if the voltage stays >11.5V for more than 20 seconds, the batter is ok. o if the voltage drops below 11V during the 20 seconds, the battery has to be replaced.
&$87,21
,I D EDWWHU\ KDV WR EH UHSODFHG GRQW WKURZ WKHP LQWR WKH ZDVWHSDSHU EDVNHW RU GXVW ELQ %H DZDUH WKDW \RX GLVSRVH WKH EDWWHU\ VWULFWO\ LQ DFFRUGDQFH ZLWK WKH ORFDO UHJXODWLRQ IRU WKH SURWHFWLRQ RI WKH HQYLURQPHQW 7KH\ KDYH WR EH WUHDWHG DV VSHFLDO UHIXVH Reconnect the cables to the batteries. Switch ON the Master Lab+.
3ULQWHU SDUW SRZHU VXSSO\
To access the power supply:
saml05010a
Remove the cover over the electronic rack.
Master Lab / Master Lab+
saml05011a
Turn both screws holding the electronic board 90o counterclockwise and tilt the board down.
Service Manual
115
Power supply
'$1*(5
98.22.56 Edition 3 Master Lab / Master Lab+
%H YHU\ FDUHIXO EHKLQG WKH SURWHFWLYH FRYHU DUH GDQJHURXV YROWDJHV
saml05012
Turn the four screws of the protective cover 90o counterclockwise and remove the protective cover. Remove the transparent protective plate.
(OHFWURQLF SRZHU VXSSO\
To measure and adjust the voltages proceed as follows: Switch OFF the machine. Get access to the power supply as described in 5.4.3 Connect a voltmeter between the test point GND and +5V on the CBO/ CBO2 board.
saml05013a
CBO
U8 Paper extractor U7 Paper deck U15 Filterwheel U14 Filmdeck
U9 Zoom
J412 +24V +5V
J410 +45V +40V
J407
GND
116
Service Manual
Power supply
saml05014a
CBO2
98.22.56 Edition 3
F2
F1 +34V
+24V GND +5V F3 42V
saml05015a
Electronics Power Supply
R21
Switch ON the machine. Turn the potentiometer (R21) on the electronics power supply board until the measured voltage is between 5.0V and 5.1V.
F1
6XSSO\ IRU WKH H[SRVXUH ODPS
Master Lab / Master Lab+
:$51,1*
:KHQ \RX ZRUN DURXQG WKH H[SRVXUH ODPS EH DZDUH WKDW WKH ODPS DQG WKH ODPS VXSSRUW PD\ EH YHU\ KRW 'RQW WRXFK WKH KRW DUHDV \RX PD\ EXUQ \RXU ILQJHUV The supply voltage for the 250W exposure lamp must be set to 20.0V+/-0.1V.
Service Manual
117
Power supply
saml05016a
Connect a voltmeter to the terminal block in the lamp house.
Switch on the lamp with the menu 0$,17! Enter the password (default is 7890) and confirm with (17(5!. Move further down the menu through: 35,17(5 /$036<6 02'( 21
&$87,21
'RQW XVH 5(7 DQG 287 WR DGMXVW WKH ODPS YROWDJH 7KH YROWDJH GURS EHWZHHQ SRZHU VXSSO\ DQG ODPS LV WRR KLJK 7KH ODPS ZRXOG QRW KDYH HQRXJK SRZHU
saml05017a
Electronics Power Supply
RET +OUT
F1
Lamp Power Supply
R18
IN
Turn the potentiometer R13 on the lamp power supply until the voltage is 20.0V+/-0.1V
Master Lab / Master Lab+
R13
After readjusting the lamp voltage you have to recalibrate the system. Disconnect the voltmeter from the terminal block. Close the lamp house cover. Select the menu &+(&.! 35,17(5 (;326( and proceed as described in the Operating Manual.
118
Service Manual
98.22.56 Edition 3
Open the lamp house cover and manually activate the lamp house cover switch
Power supply
6FKHPDWLFV :HW SDUW
98.22.56 Edition 3
7LWOH
Sch. ELT. ALIM. M_L (circuit diagram) Alimentatore Master Lab (layout drawing) Overview Overview Schematic Layout Overview Schematics Layout Schematics Batery charger Layout battery charger Schematics battery charger Layout battery charger ATEX ATEX ATEX Power control Power control Power control ATEX ATEX Power control Power control
'UDZLQJ
17319.014.2 14074.243.2 Fig. 1 14074.208.0 15074.0119.0 15074.0119.0 14074.208.0 SE0133.SCH C.S. B226 15074.0120.0 15074.0120.0 C.S. B227
3DJHVVKHHWV
1 to 4 1 1 1 1 1 1 1 1 1 1 1 1
3ULQWHU SDUW
7LWOH
PBA Power Distributor PBA Power Distributor PBA Power Distributor PODIS (new) PODIS (new) PODIS (old)
'UDZLQJ
34.79.13 ES 34.79.13 AZ 34.79.13 AZ
3DJHVVKHHWV
1 1 2
Master Lab / Master Lab+
Service Manual
119
120
98.22.56 Edition 3
Power supply
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
3ULQWHU HOHFWURQLFV
2YHUYLHZ
saml06001a
Film Deck
ADM slave Slave E Distributor
Measuring System
A/D converter
Slave C Paper deck Paper Transport
Memory Card
Keyboard
Frame #
Densitometer D188/D19C
Main Processor
CPU 80186
Control Board
80186
MOF Indexprint slave
Lineprinter Slave D Filterwheel
Master Lab / Master Lab+
Pricing Modem
Optical System
Aux. 1
Aux. 2 Slave B Wet section Date / Time
Power Supply Printer section Power Supply Wet section
)LJ
%ORFN GLDJUDP RI &38 V\VWHP
Service Manual
121
Printer electronics
0DLQ SURFHVVRU ERDUG &38 2YHUYLHZ
The main processor board is the heart of the Master Lab+. The software on this board controls the entire machine. All sensors are connected to this board either directly or indirectly, and all acting parts are controlled from here. Furthermore the main processor board maintains all kinds of communication, e.g. the dialogue with the keyboard, printing on the line printer or reading from the densitometer.
saml06002a
36 9 x RS232 8 Bit Bus IN 32 OUT 20 IN
Serial Communication Interface Clock
Bus Interface for Memory Backup
Parallel Interface
A/D Interface
CPU 80186
General Purpose Input Port
General Purpose Output Port
Data Memory 256 kByte
Code Memory 768 kByte
Reset Circuit
Backup Supply
)LJ
%ORFN GLDJUDP RI WKH &38
7KH SURFHVVRU
Processor type Clock rate Single bus cycle Memory cycle time Address range AMD 80186 8MHz 125ns 4 cycles for even word/byte access 8 cycles for odd word access 1024 kilobytes
5HVHW FLUFXLW
This functional unit is used to initialize the hardware. When the power supply is switched on, the reset signal will be kept active 43ms longer than the supply voltage needs to reach the allowable minimum value of 4.75V The reset signal may also be triggered by actuating the input signals HARDWARE RESET, SOFTWARE RESET or BREAK.
122
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Printer electronics
saml06003a
Supply Voltage 4.75V UART Reset jumper
98.22.56 Edition 3
Reset Logic
CPU 80186
Keyboard (F-Clear)
GPO Port Offboard
Software Reset (GPO 0)
Slave C Slave D
)LJ
%ORFN GLDJUDP RI UHVHW FLUFXLW
&RGH PHPRU\
The code memory stores the machine program (software). The maximum storage capacity of 768 kilobytes is divided in 6 EPROMS of 128 kilobytes each. The EPROMS must be inserted in the corresponding IC-sockets U15 to U20. Two larger EPROMS may be inserted in the sockets U17 and U20 replacing the chips in socket U16, U17, U10 and U20. The jumper settings are described in chapter 6.4. The maximum access time for the code memory is 162ns with a CPU 80168 running at 8MHz.
'DWD PHPRU\
The data memory holds the setup paprameters for the machine. The maximum storage capacity is 256 kilobytes, using two static RAM chips (SRAM) of 128 kilobytes each. The jumper settings are described in chapter 6.4. The maximum access time for the data memory is 170ns with a CPU 80168 running at 8MHz.
Master Lab / Master Lab+
%DFNXS VXSSO\
This functional unit maintains the supply voltage to the data memory thus preserving the memory contents on shutdown of the regular power supply. Buffering however is limited to the +VBAT voltage (nominal value = 5V). Upon shutdown of the mains supply the battery maintains the supply voltage.
saml06004a
+5V +VBat Lithium Battery
)LJ
%ORFN GLDJUDP RI EDFNXS VXSSO\
Service Manual
123
Printer electronics
The higher voltage (either the nominal +5V or the battery) will be used as +VBAT to supply the data memory. The battery capacity is 1.7Ah.
98.22.56 Edition 3 Master Lab / Master Lab+
Depending on the production tolerances of the used components the working life of the battery varies between a minimum of 11 months and an average of 10 years. If you encounter an error message indicating a low battery, save your data on a memory card immediately. Then replace the lithium battery (refer to chapter 6.9.3) and restore the saved data afterwards.
6HULDO FRPPXQLFDWLRQ LQWHUIDFH
This functional unit allows to address nine peripheral units using a serial link. The operation mode is asynchronous and full-duplex which means that data can be sent and received simultaneously. The channels A, B, C, E and K use the same selectable baud rate, while for all other channels it may be selected independently. This functional unit includes a clock generator, 6 baud rate generators and 9 serial interface channels. The clock generator generates the 1.8432MHz supplied to the baud generator and the serial interface channels. With this clock, the baud rate generator creates the transfer rates for the serial interface channels. The serial interface acts as a parallel / serial converter. A BREAK on channel A ( )! &/($5!) actuates a reset, while a BREAK on channel I may trigger an NMI (selectable via J2).
3RVLWLRQ 0RGH 1-2 2-3 7DE The BREAK signal on the interface I is ineffective The BREAK signal on the interface I triggers a non maskable interrupt (NMI)
- VHWWLQJ IRU %5($. VLJQDO RI LQWHUIDFH ,
The interface configuration is as follows:
A B C E F G H I K 7DE
Keyboard Wet part Paper transport Densitometer Line printer Modem Aux. 1 Aux., CRT Backprinter
19200 bps 19200 bps 19200 bps 1200 bps 9600 bps 2400 bps 19200 bps 9600 bps 1200 bps
RS232 mode (+12V, -12V) special mode (isolated by opto-isolator) special mode (0, +5V, inverted signals) RS232 mode (+5V TTL) for external communication RS232 mode (+12V, -12V) for ext. communication RS232 mode (+12V, -12V) for ext. communication RS232 mode (+12V, -12V) for ext. communication RS232 mode (+12V, -12V) for ext. communication special mode (0, +5V, inverted signals)
,QWHUIDFH FRQILJXUDWLRQ
124
Service Manual
Printer electronics
The data format is as follows:
q 98.22.56 Edition 3 q q
8 data bits per character 1 stop bit even parity
3DUDOOHO LQWHUIDFH
This functional unit allows the integration of peripheral sensors and drivers. It provides 36 inputs and 32 outputs. 16 inputs are latched and from there 8 latched outputs are led to the INT3 and two are led to the INT1. The inputs and outputs are TTL compatible. All inputs are provided with a RC filter and a pull-up resistor.
(3/'
All inputs use a programmable EPLD (type 5C180) which allows the integration of the interrupt logic including all FF and OR connectivity. 24 outputs are latched (3 latches of 8 bits), the remaining outputs are part of the EPLD
$' ,QWHUIDFH
The analog - to - digital interface serves as connection between the analog data of the measuring system, the film deck and the paper deck on one side and the digital data processing of the 80186 CPU on the other side. All elements of the measuring system are supplied with electrically isolated voltages generated on the CPU board.
saml06005a
1 Uref (on board)
CPU A/D Converter
1 S/H
1 prog. Gain
1 MUX
12
12 12 integrators
Master Lab / Master Lab+
Control
)LJ
%ORFN GLDJUDP RI $' LQWHUIDFH
The A/D interface provides 20 analog inputs. To reduce noise, the 12 signals from the photo diodes of the scan array and the paper deck are integrated internally. The remaining 8 inputs are measured directly. There is an additional input for the internal reference voltage. A control logic switches through the channels. It controls the read/conversion mode of the A/D converter and the integrators.
Service Manual
125
Printer electronics
0HPRU\ FDUG LQWHUIDFH
The bus interface is used to integrate a memory card into the system by connecting it to the microprocessor bus. The maximum addressable storing capacity is 32 Kilobytes. 1RWH 8S WR VRIWZDUH YHUVLRQ D NLORE\WH PHPRU\ FDUG LV XVHG 8S IURP VRIWZDUH YHUVLRQ D NLORE\WH PHPRU\ FDUG LV XVHG
*HQHUDO SXUSRVH LQSXW SRUW
The general purpose input port provides 8 inputs. These inputs are: o DIP switches (2 - 6) o RAM/ROM select of external memory card o Check of external memory card (low = connected) o Battery check (high = battery discharged)
*HQHUDO SXUSRVH RXWSXW SRUW
The general purpose output port provides 8 outputs used for general system functions on the board.
&ORFN
The clock is not implemented because the clock of the wet part is used as system clock.
3RZHU FRQVXPSWLRQ
Voltage Power consumption (measured values) +5V 1.6A +12V 80mA -12V 80mA
126
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Printer electronics
,QGLFDWRUV RQ WKH &38 ERDUG
saml06006a
98.22.56 Edition 3
,% ,# ,$
, &
)LJ
,QGLFDWRUV RQ WKH &38
LED D5 D6 D7
When ON Board receives -12Vdc power Board receives +12Vdc power Board receives + 5Vdc power
The LED 18 on the CPU displays three conditions recognizable by the blinking rhythm illustrated below.
saml06007a
on
CPU ok
off
*=JJAHO
3s
8s
6s
approx. 1Hz
on
EPROM defect
off
3s
approx. 1Hz
Master Lab / Master Lab+
on
RAM defect
off
3s
Reset of the CPU
)LJ
3XOVH GLDJUDP RI /(' '
Service Manual
127
Printer electronics
/LVW RI ',3 VZLWFKHV DQG MXPSHUV 6RIWZDUH YHUVLRQ EHORZ
',3 VZLWFK 'HIDXOW VHWWLQJ 6 SW1 SW2 SW3 SW4 SW5 SW6 SW7 -XPSHU J2 J6 J7 J8 J9 J28 J30 OFF OFF OFF OFF OFF OFF OFF 1-2 2-3 2 - 3, 4 - 5 2 - 3, 4 - 5 X 2-3 open Shows run-time error without shutter/distributor with wet part with lens turret with film processor CPU test off unused BREAK I (NMI) disabled &RGH PHPRU\ 6 x 128 kilobyte (U15, U18) U16, U19 U17, U20 Battery on No reset of CPU 1-2 2 - 3, 4 - 5 X,X 1-2 1-2 1-2
98.22.56 Edition 3 Master Lab / Master Lab+
2SWLRQ ON ON ON ON ON ON ON 2SWLRQ 2-3 NMI enabled &RGH PHPRU\ 2 x 128 kilobyte (U15, U18) 2 x 256 kilobyte (U17, U20) Battery off Reset of CPU For R&D purposes only with shutter/distributor without wet part without lens turret without film processor CPU test on ---
'HIDXOW VHWWLQJ
6RIWZDUH YHUVLRQ DQG KLJKHU
',3 VZLWFK 'HIDXOW VHWWLQJ 6 SW1 SW2 SW3 SW4 SW5 SW6 SW7 -XPSHU J2 J6 J7 J8 J9 J28 J30 OFF OFF OFF OFF OFF OFF OFF 1-2 2-3 2 - 3, 4 - 5 2 - 3, 4 - 5 X 2-3 open unused unused with wet part with lens turret with film processor CPU test off unused BREAK I (NMI) disabled &RGH PHPRU\ 6 x 128 kilobyte (U15, U18) U16, U19 U17, U20 Battery on No reset of CPU 1-2 2 - 3, 4 - 5 X,X 1-2 1-2 1-2
2SWLRQ ON ON ON ON ON ON ON 2SWLRQ 2-3 NMI enabled &RGH PHPRU\ 2 x 128 kilobyte (U15, U18) 2 x 256 kilobyte (U17, U20) Battery off Reset of CPU ----without wet part without lens turret without film processor CPU test on ---
'HIDXOW VHWWLQJ
128
Service Manual
Printer electronics
saml06025a
J18
98.22.56 Edition 3
J14 S178 1 7
32 17 32
J17
J2 1
17
J16
U14 RAM J13
1 16 1
U21 RAM
16
J11
J7 J8 1 1 1 J6 J30 J28 + Battery DC-DC converter J9
1 1 1 J1 8 J25 J27 J24 J26
A / D converter
)LJ
/RFDWLRQ RI MXPSHUV SOXJV DQG ',3VZLWFKHV
Master Lab / Master Lab+
3LQ DVVLJQPHQW RQ SRZHU VXSSO\ SOXJ -
3LQ 'HVLJQDWLRQ 1 2 3 4 5 6 7 8 +12V +5V Code Ground Ground -12V Ground +5V (input) (Input) (Input) (Input) (input) (input) (output to CBO) (output to CBO)
Service Manual
129
Printer electronics
&RQWURO %RDUG &%2 DQG &%2 2YHUYLHZ &%2
The control board contains the stepper motor drivers and the control for the solenoids of the Printer.The stepper motor drivers are either triggered directly by the CPU or via two slave processors located on the Control Board called slave C and D. The control board also processes the signals received from the sensors (light barriers or Hall elements) that monitor the functions of the Printer. Slave C is a microcontroller 8031 (U6) with its EPROM 27128 (U4). It controls in particular the paper transport which includes: o paper deck o zoom drive o paper extractor
saml06008a
Test connector
internal tests
J403
D20
J416
U13
U11
U4
Slave D Filterwheel
Slave C Papertransp.
for
J417
U6
Paper extractor
Paper deck
Filterwheel
Filmdeck
)LJ
&%2
J411
Zoom
U15
U14
U7
U8
U9
Slave C also controls the slave E, located in the distributor with its own microcontroller and EPROM. The slave D controls the filter wheel. It has the same microcontroller (U13) and EPROM (11) as the slave C. As of software version 1.30 a Counter CBO board is installed on connector J411 in series with the print counter. This board suppresses the single count signal for the print counter when the Master Lab+ is switched on.
130
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Printer electronics
2YHUYLHZ &%2
The CBO2 is an updated design of the CBO. It contains the same functions as the former CBO; drivers for the stepper motors and the controls for the solenoids. The print counter is now connected directly to J411 and no longer via an additional circuit board.
saml06009a
98.22.56 Edition 3
Filterwheel Film deck
D20 Extractor J417 D9 S4
D11 Paper deck
Zoom
S2
)LJ
&%2
The new CBO2 has improved stepper motor drivers and additional features required for APS film decks. Also new is the connection of the ADM (Automatic Densitometer).
Master Lab / Master Lab+
The test connector J417 is normally used for internal tests. As an exception, it may be used with old cables from the backprinter in the Master Lab.
Service Manual
131
132
Printer electronics
)LJ
&%2
RS 232 >=1 Mem Adr. CPU 8031 SLAVE C Data Int 0 Int 1 Zoom Home & GSD 200 Zoom motor GSD 200 S GSD 200
HW Reset
Reset SLAVE C
+ 45V + 40V + 24V Pwr.Gnd + 5V Log.Gnd L 6508 L 298 Port A Port B Feeder end Port C 8255 PIO PORT clock I set direction
Magazine motor
%ORFN GLDJUDPV
%ORFN GLDJUDP RI &%2
Deck motor Paper width Int 0 >=1 >=1 Int 1 45 V PWM 3524 Vacuum fan ON/OFF Print counter Splice Paper end DC Vacuum fan Print counter >=1 Cassette present Cassette code 0...15 HW Reset Paper width Start Distr. active Busy Error Reset & Distr. connected LED Obj. ON/OFF OB 5 OB 4 OB 3 OB 2 OB 1 Objective changed
Knife motor DC
Feeder motor DC
Feeder Print
Knife right
Knife left
Feeder Printerpos.
Feeder Processorpos.
Hall switches
Distributor
saml06010a
Service Manual
SLAVE E
Master Lab / Master Lab+
98.22.56 Edition 3
Master Lab / Master Lab+
98.22.56 Edition 3
Feeder Printer pos. Feeder Proc. pos.
Paper width
OB 4
OB 5
OB 3
Splice OB 1
OB 2
OB 5
OB 4
OB 3
OB 2
Cassette present
OB 1
distributor
Distr. active Busy Error Reset Distr. conn.
To CPU
HW Reste
Obj changed
Printer electronics
Paper
Start
Paper width
Cassette code
Service Manual
)LJ
&%2
Print counter
Pwr GND
+42V +34V +24V
Vacuum fan
+24V GND
Panorama feeder (Magnet)
Reset from CPU
%ORFN GLDJUDP RI &%2
Control EPROM 8255 Knife motor Control Feeder motor Paper width Feeder end
TxD
Sens ML digit.
Extractor
Paper deck
Feeder
CPU 80C32
Board
Zoom
Control
Knife right
RxD
Knife left
Zoom home
Lens-Sensor Board
Hall switches
Obj changed
saml06011a
133
Printer electronics
saml06012a
Main CPU
Backprinter
Shutter motor
Serial 3 (Reserve)
Shutter closed
Serial 4 (Reserve)
80C188
Serial to Host
DATA
DATA
DATA
Film cleaner
ADDR
ADDR VBatt
CPU
ADDR
Index
UART
Reset DIP-Switch
ADM
DATA
Battery
MLCPU
UART
RxD To CPU 80C32 TxD
Reset
LED array
MOF
EPROM
CPU 80C31
Control
Filterwheel
Light attenuator Home pos. Filterwheel Light shaft code 1 Reset Light shaft code 2
To CPU
Control
Film deck motor
Negative clamp
Film deck
+24V Negative viewer Film notch pos. 2 Film notch pos. 1 Film deck code 1 Film deck code 3 Film deck code 4
)LJ
%ORFN GLDJUDP RI &%2
)XVHV RQ &%2 DQG &%2 )XVHV RQ &%2
The CBO contains no fuses!
134
Service Manual
Master Lab / Master Lab+
Film deck code 2
98.22.56 Edition 3
Shutter open
Shutter board
EPROM
82510
SRAM
Printer electronics
)XVHV RQ WKH &%2
saml06013a
98.22.56 Edition 3
.
.!
)LJ
)XVHV RQ WKH &%2
)XVH F1
9DOXH 'LPHQVLRQ 7\SH >$@ >PP@ 6.3 T 5 x 20
31 11.21.24 +34Vdc
3URWHFWHG SDUWV
Stepper motor paper deck Stepper motor extractor Stepper motor filter wheel
F2 6.3 T 5 x 20 11.21.24 +24Vdc
Master Lab / Master Lab+
Knife motor Feeder motor Panorama feeder motor Light attenuator solenoid Shutter motor Stepper motor film deck Negative clamp Negative viewer lamp Stepper motor zoom Mirror motor (Customizer) Format wheel motor (optical APS)
F3 6.3 T 5 x 20 11.21.24 +42Vdc
Vacuum fan
1) T = surge resisting fuse (slow blow) F = quick acting fuse (fast blow)
Service Manual
135
Printer electronics
,QGLFDWRUV RQ WKH &%2 DQG WKH &%2
&%2
saml06014a
saml06015a
D 20
,
D 11 D9
D20 When ON indicates zoom in home position
D20 D9/1 D9/2 D9/3 D9/4
D9/6
D9/7
D9/8
D9/9 D9/10
When ON indicates zoom in home position Not used Failure RAM-Battery Continuously ON when failure Failure RAM Continuously ON when failure Paper transport Shortly ON during communication ADM Shortly ON during communication Index-Slave Shortly ON during communication CBO-CPU Shortly ON during communication MOF Shortly ON during communication Not used Not used
136
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
&%2
+12V
+24V
+34V +42V
-12V
+ 5V
Printer electronics
98.22.56 Edition 3
.H\ERDUG 2YHUYLHZ
The keyboard is the man-machine interface. It communicates with the main processor via a serial interface. The microprocessor in the keyboard receives the commands for the LCD display and the LEDs. When a key is activated a corresponding key code is sent to the main processor.
saml06016a
POWER
ON
OFF
TIMER
FILM
FORMAT
PAPER
MENU
COMM CHECK
DATA
CORRECTIONS
CLEAR
FIX
SET
DISP
.
ENTER
MAINT
STAT
OPERATION
MAN
AUTO
ORDER
STOP
)LJ
9LHZ RI NH\ERDUG
The keyboard is based on a matrix of 7 columns by 6 rows, with the keys situated at the nodes on the PBA. First, the microprocessor feeds a logical 0 to the first row of the matrix and a logical 1 to all the other lines. Then all columns are read in consecutive order. With the next step, the logical 0 is fed to the second row and so on. If a key is closed, the row and the corresponding column of the node have a logical 0 the corresponding key code is then sent to the main processor.
Master Lab / Master Lab+
6SHFLDO FRQQHFWLRQ RI NH\V
The keys 21!, 2))! and 7,0(5! including their LEDs are connected directly to the wet part and NO electrical connection with the printer part is made.
,03257$17
7KH 0DVWHU /DE FDQQRW EH VZLWFKHG 21 RU 2)) ZLWKRXW WKH NH\ERDUG
6SHFLDO NH\ FRPELQDWLRQ
A reset can be triggered on the main processor with the special key combination )! &/($5!.
Service Manual
137
138
Contrast
Printer electronics
)LJ
Control-Bus
RS232
Buffer
%ORFN GLDJUDP
RXD
TXD
Data-Bus
LCD
4 x 40 Characters
%ORFN GLDJUDP RI WKH NH\ERDUG
Latch
CTS
RTS
Maskprogrammed
Power Control Buzzer
MCB Key - Matrix 1 x 6 + 1 ( Menu Keys )
Key - Matrix 7 x 6 - 1 ( 41 Keys )
Microprocessor
saml06017a
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Printer electronics
/&' GLVSOD\
The LCD displays 4 x 40 characters. It is controlled by a microprocessor via an 8 bit bus. The display supports the whole ASCII character set without control characters. The microprocessor provides additional functions such as absolute cursor addressing, erase, video attributes, cursor blink and beep. There are two types of displays (driver and software):
q q
98.22.56 Edition 3
standard European languages and Russian (Cyrillic) Japanese
P/N 37.05.69 P/N 34.55.31
saml06018a
)LJ
/RFDWLRQ RI GLVSOD\ FRQWUROOHU
,03257$17
7R HQVXUH D FRUUHFW RSHUDWLRQ LW LV DEVROXWHO\ QHFHVVDU\ WR KDYH WKH ULJKW FRPELQDWLRQ RI GLVSOD\ FRQWUROOHU DQG (3520
Master Lab / Master Lab+
&RQWUROOHU QXPEHU HD44780A00 HD44780A02
(3520 YHUVLRQ >8@ 1.02 1.03
Display controller
(3520 >31@ 34.59.07 37.06.48
The following combinations have to be watched:
/DQJXDJH ja en, de, fr and so on ru 'ULYHU 31 34.55.31 37.05.69 37.05.69 (3520 31 34.59.07 34.59.07 37.06.48
1) Language abbreviations according DIN 2335 and ISO 639
Service Manual
139
Printer electronics
/('V
The LEDs assigned to certain keys may be addressed via the serial interface using an ESC commands. Via a latch on the bus, the microprocessor converts the commands to signals triggering the LEDs.
6HULDO LQWHUIDFH
The serial interface allows the connection of external devices to the Master Lab+
saml06019a
Densitometer
Modem
Line printer
Aux. 1
Aux. 2
)LJ
/D\RXW RI VHULDO LQWHUIDFH
Such devices are:
q q q q q
With the exception of the interface for the Densitometer, all interfaces meet the RS232 standard and have a 25 pin Sub-D connector. The Densitometer is connected via a 9 pin Sub-D connector which includes a connection to a current source to recharge the batteries in the Densitometer. The charging circuit is located on the CPU. The data format for serial communication is: o 8 data bits per character o 1 stop bit o even parity.
140
Service Manual
Master Lab / Master Lab+
Densitometer Modem Line printer (for software version below 5.0) Aux. 1 Aux. 2
1200 Baud (TTL-level) 2400 Baud 9600 Baud 9600 Baud 19200 Baud
98.22.56 Edition 3
Printer electronics
98.22.56 Edition 3
0HPRU\ FDUG 2YHUYLHZ
The plug-in CMOS-RAM memory card with integrated lithium battery is used to backup and restore setup data. The required storage capacity of the memory card is 8kilobytes for main software below version 1.30. As from main software version 1.30 and upward the required storage capacity is 32kilobytes. The memory card is equipped with a switch to protect data from being overwritten (write protect switch). As the card is delivered, the switch is in the QRW SURWHFWHG position.
saml06020a
)LJ
9LHZ RI PHPRU\ FDUG
The memory card stores the machine specific data (based on software version 3.16), i.e.: o all film memories o all paper memories o all format memories o master memory o exposure memory o adjustment value of film position for several film decks o setup values of the wet part o statistics (NOD / MAD) o quality (chemistry) reference and corrections only, no daily data o ADM calibration o backprinter text string o index calibration values
Master Lab / Master Lab+
For further information on handling the memory card, please consult the Operating Manual supplied with every machine.
:$51,1*
'R QRW OHDYH WKH PHPRU\ FDUG LQ WKH PDFKLQH GXULQJ QRUPDO RSHUDWLRQ RWKHUZLVH WKH GDWD PD\ EH RYHUZULWWHQ RU GH VWUR\HG XSRQ D PDFKLQH IDLOXUH 6WRUH WKH PHPRU\ FDUG LQ D VDIH SODFH
Service Manual
141
Printer electronics
5HVWRULQJ GDWD IURP WKH PHPRU\ FDUG
When restoring data from the memory card there are some special behaviors of the software to be known:
5HVWRULQJ D ILOP FKDQQHO
q
When you restore a VLQJOH film channel, the DX-table is 127 restored from the memory card! When you restore all film channels, the DX-table is also read from the memory card.
5HVWRULQJ DOO GDWD
q
When you restore DOO data (using the menu &200! 6<67(0 5( 6725( 35,17(5 $//) the NOD and MAD data are 127 read from the memory card. If you want these data as well, you have to restore them separately with the menu &200! 6<67(0 5(6725( 35,17(5 27+(5 12'0$'.
$GMXVWPHQWV UHSODFHPHQWV $GMXVWPHQWV RQ WKH &38
There is no adjustment required on the Printer CPU.
5HSODFLQJ WKH &38
saml01001a
POWER
ATS
saml05010a
Switch off the machine.
Remove the cover of the electronics Disconnect all the cables from the CPU. Remove all screws holding the CPU and remove the PBA.
142
Service Manual
Master Lab / Master Lab+
If not already done, make a backup of all machine data on a memory card.
98.22.56 Edition 3
Printer electronics
Remove all the EPROMS containing software from the old CPU and insert them at the same places on the new CPU board. After replacement, proceed in reverse order. Set the battery jumper on the new board to ON. Restore the previously written backup of the machine data.
98.22.56 Edition 3
5HSODFLQJ WKH EDFNXS EDWWHU\ RQ WKH &38
To replace the battery on the CPU proceed as follows: If not already done, make a backup of the data. Switch off the machine and open the cover of the electronics as described in chapter 6.9.2 Set the jumper J28 to OFF
saml06021a
Desolder the battery Solder the new battery. :DWFK WKH SRODULW\
+ J28 ON/OFF + Battery -
1RWH
&$87,21
,I D EDWWHU\ KDV WR EH UHSODFHG GRQW WKURZ WKHP LQWR WKH ZDVWHSDSHU EDVNHW RU GXVW ELQ %H DZDUH WKDW \RX GLVSRVH WKH EDWWHU\ VWULFWO\ LQ DFFRUGDQFH ZLWK WKH ORFDO UHJXODWLRQ IRU WKH SURWHFWLRQ RI WKH HQYLURQPHQW 7KH\ KDYH WR EH WUHDWHG DV VSHFLDO UHIXVH
Master Lab / Master Lab+
Set the jumper again to ON. Switch on the machine Restore the previously written backup with the machine data from the memory card to the printer as described in chapter 6.8.2
&OHDULQJ WKH 5$0V
Before upgrading software or after replacing the backup battery it is necessary to bring the RAMs on the CPU into a defined status, i.e. all RAM locations are in the same logical 1 status. An undefined status could cause start-up problems due to wrong parameters in the RAMs.
Service Manual
143
Printer electronics
The procedure is as follows: Save your data onto the memory card. First switch OFF the machine at the keyboard followed by the main switch. Open the cover of the electronic rack as described in chapter 6.9.2 On the CPU board, remove the inserted EPROMs U15 to U20. 8VH RQO\ GHGLFDWHG WRROV WR KDQGOH WKH (3520V DQG WDNH VSHFLDO FDUH QRW GHVWUR\LQJ WKH OD\HU EHWZHHQ ,& VRFNHW DQG FLUFXLW ERDUG
1RWH
Insert the four EPROMs delivered in the kit. Ensure that the jumper J28 for the battery on the CPU board is set to ON. Switch ON the machine.
saml06026a
Watch indicator D18 on the CPU board. It has to blink at a frequency of 1Hz for about 17 seconds indicating the boot status.
After the boot sequence the indicator D18 stays ON for several seconds indicating the running RAM clearer program writing FF (Hex) to each address of the memory. A following unstable blinking sequence indicates a successful finish of the program.
saml06027a
$GMXVWLQJ WKH &%2 &%2
There are no adjustment, neither on the CBO nor on the CBO2.
5HSODFLQJ WKH &%2 &%2
First switch OFF the machine at the keyboard followed by the main switch
144
Start
Memory will be cleared and tested
Blinking indicates a properly cleaned memory
Service Manual
Master Lab / Master Lab+
End
98.22.56 Edition 3
A RAM clear kit V1.00 (P/N 37.63.25) is available to bring the RAMs into a defined status. This kit contains a description about the procedure and 4 EPROMS: o RAM clearer Version 1.00 CPU U15 P/N 37.63.26 o RAM clearer Version 1.00 CPU U17 P/N 37.63.27 o RAM clearer Version 1.00 CPU U18 P/N 37.63.28 o RAM clearer Version 1.00 CPU U20 P/N 37.63.29
Printer electronics
Open the cover of the electronics as described in chapter 6.9.2
saml05011a
98.22.56 Edition 3
Turn both screws holding the electronic board 90o counterclockwise and tilt the board down. Disconnect all cables from the CBO respectively CBO2. Remove all screws holding the board and remove the board. Remove all the EPROMS containing software from the old board and insert them at the same places on the new board.
Reassemble in reverse order
&RQWUDVW DGMXVWPHQW IRU WKH /&'
saml06022a
Contrast potmeter
POWER
ON TIMER OFF
Above the 2))! key in the upper right corner is a recessed potentiometer. Take a screw driver #1 and adjust the contrast.
5HSODFLQJ WKH EDFNXS EDWWHU\ LQ WKH PHPRU\ FDUG
:$51,1*
Master Lab / Master Lab+
1HYHU UHPRYH WKH EDWWHU\ IURP WKH PHPRU\ FDUG LI LW LV QRW SRZHUHG E\ DQ RWKHU VRXUFH <RX ORVH \RXU GDWD 5HSODFH WKH EDWWHU\ DOZD\V ZLWK WKH PHPRU\ FDUG SOXJJHG LQWR WKH PDFKLQH 7KLV HQVXUHV WKDW WKH FDUG LV XQGHU SRZHU DQG WKH GDWD UHPDLQ VWRUHG
Service Manual
145
Printer electronics
saml06023a
Take out the lithium battery.
&$87,21
,I D EDWWHU\ KDV WR EH UHSODFHG GRQW WKURZ WKHP LQWR WKH ZDVWHSDSHU EDVNHW RU GXVW ELQ %H DZDUH WKDW \RX GLVSRVH WKH EDWWHU\ VWULFWO\ LQ DFFRUGDQFH ZLWK WKH ORFDO UHJXODWLRQ IRU WKH SURWHFWLRQ RI WKH HQYLURQPHQW 7KH\ KDYH WR EH WUHDWHG DV VSHFLDO UHIXVH
saml06024a
Confirm the polarity as shown and insert the new battery. Insert the battery cover. Remove the memory card from the machine.
146
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Place your finger on the hook and remove the battery cover.
Printer electronics
6FKHPDWLFV
98.22.56 Edition 3
7LWOH Master Lab+ Overview Functional units on CPU board PBA Main Processor CPU (old type of CPU) PBA Main Processor CPU PBA Main Processor CPU PBA Control Board CBO PBA Control Board 2 CBO2 PBA Control Board 2 (CPU 80C188) PBA Control Board 2 (CPU 80C32) PBA Control Board 2 (CPU 80C31) PBA Counter CBO PBA Counter CBO PBA Keyboard 1 PBA Keyboard 2 Memory card reader cpl. Memory card reader cpl. Memory card reader cpl. PBA Serial Interface SERIN PBA Serial Interface SERIN (old) Gruppo Connectori Accesori (new)
'UDZLQJ
34.58.52 ES 34.58.52 BS 34.74.24 AZ 34.59.83 AZ 34.59.83 AZ 34.59.85 AZ 36.45.20 AZ 36.45.20 BS 36.45.20 BS 36.45.20 BS 36.08.82 ES 34.08.82 AZ 34.75.61 AZ 34.78.25 AZ 34.79.15 ES 34.79.15 AZ 34.79.15 AZ 34.55.44 ES 34.55.44 AZ 14074.227.1
3DJHVVKHHWV
1 to 10 1 1 1 2 1 1 1 2 3 4 1 1 1 1 1 1 2 1 1 only 1
PBA Control Board 2 (reduced layout drawing) 36.45.20 BS
Master Lab / Master Lab+
Service Manual
147
148
98.22.56 Edition 3
Printer electronics
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
2SWLFDO V\VWHP
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ
The optical system of the Master Lab+ includes the lamp house, the light shaft, the measuring optics and the printing optics.
saml07001a
LAMP HOUSE
Exposure lamp 24V/250W IR cut-off Filter Band-pass filter Light attenuator/Testfilter Filterwheel Filter motor Light cone
Light shaft 110, Disc, 126 135, APS, 120
Film deck 110 autom. 135 autom. APS autom. Universal Shutter (in x40 and Index only)
Master Lab / Master Lab+
Lens turret Lock mechanism Lens code reader
Zoom lens motor Zoom lens
Paper deck
)LJ
2SWLFDO V\VWHP
Service Manual
149
Optical system
The negative is measured in the same light path that is used for printing. The advantage of this system is that all parameters affecting the exposure light will be included in the measurement. The printing filters are also used during the measuring cycle. Below the film level, the light path is split into two sections:
q 98.22.56 Edition 3 Master Lab / Master Lab+
The first section with the printing optics is located in the prolongation of the optical axis. It comprises either of a fixed-focus lens or a zoom lens. The printing optics projects the negative onto the paper. The zoom lens has a motor driven adjustment of the magnification. The optical distance between the negative and the print is 800mm (31,5). The second section of the light path makes the light pass through a small gap below the film level where it is deflected horizontally by 90o via a mirror. The light is projected via optics and filters to the photo diodes of the scanner. The mirror and the measuring optics are located in the optic box which has to be exchanged according to the film formats. A filter pack is located in front of the photodiodes of the measuring system (MESY).
All Master Lab+ x40 models and machines with index printer have a shutter located between the film deck and the printing optics. This shutter doesnt affect the light path used for measuring.
/DPS KRXVH
The filter wheel, the light attenuator, the test filter, the pre-filters, the lamp and a fan are located in the lamp house. There are two guiding rails in the lamp house to mount the light shaft. The code of the light shaft is sensed by two light barriers. An additional light barrier is used to detect the home position of the filter wheel. A fan is provided to cool the lamp. In Master Labs this fan is connected in parallel to the lamp where as in the Master Lab+ it is connected fix to 24Vdc. The electrical polarity is correct, if the air is exhausted from the lamp house to the back. The pre-filter closest to the lamp is an IR cutoff filter (heat protection filter), the second filter is a band-pass filter. When mounting the filters, make sure that the surface with the black dot is away from the lamp.The coated side faces the lamp.
saml07002a
Coated area
Black dot
)LJ 9LHZ RI ILOWHU
150
Service Manual
Optical system
)LOWHU ZKHHO
The filter wheel is an aluminum disk divided into six sections. These sections are used for: o three diachroic color filter sections (blue, green and red) o two opaque sections and o a fully transparent section
saml07003a
98.22.56 Edition 3
)LJ
)LOWHU ZKHHO VHFWLRQV
The disk has a home position indicator, sensed by a light barrier. The filter wheel is belt-driven by a stepper motor. The following drive circuits are used: o with the CBO: a GSD-200, controlled by a microprocessor o with the CBO2: a L297 and two L6203 The filter wheel acts as a light valve for the exposure cycle and for the frame scanning. The slave processor is controlled by the CPU and executes the following commands: o accelerate to 10 revolutions per second o rotate at a constant speed (counterclockwise only) during scanning cycle o brake and stop at the home position o reset, initialize and stop at the home position The slave processor is reset either by the hardware during start-up or by a command from the CPU. In either event, the slave processor locates the home position and waits for further commands
Master Lab / Master Lab+
When the motor turns, the slave processor switches the supply from the standby value of 0.4A to 1.8A. After the rotation, the increased current is maintained for 65ms to increase the braking torque on the motor.
Service Manual
151
Optical system
%ORFN GLDJUDP DQG WLPLQJ
saml07004a
SM-D Continuous
SM-D Load J1/P14 SM-D Direction J1/P15 8031 Logic L 297 2x L 6203 SM Filterwheel
Slave-D Busy J1/P44 Reset\ Slave-D J1/P16 Meas. pos. Filterwheel J1/P38
Fork type light barrier
Home pos. Filterwheel J1/P40
The signal Filter wheel measuring position is generated by the slave processor for the three color positions of the filter wheel. The detailed chart is provided in chapter 8.1.4. The following command execution times may be considered: o Reset: min. 34ms to max. 1s o turn: o 60 39.2ms o Cont -> Home: min. 150ms to max. 270ms o 1 turn: 97.4ms, i.e. 10.27 revolutions per second o Min. time interval between two consecutive commands for a 60 turn 40.0ms o Max. exposure time per color:60s o Clock rate of slave:11.529MHz.
/LJKW DWWHQXDWRU WHVWILOWHU
The light attenuator is a rectangular perforated aluminum plate to provide a precise reduction of light. This light attenuator is located in the lamp house above the filter wheel. In the Master Lab+, the light attenuator is the same as in the Master Lab but has an additional testfilter. The attenuator has two positions: o light path position to reduce the amount of light or o home position A solenoid moves the attenuator into the light path whereas a tension spring pulls it back to home after the current for the solenoid is switched off.
152
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
J1/P13
Optical system
/LJKW VKDIW
The light shaft homogeneously distributes the light over the entire negative. Each light shaft has two diffusers, one at the top and one at the bottom. There are three different light shafts available: o one for 110 film and DISC o one for 135 and 126 film o one for 120 film Each light shaft has a code which allows the machine to detect the presence of the shaft at one side and to check for the correct shaft. As seen from the front, the light barrier LC1 is at the left side and the light barrier LC2 is at the right side of the lamp house. This gives the following codes:
98.22.56 Edition 3
/& 0 1 0 1
/& 0 0 1 1
/LJKW VKDIW No light shaft Light shaft for 110 film and DISC Light shaft for 135 and 126 film Light shaft for 120 film
6KXWWHU
Only Master Lab+ X40-models and machines with index printer are equipped with a shutter. The shutter prevents the light from reaching the paper deck during the scanning cycle for the following negative. This is necessary because at the same time the previously exposed paper is transported from the paper deck to the feeder and distributor. A small DC motor with a worm gear drives the shutter blade. Light barriers detect both end positions. The time for opening and closing the shutter is about 200ms. In case of a shutter failure, a time-out is released after 300ms, indicating the error.
Master Lab / Master Lab+
/HQV WXUUHW
2QO\ PXOWLIRUPDW PDFKLQHV KDYH D OHQV WXUUHW The lens turret holds up to four printing lenses. The suitable lens may be brought into position by pressing the unlock button and turning the turret through the opening in the front panel. Each lens has a code which is read by five reflective light barriers. The code is transmitted to the main processor which identifies the lens. Zoom lenses are inserted into the turret from below and fixed with two screws. Fixed-focus lenses are inserted from the top and not fixed with screws.
Service Manual
153
Optical system
The position of the unlock button is monitored by a light barrier. Pressing the button causes an interrupt on the main processor board. This ensures that the lens is locked correctly in position. Machines without a lens turret require a jumper in J413 on the CPU.
saml07005a
J413
Jumper P/N 14.16.71
10
)LJ
-XPSHU LQ - RQ WKH &38
/HQV FRGH
A label with the lens code is glued to the lens barrel. The label is divided into five sections.
saml07006a
OB 1 OB 2 OB 3 OB 4 OB 5
Master Lab / Master Lab+
)LJ
/DEHO GHVLJQ
The white area indicates a logic 1 where as the black area indicates a logic 0. These five sections give a total of 32 possibilities (o ... 31). Due to mechanical reasons the label with code 5 is smaller.
154
Service Manual
98.22.56 Edition 3
Zo
Optical system
saml07007a
Code 2 used for Zoom A Code 3 used for Zoom B Code 20 used for Fix-lens F = 90
98.22.56 Edition 3
)LJ
&RGH H[DPSOHV
The following table gives an overview of the codes used for the various lenses.
2% 2% 2% 2% 2% /HQV FRGH 0 0 0 0 0 0 1 0 0 0 0 1 0 1 0 0 0 2 1 1 0 0 0 3 0 0 1 0 0 4 1 0 1 0 0 5 0 1 1 0 0 6 1 1 1 0 0 7 0 0 0 1 0 8 1 0 0 1 0 9 0 1 0 1 0 10 1 1 0 1 0 11 0 0 1 1 0 12 1 0 1 1 0 13 0 1 1 1 0 14 1 1 1 1 0 15 0 0 0 0 1 16 1 0 0 0 1 17 0 1 0 0 1 18 1 1 0 0 1 19 0 0 1 0 1 20 1 0 1 0 1 21 0 1 1 0 1 22 1 1 1 0 1 23 0 0 0 1 1 24 1 0 0 1 1 25 0 1 0 1 1 26 1 1 0 1 1 27 0 0 1 1 1 28 1 0 1 1 1 29 0 1 1 1 1 30 1 1 1 1 1 31
7DE /HQV FRGH WDEOH
5HPDUNV no lens Large format zoom Zoom A Zoom B Wide range zoom II Index tubus Wide range zoom III CRT optics (ML Digital only!) Fix lens F = 72 Passport 4-UPs (135 film) Wallet 2-UPs Fix lens F = 124 Passport 4-UPs (120 film) Fix lens F = 157 Fix lens F = 123 Fix lens F = 135 Fix lens F = 150 Fix lens F = 145 Fix lens F = 187 Fix lens F = 50.5 Fix lens F = 90 Fix lens F = 121 Fix lens F = 120 Fix lens F = 171 Fix lens F = 162 Fix lens F = 140 Fix lens F = 108 not yet in use! Fix lens F = 172 Fix lens F = 167 Fix lens F = 127 not yet in use!
Master Lab / Master Lab+
Service Manual
155
Optical system
&DOFXODWLRQ RI IRFDO OHQJWK
Use the following formula to calculate the required focal length for a particular magnification:
f=
m A - - - - - - - - - - - - - - - - - - - -2 (m + 1 )
where:
f A m
= = =
focal length in mm distance from film to paper deck in mm (800mm for Master Lab+) magnification (print length / negative length)
Example:
Print size Negative size Magnification Focal length As read from the table
8 x 12 60mm x 70mm m = 305mm / 69mm = 4.42 f = 800mm x (4.42 / 5.422) = 120.37 f = 120, a fix-lens with code 22
The dioptric, an optical correction to compensate for the difference between the target and the actual focal length is calculated with the following formula
- - - - - -1 - - - - - -- - - - - - - 1- - - - - - - 1 0 0 0 f t a r g e t f a c t u a l
=RRP GULYH
The zoom is driven by a stepper motor. When turning the lens turret, a pinion catches the crown gear of the zoom. When switching to the zoom, the home position (label) will be located first. Then the stepper motor carries out the number of steps stored in the format memory. The lens turret should not be turned too rapidly in order to prevent excessive wear on the pinion.
156
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Optical system
5HSODFHPHQWV DGMXVWPHQWV 5HSODFLQJ WKH H[SRVXUH ODPS
98.22.56 Edition 3
,03257$17
%HIRUH FKDQJLQJ WKH H[SRVXUH ODPS PDNH VXUH WKH 3ULQWHU LV VZLWFKHG 2)) Open the lamp house cover
:$51,1*
7KH ODPS DQG WKH ODPS VXSSRUW PD\ EH YHU\ KRW 'RQW WRXFK WKH KRW DUHDV /HW LW FRRO RII RWKHUZLVH \RX PD\ EXUQ \RXU ILQJHUV Replace the lamp. Close the lamp house cover Switch ON the machine. Recalibrate the system by performing a printer test (see Operating Manual).
$GMXVWLQJ WKH ODPS YROWDJH
To check and adjust the lamp voltage proceed as described in chapter 5.4.5. After an adjustment of the lamp voltage you have to recalibrate the system by performing a printer test (see Operating Manual).
Master Lab / Master Lab+
$GMXVWLQJ ILOWHU ZKHHO
Switch OFF the machine. Open the lamp house cover.
Service Manual
157
Optical system
saml07008a
tension: 1 kg
Loosen the stepper motor which drives the filter wheel. Hook a spring scale to the motor shaft. Adjust the tension of the belt to 1kg. Tighten the screws of the stepper motor.
98.22.56 Edition 3 Master Lab / Master Lab+
the lamp house cover. Switch ON the machine.
$GMXVWLQJ WKH OHQV WXUUHW
saml07009a
Remove the light shaft.
saml07010a
saml07011a
Remove the film deck.
Remove all lenses.
158
Service Manual
Optical system
saml07012a
A Shielding plate B C
98.22.56 Edition 3
D
Remove the table by loosening the screws ($, %, &, ' and ().
saml07013a
Disconnect cable
G H
Remove the shutter by loosening the screws (), * and +). Disconnect the cable.
saml07014a
From the top, loosen screw (,) in the turret shaft.
saml07015a
Master Lab / Master Lab+
Unhook the tension spring (1) from the light barrier mounting bracket.
Place the centering tool (P/N 95.16.96) in the opening of the base plate and the lens turret. The openings have to match.
Service Manual
159
Optical system
saml07014a
Tighten screw (,) in the turret shaft.
saml07016a
Adjust the latching mechanism by loosening both screws (2) on the zoom drive, below the brass cylinder.
Hookup the tension spring (1). Pullout the unlock button and fasten both screws (2) on the brass cylinder.
Remove the centering tool. Check the snap-in lock at all four lens positions and ensure every time that the centering tool can easily be inserted. Remount the lens or lenses. 1RWH ,I \RXU ]RRP GULYH LV VSULQJ ORDGHG LJQRUH WKH IROORZLQJ DGMXVW PHQW
saml07017a
~ 0.2mm
Master Lab / Master Lab+
Loosen the three screws of the zoom drive. Move the plate until the crown gear of the zoom has a distance of ~0.2mm.
160
Service Manual
98.22.56 Edition 3
Optical system
/HQV FRGH UHDGLQJ
Five infrared reflective light barriers mounted on the PBA LESE are reading the code information of the lens. 1RWH ,Q PDFKLQHV ZLWKRXW D OHQV WXUUHW LQVHUW D MXPSHU LQ - EHWZHHQ SLQ DQG RQ WKH &%2 &%2 ERDUG
98.22.56 Edition 3
To adjust the sensitivity of these sensors proceed as follows:
saml07018a
POT . SENSORS METERS TEST POINTS
GND LS1 LS2 LS3 LS4 LS5
OB1 OB2 OB3 OB4 OB5
On the PBA LESE connect a voltmeter between GND and the test point LS1 to LS5 (depending on the sensor to be tested or adjusted).
J 803
saml07019a
Code label
0.4V
Cover all sensors with the black pattern of the label Adjust the voltage of each sensor to 300mV. Cover all sensors with the white pattern of the label. Check the voltage of each sensor. It should be 3.5V or more.
BLACK: logic 0 =
saml07020a
Code label
3.5V
WHITE: logic 1 =
To verify correct adjustment, insert various lenses and check for correct reading. Select the menu: 0$,17! 35,17(5 27+(5 237,&6 &2'( The screen displays the detected color and the resulting lens code.
Master Lab / Master Lab+
1RWH
7KH IROORZLQJ VFUHHQ GLVSOD\ GRHVQW VKRZ XS LPPHGLDWHO\ 7KH GLVSOD\ KDV D VORZ UHDFWLRQ %H SDWLHQW
MAINT
PRINTER
OTHER
OPTICS
CODE
Lightbar. 0: Black Lightbar. 1: White Lenscode: 02
Lightbar. 2: Black Lightbar. 3: Black Lighrbar. 4: Black
Service Manual
161
Optical system
=RRP OHQV 3UHSDULQJ WKH IRFXV DGMXVWPHQW
,03257$17
0RYH WKH OHQV WXUUHW LQWR WKH SRVLWLRQ IRU WKH SDUWLFXODU ]RRP DQG UHLQL WLDOL]H WKH V\VWHP '217 WXUQ WKH OHQV WXUUHW GXULQJ WKH IROORZLQJ IRFXV SURFHGXUH WR SUH YHQW D UHLQLWLDOL]DWLRQ RI WKH V\VWHP 2WKHUZLVH WKH ]RRP KRPH ZLOO EH LQFRUUHFW Remove the front cover.
saml07021a
Lens turret
X Ring 1
Loosen the three set screws (;) on the head ring (Ring 1) to allow the zoom to be turned for focusing.
There are two ways to adjust the focus: o with grain finder if available or else o without grain finder, by means of a printed focus ring.
$GMXVWLQJ ZLWK JUDLQ ILQGHU
saml07022a
Insert the focus test film (P/N 34.91.51) in the film deck.
Select the menu: &200! 35,17(5 6(7/(16 6(7)2& 7KH FRQILJXUDWLRQ KDV WR FRUUHVSRQG ZLWK WKH IRUPDW Service Manual
1RWH 162
Master Lab / Master Lab+
98.22.56 Edition 3
Optical system
saml07023a
98.22.56 Edition 3
Turn the crown gear of the zoom clockwise to the mechanical endstop (highest magnification).
Crown Gear CW
Place a piece of white photo paper onto the paper deck. Place the grain finder onto the paper. Press the key below 67$57. The negative is now visible on the paper. Adjust the focus by turning the lower part of the zoom while checking the focus with the grain finder.
saml07021a
Lens turret
X Ring 1
Tighten the three set screws (X) without altering the position of the zoom.
Remove the photo paper from the paper deck.
Readjust the home position of the zoom as described in chapter 7.2.7
$GMXVWLQJ ZLWKRXW JUDLQ ILQGHU
Master Lab / Master Lab+
saml07023a
Turn the crown gear of the zoom clockwise to the mechanical endstop (highest magnification).
Crown Gear CW
saml07024a
"
Prepare a piece of adhesive paper tape with 7 marks at about every 2.5cm (1) and number them from 1 to 7.
Service Manual
163
Optical system
saml07025a
Ring 1
1 2 3 4 5 6 7
1RWH
'RQW DOWHU WKH SRVLWLRQ RI WKH ORZHU SDUW RI WKH ]RRP
saml05022a
Insert the focus test film (P/N 34.91.51) in the film deck.
Select the menu: &200! 35,17(5 6(7/(16 6(7)2& Turn the lower part of the zoom to position 1 marked on the tape. Close the front cover. Expose two prints by press the key below 67$57 twice (not too fast!) The first print will be fogged, the second print will be good. Wait at least 20 seconds after the second exposure then open the front cover again.
Turn the lower part of the zoom to the next mark. Repeat step 7 to 10 until all prints are ready for evaluation.
Open the front cover. Evaluate the prints for best focus and set the zoom to the corresponding mark on the tape.
Master Lab / Master Lab+
164
Service Manual
98.22.56 Edition 3
Stick this prepared paper tape carefully to Ring 2 so that the mark 4 is positioned exactly below the screw hole of Ring 1.
Optical system
saml07021a
Lens turret
98.22.56 Edition 3
X Ring 1
Tighten the three set screws on the zoom.
Readjust the home position of the zoom as described in chapter 7.2.7.
6HWWLQJ WKH KRPH SRVLWLRQ
saml07026a
Ring 2
Loosen the set screw in ring 2. Turn the crown gear of the zoom counterclockwise to the mechanical end stop and hold it in this position.
Set screw Crown Gear
CCW
saml07027a
CBO
Filterwheel
Slave D
U15 Filterwheel
U11
U13
J403
Papertransp.
U14 Filmdeck
U4
Slave C
U6 J416
J411
U7 Paper deck
D20
Test connector for internal tests
J417 U8 Paper extractor
Master Lab / Master Lab+
U9 Zoom
CBO2
Filterwheel Film deck
Slowly turn ring 2 counterclockwise until the LED D20 on the CBO/CBO2 lights up
D20
Extractor
D11
J417
Paper deck
D9
S4
Zoom
S2
Service Manual
165
Optical system
saml07028a
Ring 2
CCW
saml07026a
Ring 2 Set screw Crown Gear
Ensure that ring 2 sits properly on the crown gear. Tighten the set screw in ring 2.
CCW
Check the correct adjustments with the menu 0$,17! 35,17(5 27+(5 237,&6 &2'(
MAINT PRINTER OTHER OPTICS CODE Lightbar. 0: Black Lightbar. 1: White Lenscode: 02 Lightbar. 2: Black Lightbar. 3: Black Lighrbar. 4: Black
1RWH
7KH DERYH VKRZQ VFUHHQ GLVSOD\ GRHVQW VKRZ XS LPPHGLDWHO\ 7KH GLVSOD\ KDV D VORZ UHDFWLRQ %H SDWLHQW
)RFXVLQJ D IL[HGIRFXV OHQV
saml07029a
Lens Barrel
Set screw Counter-Ring Lens
Adjust the focus: o with grain finder as described in chapter $'-867,1* :,7+ *5$,1 ),1'(5 o without grain finder as described in chapter $'-867,1* :,7+287 *5$,1
),1'(5
Tighten the counter-ring or the set screw on the lens barrel (depending on the lens) Service Manual
166
Master Lab / Master Lab+
Loosen the counter-ring or the set screw on the lens barrel (depending on the lens).
98.22.56 Edition 3
Now turn ring 2 additionally in counterclockwise direction o 4 teeth with zoom A and B o 3 teeth with a wide range zoom
Optical system
$GMXVWLQJ WKH RSWLFDO D[LV
When ever you adjust the optical axis, it is important to proceed in the following sequence: Adjust the lens turret following the instruction given in chapter 7.2.4. For this purpose the centering tool (P/N 95.16.96) is required. Adjust the paper position mechanically and via the software (see chapter 10.3.11 and 10.3.12) Adjust the film position via the software (see chapter 9.7.2)
98.22.56 Edition 3
$XWRPDWLF 'HQVLWRPHWHU
The Master Lab+ is capable to work with two kinds of Densitometers: o Densitometer D188 / D19C o automatic Densitometer ADM Information about installation, setup, operation and maintenance are given in separate manuals, listed below:
q q
UPKIT Automatic Densitometer (ADM) 34.90.98 BV (see chapter X) Operating Manual SETUP 98.27.52 (German) 98.27.54 (English) 98.27.56 (Italian) 98.27.58 (French) 98.27.60 (Spanish) 98.27.62 (Danish) 98.27.64 (Dutch) 98.27.66 (Portuguese)
Service Manual ADM 98.26.28 (this manual has to be ordered at GRETAG Macbeth)
Master Lab / Master Lab+
Service Manual
167
Optical system
6FKHPDWLFV
PBA Shutter Connector SHUT PBA Shutter Connector SHUT PBA Lens Sensor LESE PBA Lens Sensor LESE
34.55.63 ES 34.55.63 AZ 34.78.91 ES 34.78.91 AZ
1 1 1 1
168
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
7LWOH
'UDZLQJ
3DJHVVKHHWV
98.22.56 Edition 3
0HDVXULQJ V\VWHP
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ
The measuring system is below the film deck. It encompasses mainly three parts: o the optic box o the measuring box o the film positioning and DX-Code detection on the automatic film deck The only electronics in the measuring system are photo diodes with some filters and drivers. The main part of the electronics is in the CPU, starting with the analog-to-digital interface as connection between the analog signals of the measuring system and the digital processing of the CPU. Basically there is a difference between channels whose signals are integrated to reduce noise (scanner) and channels that are measured directly (film position and DX-Code detection).
Master Lab / Master Lab+
Service Manual
169
Measuring system
saml08001a
Lamp Lamp house Prefilter
upper Diffusor Filter Wheel
Light shaft
lower Diffusor Film Photodiode Film deck
Antireflection angle
Optic Box Measuring Filter MESY
Silver Mirror coating
Triplet
MESY Measuring Box thread
Detail A
Detail B
)LJ
2YHUYLHZ RI PHDVXULQJ V\VWHP
2SWLF ER[
The optic box is part of the film deck and projects the different film formats to the measuring system (MESY). There are 3 different optic boxes. For the universal film deck they are interchangeable but in the automatic film decks they are permanently attached.
170
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Light attenuator/Testfilter
Measuring system
saml08002a
98.22.56 Edition 3
Optic box 110
Optic box 120
Optic box 135
)LJ
7\SH RI RSWLF ER[HV
The lens in the optic box is mounted in such a way, that the threaded ring faces the scanning diodes (see Detail B in Fig 8-1). The mirror is mounted with the coated surface facing the light path (see Detail A Fig 8-1). 1RWH 7KH PLUURU LV LQVHUWHG ZURQJ LI WKH OLJKW KDV WR SDVV WKH JODVV ILUVW EHIRUH LW LV GHIOHFWHG
The optic box contains a fibre optic to measure the blue, green and red light directly from the light source through the filters of the filter wheel.
saml08003a
Master Lab / Master Lab+
Triplet Mirror Fiber optic
)LJ
2SHQ RSWLF ER[ YLHZHG IURP WKH ERWWRP
Service Manual
171
Measuring system
0HDVXULQJ ER[ ZLWK PHDVXULQJ ERDUG VFDQQHU
Scanning pattern for all film formats: Optic box & Format light shaft Width Length (mm) (mm) 48 96 48 120 120 120 96 48 120 100 96 48 120 80 80 100 120 135 135 135 110 135 135 135 110 110 135 135 135 110 120 120 120 120 12 24 24 12.9 15.6 15.6 9.6 8.25 12.9 28.1 24 24 18 56 41.5 56 56 36 36 18 17.0 22.3 27.4 27.4 10.6 17.0 28.8 36 18 24 41.5 56 56 72
98.22.56 Edition 3 Master Lab / Master Lab+
Scanning grid Film decks Diodes y Diodes x PPL1) LPP2) Automatic types Panorama 135 auto Full frame Half frame 110 auto Classic APS HTV Panorama Universal type Disc 110 126 135 135HF3) 135HF Q4) 120 (4.5 x 6) 120 (4.5x6Q)5) 120 (6 x 6) 120 (6 x 7)
1) PPl = Pixels per line 2) LPP = Lines per picture 3) HF = Half frame 4) HF Q = Half frame across 5) Q = across
4 8 8 10 10 10 8 6 10 10 8 8 10 10 8 10 10
12 12 6 12 12 12 12 8 12 10 12 6 12 8 10 10 12
)LOP SRVLWLRQLQJ DQG ';&RGH GHWHFWLRQ
The sensor assembly for film positioning and DX-Code detection is described in detail in chapter 9.4
6FDQQLQJ
Upon scanning, the main processor starts the filter wheel and waits for the home signal sent by the light barrier of the filter wheel. This signal triggers three signals issued by the software from the slave (filter wheel) corresponding to the three colors blue, green and red. As soon as the maximum light intensity of the respective color has been reached, the corresponding signal changes to active (low). At this time the filter fully covers the light path. Based on this signal, the
172
Service Manual
Measuring system
hardware starts integrating the signal for an average time of about 3.8ms. After this time, the integrator changes to the hold state, using the positive slope causing an interrupt on the main processor. The main processor now sequentially reads the values stored in the integrators and converts them to digital data.
98.22.56 Edition 3
After this procedure has been carried out for a particular scan line (4 to 10 diodes, depending on the format) the main processor transports the film to the next position while the filter wheel finishes the current turn. The described procedure is repeated until all lines (4 to 12, depending on the format) have been measured.
saml08004a
J1/P40 Homepos IN16
J14/P40 IN16 10 EPLD U49
CPU-Board
J4/ P9 6
SlaveD 8031 U13
Meas. 10 pos. IN14 J1/P38 IN14 J40/ P38 12 63
GLS HomeFilterwheel pos.
Control board
1 > 1 2 U82 3 10 9 > 1 8 INT1 U82 6 1 5 Reset, Start Integrators U1 23 TMR01 uP 80186 U107
44
)LJ
'HWHFWLRQ RI ILOWHU ZKHHO URWDWLRQ
Master Lab / Master Lab+
Service Manual
173
Measuring system
saml08005a
Logic J24 Processor 11x
11x
Scandiodes MESY Photodiode
*1 Buffer Amp U/I-Con.
Integrator Multiplexer J25 25 : 1 To ADC
3x
DX and PosDiodes FIDE Photodiode
I/U-Conv.
*1 Buffer Amp J24
Temperature Scanarray
C Temp.Sensor
*1 Buffer Amp.
Reserve N.C.
CPU
)LJ
%ORFN GLDJUDP RI VHQVRU GHWHFWLRQ
saml08006a
D0 - D10 D12- D14 D 15 State AD DX and Pos.-Diodes, Temperatures, Uref, Reserved Inputs Mode -20 dB Dek 20- 2 7 -1 S/H Mux PhotoDiodes
1-12
A D
D0- D11
- Uedt
Data exchange channel selection CS, CE, R/C Reset, Start
Control logic
System clock from CPU
Control logic
WR RD
AD +5V AD GND
DC DC
INT1 to CPU, Read measuring values Start of measuring SlaveD, Filter wheel
+ 15V + 5V - 10V - 15V AGND
A1 A2 A3 A4 PCS2
)LJ
3ULQFLSOH RI $' FRQYHUVLRQ
The following timing diagram of a scanning cycle shows two full turns of the filter wheel, respectively 1 line of 11 diodes.
174
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
I/U-Conv.
Measuring system
saml08007a
Start Scanning
Home
Home
5.32msec
Filter wheel home signal
97.2msec 102.6msec
98.22.56 Edition 3
13.56ms 21.65ms
Measuring position of filter wheel
29.75ms 37.85ms
45.95ms 53.05ms
Light intensity, e.g. illumination measuring
D 2
D 1
D 2
Integrator gate, e.g. U58/P11
1 = Hold or Sample 0 = Reset
Average time
3.85ms 3.85ms 3.85ms
Integrator hold, e.g. U58/P6
1 = Hold 0 = Sample or Reset
ca.250nsec
Select channel resp. gain U67, U68/P11
1 = Convert
ca.30usec
Status ADC resp. S/H
resp. Hold 0 = Read resp. Sample
)LJ
7LPLQJ IRU VFDQQLQJ F\FOH
0HDVXULQJ ERDUG 0(6<
The measuring board contains 11 photodiodes forming a linear array. Each photodiode has its current / voltage converter with integrated low-pass filter followed by an additional unipolar low-pass filter. The total response time of the resulting bipolar filter is approximately 200us. Each channel has an amplifier driving the line at low impedance. A temperature sensor (Q1) on the board is used for temperature compensation. The cable connecting the MESY and the A/D interface uses transposed wires (pin1 of the MESY is connected to pin 16 on the A/D interface)
Master Lab / Master Lab+
5HSODFLQJ WKH PHDVXULQJ V\VWHP
saml07009a
Remove the light shaft.
Service Manual
175
Measuring system
saml07010a
Remove the film deck.
saml08008a
)
Loosen screws $ and % .
*
saml08009a
1 Battery J28 J26 + 1 J30 1 J6
DC-DC converter
A / D converter J9 J8
On the CPU, disconnect the cable from connector J24.
disconnect J24
J24
J27
J25 8
J1 1
saml08010a
Scanner box
Remove the cable clamp and pull the cable through the cable passage. Pull out the measuring box including the cable.
Master Lab / Master Lab+
Distributor
Cable clamp Cable passage
Cable Paperdeck
After replacement, reassemble in reverse order.
176
Service Manual
98.22.56 Edition 3
Measuring system
&KHFNLQJ WKH PHDVXULQJ V\VWHP
Ensure that the automatic 135 film deck and the 135 light shaft is installed. If not, install them. Initialize the system Select the menu: 0$,17! 35,17(5 0($66<6 6&$1/,1
<MAINT> PRINTER MEASSYS SCANLIN Press <START>, to scan one line of Neg.. Read results on next screen START [ 1] GAIN
98.22.56 Edition 3
Make sure the gain is set to 1 then press the key just below 67$57 without a film in the film deck.
<MAINT> PRINTER Blue A/D-Raw Offset 1500 820 MEASSYS Green 1500 820 SCANLIN Red 1500 820 Gain 0 Diode 1 NEXT
To check the other diodes press the key just below 1(;7.
The gain can be set to 1, 2, 4, 8, 16, 32, 64 and 128. With the gain set to 1 you should get the following results:
ILOP
Conditions: o automatic 135 film deck inserted o No film in the film deck o Gain set to 1. 7\SLFDO A/D-Raw (1000 to 2000) Offset +/- 100 A/D-Raw - Offset ALARM -> A/D-Raw - Offset ' %*5 not used not used not used ' WR ' ' %*5 not used not used not used ' OLJKW YDOXH 5*% 1100 800 ~300 < 16
Master Lab / Master Lab+
%*5 1500 800 ~700 < 43 A/D-Raw < 4095
ILOP
Conditions: o Universal 120 film deck inserted o No film in the film deck o Gain set to 1.
Service Manual
177
Measuring system
7\SLFDO A/D-Raw (1000 to 2000) Offset +/- 100 A/D-Raw - Offset ALARM -> A/D-Raw - Offset
' %*5 1500 800 ~700
' WR '
' %*5 1500 800 ~700
' OLJKW YDOXH
98.22.56 Edition 3 Master Lab / Master Lab+
%*5 1500 800 ~700 < 43 A/D-Raw < 4095
5*% 1100 800 ~300 < 16
Optic box
fiberoptics (lightvalue)
Measuring box
Diodes
11 Light value 1 2 3
saml08011a
135 film
4 5 6 7 8 9 10
)LJ
'LDJUDP RI PHDVXULQJ V\VWHP
6FDQQHU FDOLEUDWLRQ IRU VWDWXV 0
,03257$17
7KH IROORZLQJ FDOLEUDWLRQ SURFHGXUH UHIHUV WR VRIWZDUH 4 RU 45YHUVLRQ RQO\ 0DVWHU /DE DQG 0DVWHU /DE ZLWKRXW $'0 In older Master Labs the following calibration procedure is used when the customer uses the scanner to measure the control strips for the film processor. The calibration adapts the measured values of the scanner to those of a transmission densitometer with status M-filters. The Master Lab calculates the correction coefficients from the difference between the measured values and the aim values. These coefficients are then automatically applied, whenever a reference strip or a control strip is measured.
6SHFLDO WRROV UHTXLUHG
q
Calibration strip P/N 36.17.68 (a strip similar to the control strip for the film processor).
178
120 film
Service Manual
Measuring system
The aim values (label with values should be on every calibration strip).
98.22.56 Edition 3
3URFHGXUH
Select the menu 0$,17! 35,17(5 0($6<6 7&$/,% $872
<MAINT> PRINTER MEASYS T_CALIB AUTO Insert Film and press <ENTER> to start
Insert the calibration strip into the film deck. Position the first measuring field in the viewing window. Start the measuring cycle wit (17(5!. Select the menu: 0$,17! 35,17(5 0($6<6 7&$/,%. Press the key just below the word $,0.
<MAINT> Y (B) [0.00] RED GREEN BLUE PRINTER MEASYS T_CALIB AIM
Enter the provided aim values in the following sequence: 1. Screen: 2. Screen: 3. Screen: 4. Screen: Y (B) Dmax (R/G/B) LD (R/G/B) press (17(5! to save data.
Master Lab / Master Lab+
In case the following event message appears, proceed as advised in the event message. M19 Scanner wrong calibrated There are no reasonable values from the calibration strip available (measured values or aim values) Repeat the calibration procedure for the scanner.
Code: Text: Cause: Remedy:
Service Manual
179
Measuring system
6HWWLQJ WKH WHPSHUDWXUH FRPSHQVDWLRQ 5HDVRQ
For Master Lab+ working under extreme temperature conditions it may be, that production changes during the day. The changes may be visible in color or density shifts. The reason is the temperature drift between morning and evening in the measuring system, influenced by the ambient room temperature. If such a problem is encountered, temperature compensation factors can be established.
3URFHGXUH
Perform a Printer Test in the morning and measure it until it has the values 0.80 / 0.80 / 0.80. In the morning select the menu: 0$,17! 35,17(5 0($6<6 6(16 Write down the actual displayed temperature from the measuring box. For example: <HOORZ 0.80 0DJHQWD 0.80 &\DQ 0.80 7HPSHUDWXUH 20oC
Morning Evening Difference
Perform a Printer Test in the evening and measure it with a densitometer. 'RQW XVH WKH (9$/ WR VWRUH WKH YDOXHV
1RWH
Select the menu: 0$,17! 35,17(5 0($6<6 6(16. Write down the actual displayed temperature from the measuring box. For example:
Master Lab / Master Lab+
Morning Evening Difference
<HOORZ 0.80 0.95
0DJHQWD 0.80 0.87
&\DQ 0.80 0.74
7HPSHUDWXUH 20oC 31oC
Calculate the difference.
Morning Evening Difference
<HOORZ 0.80 0.95 +0.15
0DJHQWD 0.80 0.87 +0.07
&\DQ 0.80 0.74 -0.06
7HPSHUDWXUH 20oC 30oC 10oC
180
Service Manual
98.22.56 Edition 3
Measuring system
To calculate the temperature compensation values use the formula:
a lu e =
V 98.22.56 Edition 3
C o l o r ( 1 0 ) -------------------------------------T e m p e r a t u r e
Regarding the values in our example: e.g. for Yellow = (0.95 - 0.80) x (-10) / 10oC = -0.15 Select the menu 0$,17! 35,17(5 (;36<6 7(03&25
Enter the calculated value for the corresponding color. As the example shows, you would have to enter: Yellow: -0.15, Magenta: -0.07, Cyan: +0.06 1RWH 8VH WKHVH SDUDPHWHUV RQO\ IRU ORQJ WHUP GULIWV RYHU D GD\ 2QO\ YDOXHV LQ WKH UDQJH IURP WR FDQ EH HQWHUHG
6FKHPDWLFV
7LWOH PBA Measuring System MESY PBA Measuring System MESY
'UDZLQJ
34.75.70 ES 34.75.70 AZ
3DJHVVKHHWV
1 1
Master Lab / Master Lab+
Service Manual
181
182
98.22.56 Edition 3
Measuring system
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
)LOP SDWK
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ
The film path mechanism basically encompasses of four different film decks:
o o
Automatic film deck 135 Automatic film deck APS This film deck is not covered in this manual. Please refer to: Service Manual Addendum APS P/N 98.27.42 for optical Indexprinter Service Manual Customizer P/N 98.29.02 for digital Indexprinter Automatic film deck 110 Universal film deck
o o
Each film deck includes at least the following assemblies and positions:
o o o o o Master Lab / Master Lab+
Drive Positioning diodes Viewing position Scanning position Exposure position
'ULYH
The drive, a stepper motor (400 half steps) is controlled by the main processor. The driver for the motor is located on the control board (CBO / CBO2). Three transport rollers drive the film on an automatic film deck. On the universal film deck, the negative is placed in a film carrier which is then moved by a stepper motor.
Service Manual
183
Film path
3RVLWLRQLQJ GLRGHV
These diodes are used to determine the frame position and to detect the DXCode information.
9LHZLQJ SRVLWLRQ
The viewing position provides an illuminated viewing window. Once a frame is positioned the viewing window, the operator may check the negative visually.
6FDQQLQJ SRVLWLRQ
Every frame entering the measuring position is scanned line-by-line using the exposure lamp and the filter wheel as a scanning filter. The scanning system is synchronized with the rotating filter wheel. The measured values are used to calculate the exposure times of every color for each single negative.
([SRVXUH SRVLWLRQ
The frame is positioned in the optical axes which also includes the lens, the exposure lamp, the filters of the filter wheel and the paper. In this position the frame is exposed. The exact position is either determined by photo diodes or by micro-switches depending on the film format.
)LOP GHFN FRGLQJ
Each film deck as a code. This allows the electronic to detect which film deck is installed and to configure certain variables accordingly. The code is made with either plugged or soldered jumpers on the electronic board in the film deck.
saml09003a
J609 J603 J604
1 1 0
)LJ
),'( ZLWK ILOP GHFN FRGH IRU ILOP
184
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Film path
saml09004a
FDECKCODE
98.22.56 Edition 3
Normal
1
FUJI 1 0
J15
)LJ
),'( ZLWK ILOP GHFN FRGH IRU )XMLILOP
saml09001a
J612 J613 J614
1 0 0
)LJ
),'( ZLWK ILOP GHFN FRGH IRU XQLYHUVDO ILOP GHFN
saml09002a
J612 J613 J614
1 0 1
)LJ
),'( ZLWK ILOP GHFN FRGH IRU ILOP
Master Lab / Master Lab+
Service Manual
185
Film path
%ORFN GLDJUDPV RI ILOP GHFNV $XWRPDWLF ILOP GHFN
saml09005a
- Power supply - Steppermotor J 601A - Digital signals J 409
CBO
Analog signals: - Positioning diodes J 602 - DX-diodes J 25 A/D - Interface
Power source for LED's
CPU
Amplifiers for photodiodes
J 655
J 605
6 Photodiodes FIPOR
5 LED's
FIPOT
Receiver
Transmitter
Coding (3)
LSB BC 1
J 609
J 606
2 Viewing lamps FIVI 135
J 607
BC 2
J 603
Pressure solenoid
MSB BC 3
1 0
J 604 J 608
Steppermotor
FIDE 135
186
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Film path
$XWRPDWLF ILOP GHFN IRU )XML FRGH
saml09008a
- Power supply
98.22.56 Edition 3
- Steppermotor - Digital signals J 409 J 2
CBO
Analog signals: - Positioning diodes - DX-diodes J 1 J 25 A/D - Interface
Power source for LED's
CPU
Amplifiers for photodiodes
7 PhotoJ 8 J 9 diodes FIPOR
6 LED's
FIPOT
J 15
Receiver
Transmitter
Normal 135
Fuji code
1 0
J 14
2 Viewing lamps FIVI 135
J 5
Pressure solenoid
J 4
Steppermotor
FIDE 135/2
Master Lab / Master Lab+
Service Manual
187
Film path
$XWRPDWLF ILOP GHFN
saml09006a
CBO
J 616
Positioning switch
J 618
Positioning switch
Coding (5) LSB BC 1 J 612 J 621 1 Viewing lamp
FIVI 110
J 620
BC 2
J 613
Pressure solenoid
MSB BC 3
1 0
J 614 J 624 Steppermotor
FIDE 110/U
188
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
J 601B
- Power supply - Steppermotor - Digital signals J 409
Film path
8QLYHUVDO ILOP GHFN
saml09007a
98.22.56 Edition 3
J 601B
- Power supply - Steppermotor - Digital signals J 409
CBO
J 615
Lightbarrier home position
Coding (1) J 621 LSB BC 1 J 612
5 Viewing lamps 1 Hall sensor FIVI UNI
BC 2
J 613
MSB BC 3
1 0
J 614 J 625 Steppermotor
FIDE 110/U
Master Lab / Master Lab+
Service Manual
189
Film path
7KH DXWRPDWLF ILOP GHFNV ILOP GHFN
The automatic 135 film deck uses sensors to position the film. The film deck handles 135 full frame as well as 135 half-frame negatives. The minimal film strip length these film decks can handle are three full frame negatives.
saml09009a
SM
Filmtransport
Transport roller
Transport roller
Exposure station
Measuring position
Viewing position
)LJ
'LIIHUHQW SRVLWLRQV DORQJ WKH ILOP SDWK LQ WKH ILOP GHFN
The positioning diodes measure the density of the film. They provide the information to determine the frame position by the software. These diodes also read the DX-Code (film type and frame numbers according to Kodak Standard). The assembly includes a transmitter, a receiver and a diaphragm. The diaphragm has an aperture to detect the frame position and two small pin size apertures to read the DATA- and CLOCK-track of the DX-Code.On the transmitter are 5 LEDs used to illuminate the film with a spectral wavelength of 660nm. The receiver has four photo diodes to detect the right frame position and a double photo diode to read the DX-Code. The analog signals from the photo diodes are fed to the A/D converter on the CPU and then evaluated by the software.
Front view Power source
DX/Positioning diodes
Transport roller
SM
LED's
Film
Filmtransport
Diaphragm
Photodiodes
Amplifier
DA A track (DX-Code) T CLOCK track (DX-Code)
)LJ
';&RGH GHWHFWLRQ
190
Service Manual
Master Lab / Master Lab+
saml09010a
98.22.56 Edition 3
Film path
ILOP GHFN
The automatic film deck 110 uses two microswitches to position the film. It only handles 110 frames. Two microswitches detect the notch provided on the 110films and positions for the viewing position with the first and for the exposure with the second microswitch. The minimal film strip length these film deck can handle are four negatives.
saml09011a
SM Filmtransport
98.22.56 Edition 3
Exposure station
Transport roller
Transport roller
exposure position
Measuring position
Viewing position
)LJ
'LIIHUHQW SRVLWLRQV DORQJ WKH ILOP SDWK LQ WKH ILOP GHFN
7KH XQLYHUVDO ILOP GHFN *HQHUDO
The universal film deck (also called manual film deck) requires manual feed of the film. Different inserts can be attached to the sledge which is driven by a stepper motor. The stepper motor is then used to transport the film from the viewing position to the exposure position. The available inserts make it possible to handle different film formats. The home position of the sledge (= viewing position) is controlled by a light barrier.
saml09014a
Microswitch
SM
Master Lab / Master Lab+
Sledge Filmtransport
Insert Filmmask 6x6
Flap
)LJ
9LHZ RI WKH XQLYHUVDO ILOP GHFN
Service Manual
viewing position
Microswitch
Transport roller
191
Film path
,QVHUWV FRGLQJ
For each film format there is a specific insert coded by 5 magnets. A Hall sensor reads the code by moving the sledge from the viewing position to the exposure position during initialization. Depending on the insert, it also checks for the corresponding optical box and the correct light shaft. For the transport to the exposure position the film is fixed with a flap.
saml09015a
(MSB) 16
1 (LSB)
6 x 6
Top view
)LJ
9LHZ RI LQVHUWV ZLWK FRGLQJ SRVLWLRQV
The following table shows the different codes for the various inserts:
1R
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
06%
01) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1
0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
0 0 12) 1 0 0 1 1 0 0 1 1 0 0 1 1
/6%
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
,QVHUW )LOP VL]H
no insert 120 (4.5 x 6Q) 120 (4.5 x 6Q+) 110 126 135 FF (24 x 36) 135 HF (18 x 24) 120 (4.5 x 6) 120 (6 x 6) reserved reserved 120 (6 x 7.2) reserved reserved reserved Disc reserved
2SWLFDO ER[ /LJKW VKDIW
--120 110 126 135 135 120 120 ----120 ------110 --Master Lab / Master Lab+
192
Service Manual
98.22.56 Edition 3
Film path
1R
98.22.56 Edition 3
06%
/6%
,QVHUW )LOP VL]H
Cropping masks 13.8 x 19.8 (110) 18.8 x 24.8 (135HF) 24.8 x 36.8 (135FF) 42.6 x 56.8 (120 / 45 x 60) 135 HF (18 x 24Q) reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved
2SWLFDO ER[ /LJKW VKDIW
110 135 135 120 135 -----------------------------
16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 1 1 1 1 1 1 1 1
0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
0 1 1 0 0 1 1 0 0 1 1 0 0 1 1
1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
1) 0 = no magnet inserted 2) 1 = magnet inserted
&KHFNV DGMXVWPHQWV IRU DQG ILOP GHFNV
1RWH 7KH IROORZLQJ DGMXVWPHQW SURFHGXUHV DQG PHQXV DUH WKH VDPH IRU DQ DXWRPDWLF ILOP GHFN DQG DQ DXWRPDWLF ILOP GHFN 7KH GDWD DUH VWRUHG DFFRUGLQJ WR WKH ILOP GHFN FRGH
Master Lab / Master Lab+
&KHFNLQJ DQG SRVLWLRQLQJ WKH ';&RGH GLRGHV
To check the positioning and the DX-Code diodes of the 135 film deck proceed as follows: Select the menu: 0$,17! 35,17(5 ),75$&. 6(16 $
<MAINT> Pos.Diode [ 1] STEPS FORW PRINTER FITRACK Density 0.00 BACKW SENS A/D-Raw 2132 A135 Offset 816 CALIB
Without a film inserted in the film deck press the key just below &$/,%. The display will show values for the positioning diodes as shown in the table below. Be aware that the values for the DX-Code diodes are shown on the next screen! 193
Service Manual
Film path
$'5DZ
Positioning diodes DX-Code data DX-Code clock min. 1100 to max. 3500
2IIVHW
98.22.56 Edition 3 Master Lab / Master Lab+
725 to 925
$GMXVWLQJ H[SRVXUH YLHZLQJ SRVLWLRQ
Production tolerances are compensated with this adjustment. Because the viewing and the exposure position are in correlation we have to adjust in the following sequence:
o o
1st = Exposure position 2nd = Viewing position
,03257$17
6WULFWO\ REVHUYH WKH VHTXHQFH IRU DGMXVWLQJ WKH SRVLWLRQV
Prerequisites:
Automatic film deck 135, APS or 110 installed Light shaft 135 or 110 installed Paper cassette attached, e.g. 3.5 Master Lab+ initialized Paper path correctly adjusted (refer to chapter 10)
Load a full length film in the film deck and ensure that the film is below all rollers. Ensure that a frame with enough contrast is correctly positioned in the viewing window. If necessary adjust the position with the or the keys. Select the menu: 0$,17! 35,17(5 ),75$&. ,1,7 $'-(;3
<MAINT> PRINTER FITRACK INIT ADJEXP Press <START> to move Film to Exposureposition START <-7 ->
Open the front cover to get access to the paper deck. Press the key just below the word 67$57. Check the position of the negative by looking at the projection on the paper. If necessary, adjust the frame in the exposure position with the keys just below the signs or ! until no borders of unexposed mask are left at either side.
194
Service Manual
Film path
98.22.56 Edition 3
Confirm with (17(5!. Now position a frame with enough contrast in the viewing window. 'RQW FRUUHFW WKH SRVLWLRQ RI WKH IUDPH LQ WKH YLHZLQJ ZLQGRZ ZLWK WKH ILQH SRVLWLRQLQJ NH\V
1RWH
Select the menu: 0$,17! 35,17(5 ),75$&. ,1,7 $'-9,(:
<MAINT> PRINTER FITRACK INIT ADJVIEW Adjust viewer position and press ENTER -3 <->
If necessary, adjust the frame in the viewing window with the keys just below the signs <- or -> until no borders are left at either side.
Confirm with (17(5!.
$GMXVWLQJ WKH SUHVVXUH VROHQRLG
After replacing the solenoid or the mask on the film deck you have to adjust the pressure solenoid again. Remove the plastic cover of the film deck.
saml09012a
~ 0.6 mm
Loosen the set screw of the lever. Turn the shaft to push the pressure mask down. Keep the mask down and push the armature of the solenoid until it touches the lever. Measure the part of the armature protruding the coil. It should measure approx. 0.6mm. If necessary adjust by turning the lever. Tighten the set screw again.
Set screw
Master Lab / Master Lab+
Remount the plastic cover of the film deck.
Service Manual
195
Film path
$GMXVWLQJ WKH EHOW WHQVLRQ
Remove the plastic cover of the film deck.
)
SM
3.5 .. 4.5N (350 .. 450gr)
Loosen both screws $ . Take a spring balance and pull on the roller with a force of 3.5 to 4.5N (350 to 450gr). Tighten the screws without releasing the tension. Remount the plastic cover of the film deck.
$GMXVWPHQWV RQ WKH XQLYHUVDO ILOP GHFN $GMXVWLQJ KRPH SRVLWLRQ
saml09016a
flag
Home sensor
6x6
Remove the cover on the upper side of the sledge. Loosen both screws of the flag.
Master Lab / Master Lab+
1mm
Select the menu: 0$,17! 35,17(5 ),75$&. 6(16 81,
<MAINT> PRINTER FITRACK SENS Home: Magnet: FORW BACKW UNI YES NO Error stat. of film [ 1] STEPS
196
Service Manual
98.22.56 Edition 3
saml09013a
Film path
Depending on the sledge position press either the key just below the word )25: or %$&.: until a gap of 1mm to the mechanical endposition is achieved. In this position adjust the flag until the display for Home: changes to YES. 7KH GLVSOD\ RQO\ FKDQJHV E\ SUHVVLQJ RQH RU WKH RWKHU VRIWNH\ DJDLQ
98.22.56 Edition 3
1RWH
$GMXVWLQJ WKH H[SRVXUH SRVLWLRQ
Production tolerances are compensated with this adjustment. The exposure position is the only adjustment required and this adjustment is independent of the insert. The viewing position is not adjustable by software!
Prerequisites:
Universal film deck installed Home position is mechanically adjusted An insert is attached the corresponding light shaft is installed Paper cassette attached, e.g. 3.5 Master Lab+ initialized Paper path correctly adjusted (refer to chapter 10)
Load a film strip Select the menu: 0$,17! 35,17(5 ),75$&. ,1,7 $'-(;3
<MAINT> PRINTER FITRACK INIT ADJEXP Press <START> to move Film to Exposureposition START <-7 ->
Master Lab / Master Lab+
Open the front cover to get access to the paper deck. Press the key just below the word 67$57. Check the position of the negative by looking at the projection on the paper. If necessary, adjust the frame in the exposure position with the keys just below the signs or ! until no borders of unexposed mask are left at either side. Confirm with (17(5!.
Service Manual
197
Film path
/LVW RI VFKHPDWLFV
PBA Film Deck 135, FIDE 135 PBA Film Deck 135, FIDE 135 PBA Film Pos. Sens. Trans., FIPOT PBA Film Pos. Sens. Trans., FIPOT PBA Film Pos. Sens. Rec.,. FIPOR PBA Film Pos. Sens. Rec., FIPOR PBA Film Viewing 135, FIVI 135 PBA Film Viewing 135, FIVI 135 PBA Film Deck 110/UNI, FIDE 110/U PBA Film Deck 110/UNI, FIDE 110/U PBA Film Viewing UNI, FIVI UNI PBA Film Viewing UNI, FIVI UNI PBA Film Viewing 110, FIVI 110 PBA Film Viewing 110, FIVI 110 PBA Filmdeck 135/2 PBA Filmdeck 135/2 PBA Film Pos. Sens. Trans., FIPOT PBA Film Pos. Sens. Trans., FIPOT PBA Film Pos. Sens. Rec.,. FIPOR PBA Film Pos. Sens. Rec., FIPOR PBA Filmdeck, FIDT PBA Filmdeck, FIDT PBA Filmdeck rec., FIDR PBA Filmdeck rec., FIDR PBA Viewer lamp, VLB PBA Viewer lamp, VLB
34.75.68 ES 34.75.68 AZ 34.75.35 ES 34.75.35 AZ 34.75.37 ES 34.75.37 AZ 34.75.33 ES 34.75.33 AZ 34.76.00 ES 34.76.00 AZ 34.76.12 ES 34.76.12 AZ 34.76.92 ES 34.76.92 AZ 37.08.95 ES 37.08.95 AZ 37.08.98 ES 37.08.98 AZ 37.09.00 ES 37.09.00 AZ 37.01.35 ES 37.01.35 AZ 37.01.37 ES 37.01.37 AZ 37.01.98 ES 37.01.98 AZ
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 to 3 1 1 1 1 1 1 1 1 1 1 1
198
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
7LWOH
'UDZLQJ
3DJHVVKHHWV
98.22.56 Edition 3
3DSHU SDWK
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ
10
The paper transport system includes all movements of the paper from the paper cassette into the Paper processor. This transport system includes: o the paper cassette o the paper extractor o the knife assembly o the paper deck o the feeder or panorama feeder o the conveyer (ML X20) or the distributor (ML X40) The paper is extracted from the paper cassette and cut according to the specified print length. The piece of paper (further called print) is then transported onto the paper deck where it is exposed. After exposure the print is moved into the feeder which transports the print via a 90 vertical turn further to the conveyer. Finally the conveyer enters the print into the first tank of the Paper processor. For ML X40 a distributor is installed instead of the conveyer allowing the distribution of prints up to 4 with a maximal print length of 180mm into 2 tracks. With a panorama feeder installed, the possible print length on 4 paper can be up to 305mm.
Master Lab / Master Lab+
Service Manual
199
Paper path
saml10001a
11 12 13 14
98.22.56 Edition 3
10
8 7 6 5
4 3
Paper extractor unit
)LJ
3ULQFLSOH YLHZ RI SDSHU SDWK
3DSHU FDVVHWWH
The paper cassette is the storage container for the photographic paper to be used in the machine. The paper cassette is coded by small permanent magnets located at the exit of the paper cassette. The code is used to tell the computer if a paper cassette is inserted or not and to load the appropriate paper memory. Furthermore, the code is used to verify the correct format combination of light shaft, film deck and lens.
200
Service Manual
Master Lab / Master Lab+
1 3 5 7 9 11 13
Paper cassette (metal version) Locking mechanism Extractor stepper motor Paper deck stepper motor Feeder DC motor Distributor or conveyer Conveyer stepper motor
2 4 6 8 10 12 14
Light trap (Adapter) Sensor board (PAMID) Knife with DC motor Paper deck Feeder or panorama feeder Main drive from PP (1cm / sec) Distributor stepper motor (SM2)
Paper path
98.22.56 Edition 3
There are different types of paper cassettes in use: o metal cassettes used so far for paper width 3.5 to 5 o older type plastic cassettes used for paper width 3.5 to 6 o new type plastic cassettes used for paper width 3.5 to 8.25 o metal cassettes used for paper width 7 to 8.25
saml10002a saml10004a saml10003a
Metal type cassette
Plastic type cassette (old)
Plastic type cassette (new)
3DSHU H[WUDFWRU
The paper which is extracted from the paper cassette is monitored to detect paper end and paper splice. After the paper has been pulled out, it is cut according to the length specified in the format memory. This piece of paper is then transported to the vacuum table of the paper deck. If the preliminary checks encounter missing paper a corresponding error message is displayed. The paper extractor has an electronic board, the PAMID (3$per 0agazine ,'entification). This board carries the sensors. Hall sensors are used to detect the paper cassette code where as two reflective light barriers are used to detect paper end and paper splice. If a paper end is detected during the pull-in operation, an error message is displayed. The remaining piece of paper must be removed manually from the paper deck.
Master Lab / Master Lab+
Is a splice detected during pull-in operation, the procedure is aborted, an error message is displayed and the splice must be cut off manually.
.QLIH
A rolling knife is used to cut the paper. Both end stops - front and rear - are monitored by light barriers. The knife is driven by a DC motor. The cutting time is limited by a time-out. If the knife does not reach the opposite end stop within 1.5 seconds, a knife error is displayed.
Service Manual
201
Paper path
%DFNSULQWHU
The backprinter, a needle printer, is used to print important information to the rear side of each print. The number of printable characters is limited to 80.
3DSHU GHFN
The paper deck is the place where the paper is positioned for exposure. The transport of the paper to the paper deck is done with two different speeds depending on the paper size. 3.5 and 4 paper is transported with high speed where as 5, 6, 7 and 8 paper is transported with low speed. A vacuum fan in the paper deck keeps the paper at a steady position and keeps it flat for the exposure time to prevent unsharpness due to bent paper.
)HHGHU 3DQRUDPD IHHGHU
After the exposure the paper is moved to the feeder. The feeder has two positions monitored by light barriers. The positions are Printer side and Processor side. The swivelling feeder motion is limited by a time-out. If the feeder does not reach the opposite end within 1.5 seconds, a feeder error is displayed. The feeder has two light barriers to detect the presence of paper in the feeder and the width of the paper. The panorama feeder has three light barriers to detect the presence of paper, the size of paper -> distribution to 1 or 2 tracks and the length of the print (panorama).
saml10023a
Sensor 'Panorama print'
Sensor Print present
AH
Sensor Print > 4"
202
Service Manual
Master Lab / Master Lab+
.AA @
98.22.56 Edition 3
Paper path
'LVWULEXWRU 0/ ; PRGHOV RQO\
The distributor is a slave (Slave E) controlled by the paper transport slave (Slave C). During initialization the master communicates the machine version to the paper track: o 1 track for ML X20 o 2 track /2 track 12 for ML X40 In a ML X40 model the slave checks whether the distributor is installed or not. In case the distributor is missing. It issues an error message. 3.5 and 4 prints are distributed and processed on 2 tracks. 5, 6, 7 and 8 prints are not distributed and fed through the paper processor in a straight-line motion. The maximal length of prints to be distributed in a 2 track machine is 180mm and 305mm for the 2 track 12 machine with panorama feeder. The distributor moves a print as soon as the previous print has left, detected by the reflective light barriers. The belt drive motor of the distributor drives the conveyer belt via a pinion and transports the print from the feeder into the carriage at high speed. For small prints a second stepper motor moves the carriage to one of the two positions. For large prints the carriage remains in the left position and just moves the print in a straight-line motion. After that the belt drive motor transports the print until it reaches the corresponding light barrier at the top end. Now the corresponding electromagnetic clutch is activated to drive the upper belt system. At the end the paper processor transport takes over the print at a low speed of 1cm/sec. This sequence is necessary to ensure correct tracking.
saml10005a
Free wheeling Free wheeling 1 cm/sec.
98.22.56 Edition 3
Main-
Light barrier left Transport belts
Light barrier right
transport
Electromagnetic Electromagnetic clutch, left clutch, right
Master Lab / Master Lab+
Cover
SM 1
Transport belt Conveyer
Transport belt
Distributor
SM 2
Distributor
Home Free wheeling sensor
Service Manual
203
Paper path
Slave C and the distributor are connected via the following lines:
START:
A starting pulse on this line activates a distributor action if the distributor is not busy already. This line is used to inform the slave C that the distributor motion is in progress. This line remains active until the previous print has left the distributor. This line is active if the carriage is unable to detect its home position or if the light barrier for the end position has not detected a print after a couple of steps. Following an error, a pulse on this line triggers a hardware reset of the distributor slave. This line is used to inform the distributor if the paper width is 4 or smaller / 4 or larger. This line transmits the information if a distributor is connected or not.
DISTRIBUTOR ACTIVE:
BUSY:
ERROR:
RESET:
PAPER WIDTH:
DISTRIBUTOR CONNECTED:
204
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Two reflective light barriers are mounted on top of the distributor. If the respective light barrier does not detect a print after a couple of steps, an error is displayed. The left stop of the carriage is the home position. If the home position cannot be found when distributing, an error is displayed. After a restart, two clutches make the upper belts driving.
Master Lab / Master Lab+
98.22.56 Edition 3
Service Manual
1 cm/sec. 1 cm/sec. 1 cm/sec. 1 cm/sec.
)LJ
1- - - 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
SENSORS:
Feeder -> print present
'LVWULEXWRU WLPLQJ GLDJUDP
Distributor home
MOTORS:
Feeder to Printer pos.
Paper into Feeder
Feeder to PP pos.
Paper into Dist.
SM 1
Distribute
SM 2
Paper advance
SM 1
Clutch right
Clutch left
SENSORS:
Right track
Left track
Paper path
saml10006a
205
206
Timing Masterlab 320 / 520 1 Man 9 x 13
Paper path
)LJ
Transport Film
Negativ Clamp
Filterwheel rotate
Calculate Neg. Data
7LPLQJ GLDJUDPV RI SDSHU SDWK
Extract Paper
7LPLQJ GLDJUDP 0/ PDQXDO PRGH
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ..... 44
Cut Paper
Paper to Expo Pos
Expose Paper (Atten.)
Feeder to Printerpos
Paper into Feeder
Paper in Feeder
The following timing diagrams show the interaction of the various systems during normal operation and show the reason for variations in production speed.
Vacuum fan on
saml10007a
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Master Lab / Master Lab+
98.22.56 Edition 3
Service Manual
Masterlab 320 / 520 1 Auto 9 x 13 4 6 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
)LJ
Timing
Transport Film
Negative Clamp
Filter Wheel rotate
Calculate Neg. Data
Extract Paper
Cut Paper
7LPLQJ GLDJUDP 0/ DXWRPDWLF PRGH
Paper to Expo Pos
Expose Paper (Atten.)
Feeder to Printerpos
Paper into Feeder
Paper in Feeder
Vacuum fan on
Paper path
saml10008a
207
208
Masterlab 740 3 Man 9 x 13
Paper path
)LJ
saml10009a
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Timing
Transport Film
Negative Clamp
Filter Wheel rotate
Calculate Neg. Data
Shutter closed
7LPLQJ GLDJUDP 0/ PDQXDO PRGH
Extract Paper
Cut Paper
Paper to Expo Pos
Expose Paper (Atten.)
Feeder to Printerpos
Paper into Feeder
Paper into Dist.
Distribute
Track A
Track B
Vacuum fan on
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Master Lab / Master Lab+
98.22.56 Edition 3
Service Manual
Masterlab 740 1 Auto 9 x 13
)LJ
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Timing
Transport Film
Negative Clamp
Filter Wheel rotate
Calculate Neg. Data
Shutter closed
Extract Paper
7LPLQJ GLDJUDP 0/ DXWRPDWLF PRGH
Cut Paper
Paper to Expo Pos
Expose Paper (Atten.)
Feeder to Printer pos.
Paper into Feeder
Feeder to PP pos.
Paper into Dist.
Distribute
Track A
Track B
Vacuum fan on
Paper path
saml10010a
209
Paper path
6HQVRU RYHUYLHZ
saml10048a
SM
Lens/Zoom - Lens code reading group Distributor - Left track - Right track - Distributor carriage home position DC SM
= Reflective lightbarrier = Fork type lightbarrier = DC - Motor = Stepper motor = Solenoid
SM
SM
Feeder Print present Print > 4 inch Print still in feeder PP position Printer position
DC
Paper deck
SM
DC
Vacuum fan
SM
Knife assembly - Knife right position - Knife left position Paper extractor Sensor board "PAMID" - Hall sensors (4x) - Papersplice - Paperend Paper cassette
210
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
= Hall sensor
D C
Paper path
5HSODFHPHQWV DGMXVWPHQWV DQG FKHFNV /RDGLQJ SDSHU
The detailed procedure is described in the Operating Manual. 1RWH /RDGLQJ D SDSHU FDVVHWWH PXVW EH GRQH LQ D GDUN URRP
98.22.56 Edition 3
saml10011a
Metal type cassette
saml10012a
When loading a new roll of paper, the bar on the cassette exit has to be pushed down to feed the paper through. The bar works as a light trap and as a brake for the paper when the cassette is not in use.
Plastic type cassette (old and new)
saml10013a
Master Lab / Master Lab+
ca. 4 cm (~1.5 inches)
Metal type cassette
saml10014a
Pull out the paper. It should protrude from the exit approximately 4cm (~1.5)
ca. 4 cm (~1.5 inches)
Plastic type cassette (old and new)
Service Manual
211
Paper path
Three different sizes of light traps (adapters) are available for the various paper cassettes.
98.22.56 Edition 3 Master Lab / Master Lab+
Ensure the correct size is mounted.
saml10015a
$
)
%
Smallest type for metal type paper cassettes 3.5, 4 and 5 Medium type for old plastic type cassettes 3.5 to 6. Large type for metal type cassettes 6 7 and 8
B)
*
C)
'
+
When inserting the cassette into the machine, make sure that the lever is in the unlock position (turned clockwise).
saml10016a
Metal type cassette
saml10017a
The paper cassette is unlocked for removal or exchange by turning the lever clockwise. After docking the paper cassette it is locked in position by turning the lever counterclockwise.
Plastic type cassette (old and new)
212
Service Manual
Paper path
&RGLQJ WKH SDSHU FDVVHWWH
The paper cassettes are delivered uncoded (no magnets inserted) with a set of magnets and adhesive labels to mark every paper cassette individually with the paper width and the number of the paper memory.
saml10018a
98.22.56 Edition 3
& "
Coding is done according to the following table:
3DSHU PHPRU\ 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X X X X X X X X
&RGH 2 4 8
3DSHU PHPRU\ IDFWRU\ GHIDXOW Reserved for test strip cassette 3.5 MT 3.5 GL 4.0 MT 4.0 GL 5.0 MT 5.0 GL 8.0 MT 8.0 GL Paper 9 Paper 10 Paper 11 Paper 12 Paper 13 Paper 14 Paper 15
X X X X X X X X X X X X X X
X X
X X X X X X
Master Lab / Master Lab+
X X
Coding the paper cassette is basically the same for metal type and plastic type paper cassettes. The only difference is the additional washer required for the metal type paper cassette.
Service Manual
213
Paper path
saml10019a
Metal type paper cassette
saml10020a
Color dot
Insert the magnets with the color dot upwards.
Plastic type cassette (old and new)
saml10021a
Black self-adhesive label
Cover the holes with the black self-adhesive labels supplied with the cassette.
saml10022a
Paperwitdh Paperchannel
4"
metal type cassette
saml10024a
Stick the number corresponding with the magnet code onto the label on the cassette in position Paperchannel Stick the numeric label corresponding with the paper width onto the label to the cassette in the position Paperwidth.
Paperchannel
Pape rw idth
Paperwidth
Pape
rchan
nel
Plastic type cassette (old and new)
214
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Color dot Washer
)RU PHWDO W\SH FDVVHWWHV RQO\ First insert the washer (delivered with the cassette) into each hole a magnet is going to be placed.
Paper path
The code of a docked paper cassette is checked with the menu: 0$,17! 35,17(5 3$75$&. &$66 &2'(
MAINT PRINTER PATRACK CASS CODE Magnet 0: Yes Magnet 1: No Cassette code : 1 Magnet 2: No Magnet 3: No
98.22.56 Edition 3
$GMXVWLQJ WKH SDSHU FDVVHWWH WR GLIIHUHQW SDSHU ZLGWKV
,03257$17
2QO\ SODVWLF W\SH SDSHU FDVVHWWH FDQ EH PRGLILHG IRU D GLIIHUHQW SDSHU ZLGWK ZLWKLQ WKH PHFKDQLFDO OLPLWV RI WKH SDUWLFXODU FDVVHWWH All paper cassettes are available as factory assembled units with the following part numbers:
Type of paper cassettes Metal type paper cassette 3.5 cassette 4 cassette 5 cassette 6 cassette 7 cassette 8 cassette 8.25 cassette Plastic type paper cassette (old version) 3.5 cassette 4 cassette 5 cassette 6 cassette plastic type paper cassette (new version) 3.5 cassette T2 4 cassette T2 5 cassette T2 6 Cassette T2 7 cassette T2 8 cassette T2 8.25 cassette T2
Master Lab / Master Lab+
Partnumber 34.45.76 34.45.77 34.45.78 34.22.80 34.48.77 34.45.79 34.86.65
Remarks replaced by 37.61.88 replaced by 37.61.89 replaced by 37.61.90 replaced by 37.61.91 replaced by 37.64.84 replaced by 37.64.85 replaced by 37.64.86
36.24.78 36.24.79 36.24.80 36.24.81
replaced by 37.61.88 replaced by 37.61.89 replaced by 37.61.90 replaced by 37.61.91
37.61.88 37.61.89 37.61.90 37.61.91 37.64.84 37.64.85 37.64.86
It is possible to convert an existing plastic type paper cassette (old or new version) to an other paper width with the help of the particular parts. For certain conversion are conkits available containing all necessary parts.
Service Manual
215
Paper path
There are four such kits available:
Conversion to 3.5 Conversion to 4 Conversion to 5 Conversion to 6
For conversion proceed as follows:
saml04006a
Open both clips.
saml10026a
Open the paper cassette.
Master Lab / Master Lab+
216
Service Manual
98.22.56 Edition 3
Part number 36.39.32 36.39.33 36.39.34 36.39.35
Paper path
saml10027a
98.22.56 Edition 3
Remove any remaining paper core and the mandrel.
saml10028a
Loosen both screws ($) and remove the complete insert.
)
saml10029a
"
Remove the roller () and the three spacers () %H FDUHIXO QRW WR ORVH WKH VSULQJV DQG WKH ZDVKHU WKH\ DUH UHXVHG
1RWH
!
!
saml10030a
Master Lab / Master Lab+
"#
Mount the new roller () and spacers () to the guiding plates. Dont forget the washer () and the springs (). )RU D FDVVHWWH DQ DGGL WLRQDO VSDFHU KDV WR EH LQVHUWHG
1RWH
! !
Insert the guiding plates into the correct position. Slots in the lower part of the paper cassette aid you. The slots are for 3.5, 4.0, 5.0 and 6.0.
Service Manual
217
Paper path
saml10028a
Fix both screws ($).
)
In the dark room, load the paper cassette with paper.
Ensure the paper can be pulled out of the cassette - when pressing down the wedge - with a force of about 1.0 to 1.5kg. Correct the magnet setting and attach the right label to the cassette.
&KHFNLQJ WKH VHQVRUV RI WKH SDSHU H[WUDFWRU
The maintenance menu allows you to check the status of the sensors in the extractor. Select the menu: 0$,17! 35,17(5 3$75$&. &$66 6(16256
MAINT Paperend Splice Loading mechanism: PRINTER PATRACK No No closed CASS SENSORS
5HPRYLQJ WKH SDSHU H[WUDFWRU
Remove the paper cassette. Remove the front panel and the panel of the electronics. If installed, remove the backprinter from the paper deck.
Master Lab / Master Lab+
218
Service Manual
98.22.56 Edition 3
Paper path
saml10031a
98.22.56 Edition 3
distributor electronic rack
Remove screws (A) and (B). Carefully pull out the complete assembly. Disconnect the cables.
A paperdeck B
Reinstall in reverse order. Adjust the paper position in the Y-axis if necessary as described in chapter 10.3.11
&KHFNLQJ WKH NQLIH IXQFWLRQ DQG LWV VHQVRUV
The sensors and the function of the knife can be checked with the maintenance menu. Select the menu 0$,17! 35,17(5 3$75$&. &$66 .1,)(
MAINT Knife left Knife right CUTLFT CUTRGHT PRINTER PATRACK No Yes CASS KNIFE
Master Lab / Master Lab+
5HSODFLQJ WKH ORZHU NQLIH EODGH
Remove the extractor as described in chapter 10.3.5 Reinstall the extractor.
saml10032a
Remove screw ($) and (%). Exchange the lower knife blade. Adjust the distances (;) and (<) to a parallelism of +/_0.2mm. Tighten both screws ($) and (%).
PAMID
SM
)
Knife blade
Service Manual
219
Paper path
Adjust the paper position in the Y-axis if necessary as described in chapter 10.3.11
98.22.56 Edition 3
5HSODFLQJ WKH UROOLQJ NQLIH
Remove the extractor as described in chapter 10.3.5
saml10033a
Pull A
saml10034a
Loosen screw (A) in the support of the sliding bar. Push or pull the sliding bar towards the stepper motor of the paper extractor.
Push the axis in the rolling knife support towards the sliding bar.
2KID
saml10035a
Pull down the axis with the knife on it.
Down
saml10036a
Old New
Reassemble in reverse order. Reinstall the extractor
Adjust the paper position in the Y-axis if necessary as described in chapter 10.3.11
220
Service Manual
Master Lab / Master Lab+
Replace the complete circular blade.
Paper path
5HPRYLQJ WKH SDSHU GHFN
98.22.56 Edition 3
,03257$17
1HYHU HYHU WRXFK WKH VHDOHG VFUHZV
saml10037a
Sealed
SM Sealed
Loosen screw ($, %, & and ') Unplug the cables and remove the paper deck.
B Sealed C Sealed
1RWH
1R VSHFLDO DGMXVWPHQWV DUH UHTXLUHG DIWHU LQVWDOODWLRQ RI WKH SDSHU GHFN DV ORQJ DV QRQH RI WKH VHDOHG VFUHZV KDV EHHQ ORRVHQHG
$GMXVWLQJ WKH WHQVLRQ RI WKH WUDQVSRUW EHOWV
saml10038a
SM
X
Slightly loosen the screw (A) in the front and the rear side of the paper deck. Loosen the counternut (B) at the front and the rear side of the paper deck. Adjust the distance (X) to 11+/0.5mm by turning screw (C). Make sure the distance is the same in the front and the rear as both rollers have to be parallel to each other. Tighten the counternut (B) at the front and the rear of the paper deck without altering the position of screw (C). Tighten both screws (A).
A C B
Master Lab / Master Lab+
Service Manual
221
Paper path
$GMXVWLQJ WKH VLGHZLVH SDSHU SRVLWLRQ <D[LV
With this adjustment the paper on the paper deck is adjusted to ensure an equal overspill of the projection on both sides (b and b) on the paper.
saml10039a
Paper
SM
Light-up area
Y (sidewise) (sidewise)
b'
Initialize the machine. Insert a paper cassette and lock it. Leave it locked during the whole adjustment procedure. Select the menu: 0$,17! 35,17(5 (;36<6 ):+((/ &2/256 Press the key below 7851 until white light is on the paper deck. Activate the negative mask solenoid with the menu: 0$,17! 35,17(5 ),75$&. $&78$7(. Press the key below &/$03 to activate the solenoid. Now, position a print on the paper deck with the menu: 0$,17! 35,17(5 3$75$&. 75$163 )(7&+. Check the overspill of the projected light. The difference between b and b must be below 1 ... 2mm. If there is a difference greater than 2mm proceed with the following steps.
Master Lab / Master Lab+
222
Service Manual
98.22.56 Edition 3
Paper path
saml10042a
98.22.56 Edition 3
A/B
electronic rack
topview
A
Remove both screws ($) and (%) of the extractor.
paperdeck
saml10041a
4 mm
The entire extractor assembly may now be shifted sidewise by pushing or pulling the unit to the position where the projection is equal. Tighten both screws again.
$GMXVWLQJ WKH ORQJLWXGLQDO SDSHU SRVLWLRQ ;D[LV
With this adjustment the paper on the paper deck is adjusted to ensure an equal overspill of the projection on both sides (a and a) on the paper. This adjustment is done by software.
Master Lab / Master Lab+
Service Manual
223
Paper path
saml10040a
Paper
SM
Light-up area
X (longitudinal)
a'
Initialize the machine. Insert a paper cassette and lock it. Leave it locked during the whole adjustment procedure. Select the menu: 0$,17! 35,17(5 (;36<6 ):+((/ &2/256 Press the key below 7851 until white light is on the paper deck. Activate the negative mask solenoid with the menu: 0$,17! 35,17(5 ),75$&. $&78$7(. Press the key below &/$03 to activate the solenoid. Now, position a print on the paper deck with the menu: 0$,17! 35,17(5 3$75$&. 75$163 )(7&+. Check the overspill of the projection. The difference between a and a must be below 1 ... 2mm. If there is a difference greater than 2mm proceed with the following steps. Select the menu 0$,17 35,17(5 3$75$&. ,1,7 $'-867.
MAINT PRINTER PATRACK INIT ADJUST Paper position [mm] [-0.0] ADJUST
Press the key below $'-867 and enter the amount of millimeters the position should be adjusted The adjustable range is +/- 10mm. Positive numbers --> the print moves forward Negative numbers --> the print moves backward
224
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Paper path
Confirm with (17(5!.
Check the overspill again
98.22.56 Edition 3
Repeat the adjustment procedure until the overspill is correct.
&KDQJLQJ WKH W\SH RI IHHGHU
It may be necessary to change or reset the kind of feeder in the machine if e.g. the panorama feeder is installed or if you have had a loss of data. Select the menu: 6(7! 6<67(0 237,21 3$75$&.. 7KH PHQX 6(7! LV SURWHFWHG E\ D SDVVZRUG
1RWH
SET
SYSTEM
OPTION
PATRACK
Kind of Paper_Track
STD
2-TRACK
2-TRACK-12
Press the key below the word specifying the kind of feeder you want. STD = Standard (1 track machine). Was a DIP switch setting (#2=OFF) on the CPU with main software < 2.60. 2-TRACK = 2 track machine with standard feeder. Was a DIP switch setting (#2=ON) on the CPU with main software < 2.60. 2-TRACK-12 2 track machine with panorama feeder (12 length distribution). Initiate the paper track with the menu: 0$,17! 35,17(5 3$75$&. ,1,7 $//. Confirm with (17(5!.
Master Lab / Master Lab+
$GMXVWLQJ WKH VHQVRUV LQ WKH SDQRUDPD IHHGHU
Two sensors in the panorama feeder are found on the PBA PAFE2. a third one is mounted separatelly. The adjustment is done as follows: Take a piece of 12 photographic paper and cut out a window to get access to the test points and the potentiometers.
Service Manual
225
Paper path
saml10043a
Light barrier
98.22.56 Edition 3
SENS
PAFE
Left GND Middle Right
Photopaper mask
Insert the paper into the feeder that all three light barriers are covered. Connect a voltmeter between GND and the test point Left. The voltage should read <= 0.75Vdc. If the value is not correct adjust it with the Potentiometer LEFT. Do the same for the light barriers Middle and Right. Disconnect the voltmeter. Remove the paper. Reconnect the voltmeter between GND and test point Left
The voltage should now read >=4.8Vdc
&KHFNLQJ WKH VHQVRUV
Master Lab / Master Lab+
There are sensors in the feeder monitoring the paper and the end positions of the feeder. To check the sensors in the feeder enter the menu: 0$,17! 35,17(5 3$75$&. (;,7 6(16
MAINT PRINTER PATRACK EXIT
Print at feeder end: Print width > 4 Inch:
No No
1RWH
7KH DGGLWLRQDO VHQVRU QRW RQ WKH 3$)( LV QRW PRQLWRUHG DQG GLV SOD\HG
226
Service Manual
Paper path
To check the sensors monitoring the end positions of the feeder enter the menu: 0$,17! 35,17(5 3$75$&. (;,7 )(('(5
MAINT PRINTER PATRACK EXIT FEEDER Yes No Feeder in Printerposition: Feeder in Processorposition: TURNPRI TURMPRO
98.22.56 Edition 3
To check the sensor press the key below 7851352 and the feeder turn to the processor position and the sensors change their state. Press now the key below 785135, and the feeder returns to the standard position.
0DQXDOO\ PRYLQJ WKH IHHGHU
The feeder is normally at one of the end positions. In order to move it manually to an other position do the following: Switch OFF the Printer
saml10044a
Fee
der
Loosen screw ($) but dont remove it fully. Lift up the lever mounted to the motor drive shaft. Turn the feeder.
PP position
Master Lab / Master Lab+
Printer position
5HPRYLQJ WKH GLVWULEXWRU
Switch OFF the printer. Remove the front panel.
Service Manual
227
Paper path
saml10047a
Remove the knurled screws ($) and (%) of the distributor cover. Remove the nuts (') till ()) of the distributor itself. Disconnect the cables. 0DNH VXUH WKH GLVWULEXWRU DQG WKH SODWH RQ WRS RI WKH GLVWULEXWRU GRQW IDOO GRZQ
98.22.56 Edition 3 Master Lab / Master Lab+
Cover plate Distributor + . , -
Electronic rack
) Distributor cover *
1RWH
Paper deck
Reassemble in reverse order.
&KHFNLQJ WKH GLVWULEXWRU 3RZHU VXSSO\
Connect a voltmeter to TP6 (+5V) and TP9 (GND) on the PBA Distributor, DIST and check the supply (+5Vdc). If necessary adjust the voltage of the electronic power supply.
saml10049a
+ 24V Pwr.Gnd + 5V Log.Gnd
Mem.
)dr.
Data
LB End Track left LB End Track right LB Carriage Home Position CPU 8031
Paper Width > 4" Start Distributor Distr. Active Distr. Busy Distr. Error Reset Distr. Distr. connected
Conveyor Motor
Distributor Motor
Clutch right Clutch left
)LJ
%ORFN GLDJUDP RI ',67
&KHFNLQJ WKH OLJKW EDUULHUV
Check the physical alignment of both sensors at the top of the assembly. Visually align each reflective light barrier in a way that it detects paper.
228
Service Manual
Paper path
saml10045a
light barrier
98.22.56 Edition 3
3 +/- 0.3mm
Insert a piece of paper an check both light barriers if the detection surface is parallel to the paper at a distance of approx. 3mm.
0HFKDQLFDO FKHFNV
Check the mechanical operation of all moving parts. Pay particular attention to the lower carriage assembly and the free wheeling bearing on the sleeve shaft. Ensure that the captive nut is mounted the right way. Smooth movement of the lower carriage is essential.
saml10046a
Sleeve shaft Free wheel Captive nut
1RWH
1HYHU HYHU RLO RU JUHDVH WKH IUHH ZKHHO RWKHUZLVH LWV IUHH ZKHHOLQJ IXQFWLRQ VXEVLGHV
Master Lab / Master Lab+
Service Manual
229
Paper path
6FKHPDWLFV
PBA Backprinter 1 PBA Backprinter 1 PBA Backprinter 2 PBA Backprinter 2 PBA Distributor, DIST PBA Distributor, DIST PBA Papermag. Ident., PAMID PBA Papermag. Ident., PAMID PBA Pap. sens. Feeder, PAFE PBA Pap. sens. Feeder, PAFE PBA Pap. sens. Feeder 2, PAFE2 PBA Pap. sens. Feeder 2, PAFE2 Lichtschranke FEEDER 2 kpl.
36.04.38 ES 36.04.38 AZ 36.04.58 ES 36.04.58 AZ 34.24.05 ES 34.24.05 AZ 34.75.21 ES 34.75.21 AZ 34.78.85 ES 34.78.85 AZ 36.43.01 ES 36.43.01 AZ 36.43.22 AZ
1 1 1 1 only 1 1 1 1 1 1 1 1 1
230
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
7LWOH
'UDZLQJ
3DJHVVKHHWV
98.22.56 Edition 3
)LOP SURFHVVRU
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ
11
The film processor has a single track transport system using a short leader, a so called leader card with lateral holes allowing to process 110, 126, 135, 120, 220 and APS film. The film loading is based on a film cassette holding the film which is then fixed to the leader card. After the loading procedure the film enters the wet part made with 6 tanks. The tanks contain the following chemistry: o Tank 1 = Developer o Tank 2 = Bleach o Tank 3 + 4 = Fixer o Tank 5 + 6 = Stabilizer Each tank has an agitation pump to stir the liquid. A multi head pump (1 pump head for each tank) is used for replenishment. The liquid in each tank is brought to operating temperature by electric heaters. The temperature is controlled by temperature sensors. Level sensors monitor the liquid level in the tanks. When the film leaves the wet part, it is transported to the dryer and then to the film collecting bin.
Master Lab / Master Lab+
Service Manual
231
Film processor
saml04009a
98.22.56 Edition 3 Master Lab / Master Lab+
! $ # " #
$ % &
"
!
'
1 3 5 7 9 11 13 15
Exhaust fan Temperature sensor dryer Dryer fan Speedometer of transport motor Stabilizer 2 Fixer 2 Bleach Transport safety switch
2 4 6 8 10 12 14 16
Dryer Dryer heating 220V / 700W Squeegee roller Transport motor Stabilizer 1 Fixer 1 Developer Film collecting bin
6SHFLILFDWLRQV
Transport system Film loading unit Transport speed Selectable temperature range with short leader (leader card) with cassette for one track 478mm / min. 30.1 ... 50.0C for the chemical liquids 40.1 ... 79.9C for the dryer Measurable temperature range 0.0 ... 102.3C Temperature accuracy +/- 0.05C in the range of 0 ... 50C +/- 0.10C in the range of 50 ... 102.3C Selectable transport speed 190 ... 200s developer time Selectable replenishment rates developer 10 ... 100ml / m bleach 1.0 ... 50ml / m fixer 10 ... 100ml / m stabilizer 10 ... 100ml / m
232
Service Manual
Film processor
Process specification for C-41 process:
5HSO UDWH $ODUP 3XPS IORZ >POP >&@ >OPLQ@ ILOP@ Developer 195 -1/+3 37.8 +/- 0.3 +/- 0.2 20.7 12 - 18.5 Bleach 48 38 +/- 3.0 +/- 3.0 4.6 1.35 - 2 Fixer 1 48 38 +/- 3.0 +/- 3.0 29.6 2 - 2.7 Fixer 2 48 38 +/- 3.0 +/- 3.0 29.6 1.35 - 2 Stabilizer 1 48 38 +/- 3.0 +/- 3.0 35.8 2.15 Stabilizer 2 45 38 +/- 3.0 +/- 3.0 35.8 2.15 Dryer 82 55 +/- 5.0 +/- 5.0 ------%DWK 7LPH >VHF@ 7HPS >&@ 1) Length of a 135-24 film is approx. 1.10m.
7DQN YRO >O@ 11.84 2.60 2.69 2.58 2.70 2.58 ----
98.22.56 Edition 3
+HDWLQJ V\VWHP )LOP SURFHVVRU KHDWLQJ V\VWHP
Bleach, fixer and stabilizer tanks have a heating element in each tank. Only the developer has two heating elements. Each heating element is powered with 220V / 150W and is driven by the M802 board (for details refer to chapter 13.3).
+HDWLQJ HOHPHQWV
The heating element in the bleach and the fixer 1 is made of titanium where as all the others are made of stainless steel AISI. 1RWH )L[HU KDV D WLWDQLXP KHDWLQJ HOHPHQW EHFDXVH WKH FRQWDPLQDWLRQ RI WKLV EDWK E\ OLTXLG FDUULHG RYHU IURP WKH EOHDFK DQG WKH SRVVL ELOLW\ RI FRUURVLRQ LV WKHUHIRUH PXFK KLJKHU WKHQ LQ IL[HU
The difference between the two heaters is visible at the lower end.
saml11001a
saml11002a
Master Lab / Master Lab+
Bottom of a heater made of titanium
bottom of a heater made of stainless steel
Each heating element has a built-in thermal-lag switch switching the power OFF at 50C +/-5C.
Service Manual
233
Film processor
saml11003a
"
1 2 3 4 5
Heating wire 360Ohm = 0.64A Sand Thermal-lag switch 220V / 0.64A connection Ground connection
7HPSHUDWXUH OHYHO VHQVRU
Each tank has a combined liquid level and temperature sensor.The temperature is not measured in every tank, only in: o the developer o the bleach o the second fixer and o the last stabilizer.
saml11004a
Heater / sensor support
Float
Circlip
Temperature sensor
234
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Film processor
The processor board MCB compares the measured values of the temperature sensors with the preset values and calculates the required heating.
98.22.56 Edition 3
The resistance of the temperature sensors is: o at 20C: 1.97kOhm o at 35C: 2.10kOhm The level sensor in each tank monitors the liquid level. A reed contact is switched by a float. If the liquid level is too low the auto top-off system is activated. In a Master Lab without automatic top-off system, the corresponding LED under the film processor cover will light up and a warning appears on the display.
'U\HU VHFWLRQ
The heater in the dryer consists of a fan with a heater mounted directly to this fan. The heater has a rating of 220V / 700W. A built-in protective bimetal thermal switch cuts OFF the power if the temperature exceeds 85C.
saml11005a
# "
1 2 3 4 5
Fan Heater Temperature sensor Dryer cover Exhaust fan
Master Lab / Master Lab+
The actual temperature is monitored by a sensor. The film dryer temperature control is enabled as soon as the first film processing cycle is started and is disabled when the work cycle is over. The dryer fan is switched OFF 1 minute after the end of a work cycle. During the heating-up period - start of the machine - the dryer is switched OFF.
+HDWLQJ PDQDJHPHQW
A heating management is necessary to ensure that the temperatures raise as fast as possible without exceeding the maximum rated line power and to keep the temperatures stable when they have reached the setup values.
Service Manual
235
Film processor
The dryer is switched on after the temperatures in the different chemistry tanks are at the setup values.
98.22.56 Edition 3 Master Lab / Master Lab+
The different heaters are also switched ON and OFF in time slices with different power.Three phases with different conditions are responsible for the heating management: 1 Warm up phase Definition: (actual temperature) = (setup temperature) - (warm up trigger value) Keep temperature phase Definition:(actual temperature = (setup temperature - Thermostat trigger value) Cool down phase Definition:(actual temperature > (setup temperature)
The different triggers are defined as follows: &KHPLVWU\ Developer Bleach Fixer Stabilizer Dryer ZDUP XS WULJJHU (setup) - 0.2C (setup) - 2.9C (setup) - 2.9C (setup) - 2.9C ----WKHUPRVWDW WULJJHU (setup) - 0.1C (setup) - 1.5C (setup) - 1.5C (setup) - 1.5C (setup) - 0.5C DODUP WULJJHU (setup) +/- 0.2C (setup) +/- 3.0C (setup) +/- 3.0C (setup) +/- 3.0C (setup) +/- 5.0C
The heating power for each tank in the different phases is as follows: &KHPLVWU\ Developer Bleach Fixer 1 Fixer 2 Stabilizer 1 Stabilizer 2 Dryer PD[ KHDWLQJ SRZHU 300W 150W 150W 150W 150W 150W 700W ZDUP XS SKDVH 300W 75W 75W 75W 75W 75W 0W NHHS WHPS SKDVH 75W 19W 10W 75W 10W 75W 700W &RRO GRZQ SKDVH 0W 0W 0W 0W 0W 0W 0W
5HSOHQLVKPHQW V\VWHP
To replenish a chemical bath means to regenerate it with fresh chemistry. Four pumps are mounted on the same crank shaft driven by a 220V motor which is controlled by the M802 board (for details refer to chapter 13.3) For each type of chemistry bath is one pump. For chemistry bathes with two tanks, the replenishment is always fed into the second tank and the overflow is fed into the first tank.
236
Service Manual
Film processor
saml11006a
98.22.56 Edition 3
4
+5V
Drive circuit
220Vac
Fuse resistor
Fuse resistor
Stabilizer
Indicator LED
Bleach
Input to heater
Dev.
Fixer
6 2
F3
M802
F4
GND
230V~ L1 Phase
230V~ L2 Phase
Fuse F3: 4A fast blow (L2) Fuse F4: 4A fast blow (L1)
L17: Developer, Bleach, Fixer and Stabilizer replenishment pumps
)LJ
3ULQFLSOH RI UHSOHQLVKPHQW V\VWHP
1 3 5
Replenishment pump assembly Film replenishment tanks Vacuum sensor
2 4 6
Chemical filters (four) Film processing tanks Microswitch
Each pump has a different flow rate per stroke and the tubes have different colors for clear identification. For the C-41 process the following is valid:
Master Lab / Master Lab+
7DQN Developer Bleach Fixer Stabilizer
)ORZ UDWH SHU VWURNH 2.45ml 0.55ml 3.50ml 4.25ml
7XEH FRORU blue red green yellow
)ORZ VHQVRU YDFXXP VHQVRU
The flow of the replenishment one tank is checked with a flow or vacuum sensor. If there is not enough flow, the message Warning, change replenishment appears on the screen of a Master Lab+. In Master Labs up to serial number 100749 the flow is checked in the stabilizer chemistry with a float.
Service Manual
237
Film processor
In Master Lab+ from serial number 100750 the flow is checked in the developer chemistry with a vacuum sensor.
98.22.56 Edition 3 Master Lab / Master Lab+
5HSOHQLVKPHQW PDQDJHPHQW
Different phases are considered for the control of the replenishment pumps. The phases are as follows: 1 The film processor pump is enabled when 1 meter of film has been entered after the loading cassette has been unlocked. The pumps make 20 strokes in the commands: o maual replenishment and o test cycle. During start-up, when the machine is switched ON by the keyboard 21! key, the machine makes 4 strokes to check the flow of replenishment. If no flow of replenishment is detected by the vacuum sensor, the remaining number of strokes is stored and executed after the vacuum sensor detects replenisher again.
5HFLUFXODWLRQ V\VWHP
The recirculation pumps are required to ensure the stability of the chemicals. Recirculation is done by a single centrifugal pump for each tank. The pumps are located under the tanks and have an input filter.
saml11007a
"
1 2 3 4 5 6 7 8
Bleach aeration pump Bleach recirculation pump Fixer 1 recirculation pump Fixer 2 recirculation pump Developer spray pump Developer recirculation pump Stabilizer 2 recirculation pump Stabilizer 1 recirculation pump
&
$HUDWLRQ SXPS
The bleach aeration pump adds air (oxygen) to the bleach chemistry to support the oxidation. The developer has an additional spray pump.
6SUD\ SXPS
238
Service Manual
Film processor
saml11008a
1 2 3 4 5
"
98.22.56 Edition 3
Developer tank spray bar assembly Recirculation and spray bar pump Recirculation pump Chemical filter Developer overflow tank
The developer spray pump sprays chemistry directly to the film surface according to specifications of the film and chemistry manufacturer.
saml11009a
Drive circuit
+5V 220Vac
Fuse resistor
Fuse resistor
Indicator LED
GND
Dev.
Bleach
Fixer
Stabilizer
Input to heater
2
F3 F4
M802
230V~ L1 Phase
230V~ L2 Phase
Fuse F3: 4A fast blow (L2) Fuse F4: 4A fast blow (L1)
L11: Bleach air pump L12: Developer pump L13: Bleach pump L14: Fixer pump L15: Stabilizer pump
Recirculation pumps
Bleach aeration pump
The developer spray pump is working like the dryer fan: o during a work cycle the pump is ON o without a work cycle the pump is OFF
Master Lab / Master Lab+
5HFLUFXODWLRQ PDQDJHPHQW
The pumps are enabled at the following conditions: 1 2 3 In the standby mode all pumps are OFF In the warm up mode all pumps are ON. In the normal mode are two conditions to be observed: o During a work cycle the pumps are ON o Without a work cycle the pumps are continousely switched ON for 10s and switched OFF for 90s. In the shutdown mode all pumps are OFF if any work cycle is finished. 239
4 Service Manual
Film processor
7UDQVSRUW V\VWHP
The transport system is driven by a 24Vdc motor whose speed is controlled and regulated by the M802 and the MCB boards A toothed belt connects the motor to the main shaft. The worm gears on the main shaft drive the gears of the different racks.
saml11010a
7
1 3 5 7
Motor 2 Main shaft 4 Ball bearing 6 Worm gear for film loading station
Toothed belt Friction bearing Worm gears for racks
3ULQFLSOH RI VSHHG FRQWURO
A slotted disk is connected to the shaft of the motor. When rotating, the slotted disk interrupts a light barrier. The impulses of the light barrier are counted and compared with the preset value. If the speed is different to the preset value, the pulse-width of the energizing sequence will be either increased or decreased depending on the direction of the difference.
saml11011a
!
"
240
Service Manual
Master Lab / Master Lab+
1 2 3 4 5
Motor Light barrier on M806 board Slotted disk Toothed belt Main shaft
98.22.56 Edition 3
Film processor
%ORFN GLDJUDP RI VSHHG FRQWURO
saml13006a
M803 (Paper)
98.22.56 Edition 3
MCB
or M802 (Film)
slotted disk
light barrier
0RWRU HQHUJL]LQJ
The transport motor is energized by a 24Vdc pulse-width modulated supply. The pulses are repeated every 10ms and the pulse-width can vary between 0.8ms and 9.2ms depending on the load.
saml11012a
t = 0.8 ... 9.2ms 24Vdc
t = fix 10ms
)LOP ORDGLQJ VWDWLRQ
The film loading station is a molded plastic assembly, containing the cutter and the transport section. The transport section includes two pairs of rubber rollers. The rollers on the bottom side are moved by gears. These gears are driven by the main shaft also driving the gears of the racks. The free wheeling rollers on the upper side sit on the bottom rollers held together with springs.
Master Lab / Master Lab+
The cutter section includes the knife with its solenoid and the manual film cutter, the film loading cassette release solenoid two micro-switches, two springs to eject the film loading cassette, the M805a and M805b boards with the light barriers to detect the film width and the film length. After inserting a film loading cassette, the microswitch #2 is activated. This switch enables the film cutting solenoid. As soon as the sensor boards M805a (transmitter) and M805b (receiver) detect the leader card, the film transport starts. If the film loading cassette holds a 135 film, the film will be pulled out of the cartridge. At the end of the film, the cartridge is pulled forward and touches a roll
Service Manual
241
Film processor
bar activating microswitch #1. This microswitch activates the knife solenoid and the film is cut.
98.22.56 Edition 3 Master Lab / Master Lab+
If the knife is unable to cut the film the first time, it tries again for up to maximal 20 times. If the knife could not cut the film with three tries, the film transport stops automatically and the knife tries another 17 times. If it fails to cut the film, the error message ),/0 &877(5 '2(617 &87 will appear on the screen and a continuous acoustic alarm is activated. In such a case, the operator must cut the film manually with the film cutting lever. If this doesnt happen within two minutes, the knife tries it again for another 10 times. This procedure would continue endless until the film is cut and microswitch #1 is released. As soon as the film is cut, the transport starts automatically. When the film has been cut successfully, the cassette is ejected after about 30 seconds and a new film can be loaded. If a film other then 135 is loaded in the cassette, the end of the film is detected by the sensors and the cassette is ejected after about 30 seconds.
saml11013a
1 2 3 4 5 6 7
Coupled rubber rollers Spring to eject loading cassette Knife Solenoid to release loading cassette Solenoid to activate the knife Manual film cutting lever Safety switch
242
Service Manual
Film processor
saml11014a
98.22.56 Edition 3
'
&
8 9 10
Microswitch #1, activates the knife Microswitch #2, cassette present, enables the knife solenoid PBA M805a board
saml11015a
11
Roll bar, activates microswitch #1
0 ERDUG 2YHUYLHZ
Two different types of M805 boards are found in the loading station of the Master Lab. Machines delivered after October 1992 are equipped with the new M805A and M805B boards.
Master Lab / Master Lab+
The M805 board reads the film size in the film loading station. The board contains 4 optical infrared sensors (OP1 = track 1 to OP4 = track 4).
23
X
23
X X
23
X X X
23
'HWHFWHG ILOP
120 film, 220 film 135 film, 126 film 110 film Leader card
The sensor activation time is used to recognize the difference between a 126 film and a 136 film as well as the difference between a 120 film and a 220 film.
Service Manual
243
Film processor
saml13020a
Track 1
Track 2
Track 3
Leader
17mm 17mm
26.5mm
16mm
110
135 / 126
120 / 220
)LJ
0 VHQVRUV
2OG YHUVLRQ
The old version of the M805 board, installed in Master Lab delivered before October 1992, is equipped with 4 reflective sensors, all on the same board.
1HZ YHUVLRQ
The new version of the M805 Board is equipped with three transmission sensors and 1 reflective sensor. The transmission sensors are used to detect the tracks 1 to 3 while the reflective sensor detects the leader card (track 4). The reflective sensor and the transmitters of the transmission sensors are mounted on one board, the M805A, while the receivers are mounted on the second board, the M805B.
Master Lab / Master Lab+
5DFNV
Each tank in the film processor contains a rack and an other rack is in the dryer. The racks in the bleach, both fixers and the first stabilizer are the same. The rack in the last stabilizer is equipped with four squeegee rollers at the outlet. Also the rack in the developer is different, as it is longer then all the others. The racks contain rollers with gears driven by the main shaft to move the leader card. For correct operation, the racks must be synchronized and all gears must be aligned properly.
244
Service Manual
98.22.56 Edition 3
Film processor
A light shield cover is mounted on top of the racks to protect the films. Light entering the film processor would make the films foggy or even destroy all negatives on it. Therefore never open the film processor while a film is processed!
98.22.56 Edition 3
saml11016a
! " "
# $ %
1 2 3 4 5 6 7
Main gear Squeegee roller Upper roller Guides Plastic clip to fix the cross under Lower roller Cross under
All racks in the tanks are locked with a metal bracket and with plastic locker that fixes the racks to the heater cover.
saml11017a
Metal bracket
Plastic locker
Master Lab / Master Lab+
The dryer rack is screwed to the back wall
Service Manual
245
Film processor
5HSODFHPHQWV DGMXVWPHQWV +HDWLQJ V\VWHP 0DQXDOO\ VZLWFKLQJ WKH KHDWHUV
Each heater in the film processor and the dryer can be switched ON or OFF.
:$51,1*
6ZLWFK 2)) WKH KHDWHU DIWHU RQH PLQXWH WR DYRLG RYHUKHDWLQJ WKH FKHPLVWU\ Use the menu: 0$,17! )352& 7(03 +($7(5
9LHZLQJ WKH WHPSHUDWXUHV
Enter the menu: &200! )352& ',63703
The following display shows the temperatures
COMM [C] Nom : Act : F.PROC DEV 37.8 37.5 DISPTMP BLEACH 38.0 37.8 FIX 38.0 37.6 STAB 38.0 38.0 DRYER 55.0 36.4
1RWH
7KH GU\HU KHDWV RQO\ ZKHQ DOO FKHPLVWU\ WDQNV KDYH WKH FRUUHFW WHPSHUDWXUH
&KHFNLQJ FDOLEUDWLQJ WKH WDQN WHPSHUDWXUHV
Master Lab / Master Lab+
:$51,1*
:KHQ HYHU \RX KDYH WR KDQGOH FKHPLFDOV SURWHFW \RXUVHOI ZLWK JORYHV DQG JRJJOHV 1HJOHFWLQJ WKLV SUHFDXWLRQ FRXOG OHDG WR VHYHU VNLQ LUULWDWLRQ DQGRU GDPDJHV WR \RXU H\HV ,Q WKH ZRUVW FDVH OHDGLQJ WR ORVV RI H\HVLJKW Display the temperatures as told before.
246
Service Manual
98.22.56 Edition 3
Film processor
Wait until the nominal and the actual values on the display dont vary any more than 0.2C. 'RQW FKHFN WKH GU\HU WHPSHUDWXUH ,W KHDWV RQO\ ZKHQ DOO FKHPLV WU\ WDQNV KDYH WKH FRUUHFW WHPSHUDWXUH
98.22.56 Edition 3
1RWH
saml02036a
Remove the lid of the film processor. 7KH WUDQVSRUW VWRSV DXWR PDWLFDOO\ ZKHQHYHU WKH OLG LV UHPRYHG DQG WKH HUURU PHV VDJH 7UDQVSRUW $ODUP LQ )LOP 3URFHVVRU LV GLV SOD\HG
1RWH
saml11018a
Disable the safety stop by turning the screw 90 counterclockwise (service position). Press (17(5! to clear the error. If a work cycle was in progress, the transport starts again.
saml02037a
Lift the cover of the film dryer Remove the light shield covering the tanks.
Master Lab / Master Lab+
:$51,1*
:KHQ HYHU \RX PHDVXUH WKH WHPSHUDWXUH LQ GLIIHUHQW WDQNV YHU\ SURSHUO\ FOHDQ WKH WKHUPRPHWHU 2WKHUZLVH \RX FRQWDP LQDWH WKH FKHPLVWU\ LQ RWKHU WDQNV DQG WKH\ PD\ HYHQ EH XVH OHVV DIWHUZDUGV
Service Manual
247
Film processor
saml02038a
Take a precision thermometer (e..g. a mercury type). Measure the temperature of each bath close to the float of the level sensor (the place closest to the temperature sensor).
98.22.56 Edition 3 Master Lab / Master Lab+
L L LLLLLLL LLL
L LLLLL LLL LLL
L LLLLLL LL LLL
LLL L LLLL LLL
L LL LLLLL LLL
L L LLLLLL LLL
L L LLLLLL LLL
L LL LLLLL LLL
L L LLLLLL LLL
L LL LLLLL LLL
LLLLL LLL LLL
L LLLLL LL LLL
L LLLLLL LL LLL
1RWH
7KH WHPSHUDWXUH RI WKH IL[HU DQG WKH VWDELOL]HU PXVW EH PHDVXUHG LQ WKH VHFRQG WDQN RI WKH FRUUHVSRQGLQJ EDWK
In a consecutive way enter the menus: 0$,17! )352& 7(03 &$/703 '(9 0$,17! )352& 7(03 &$/703 %/($&+ 0$,17! )352& 7(03 &$/703 ),; 0$,17! )352& 7(03 &$/703 67$% to compare the measured values for every bath with the corresponding value in the menu.
Correct any difference of more than 0.2C by correcting the corresponding value in brackets with the measured value
MAINT F.PROC TMP CALTMP DEV Actual Temperature [C] [37.8]
Confirm with (17(5!. Wait a few minutes for the liquid in the tank can change its temperature. Repeat the measurement until the difference between the measured and the displayed value is less than 0.2C.
248
L LL LLLLL LLL
L LL LLLLL LLL
LLL L LLLL LLL
L L LLLLLLL LLL
L LLLLL LL LLL
L L LLLLLLL LLL
LLLLLLLLL LLL
L LL LLLLL LLL
L LLLLL LL LLL
LLLLLLLL LLL
L LLLL L LL LL
Write the measured value on a piece of paper.
saml02039a
When the temperature measurement is finished, place the light shield back over the tanks. Lower the cover of the film dryer.
Service Manual
Film processor
saml02040a
98.22.56 Edition 3
Remount the lid of the film processor.
&DOLEUDWLQJ WKH GU\HU WHPSHUDWXUH
1RWH 7R FDOLEUDWH WKH GU\HU WHPSHUDWXUH \RX QHHG DQ HOHFWURQLF WKHU PRPHWHU WR PHDVXUH WKH DLU WHPSHUDWXUH $Q RUGLQDU\ PHUFXU\ WKHUPRPHWHU FDQQRW EH XVHG LW LV WRR VORZ
saml02036a
Remove the lid of the film processor.
saml11019a
Lift the cover of the film dryer
saml11020a
Wire clamp
Master Lab / Master Lab+
Temperature sensor Dryer rack
saml11021a
Place the sensor of your electronic thermometer close to the built-in sensor and secure it.
Close the dryer cover.
Service Manual
249
Film processor
saml02040a
Make sure, the chemistry bathes are at the right temperature and in the film processor is a work cycle in progress otherwise the heater doesnt heat up correctly to its nominal value. Enter the menu: 0$,17! )352& 7(03 &$/703 '5<(5 Correct any difference of more than +/-5oC by correcting the corresponding value in brackets with the measured value
MAINT F.PROC TEMP o Actual Temperature [ C] [56.3] CALTMP DRYER
Confirm with (17(5!.
Repeat the measuring sequence until the value is within the tolerance.
&KDQJLQJ WKH WHPSHUDWXUH VHWWLQJ
To change the nominal values of the temperatures: Enter the menu: 6(7! )352& 7(03 7KH PHQX 6(7! QHHGV D SDVVZRUG WR EHFRPH DFWLYH
1RWH
SET
F.PROC
TEMP
Temperature [C] [37.8] DEV [38.0] BLEACH [38.0] FIX [38.0] STAB [55.0] DRYER
Change the value in brackets of the desired chemistry to the new value. Confirm with (17(5!.
&KHFNLQJ WHPSHUDWXUH VHQVRUV OHYHO VHQVRUV
Remove the side panel of the film processor
250
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Remount the lid of the film processor.
Film processor
98.22.56 Edition 3
Remove the cover of the cable duct. Unplug the corresponding connector of the temperature / level sensor. Take the sensor out of the tank as described in chapter . %H YHU\ FDUHIXO QRW WR VSLOO FKHPLVWU\ LQWR RWKHU WDQNV RWKHUZLVH \RX FRQWDPLQDWH WKH FKHPLVWU\ LQ WKH RWKHU WDQN PDNLQJ LW XVH OHVV
saml11022a
1RWH
Connect a Ohmmeter to pin 3 and pin 4 to check the temperature sensor (red and white wire). The resistance of the sensor (type Siemens KTY 10) is 1.97kOhm at 20C 2.10kOhm at 35C Connect the Ohmmeter to pin 1 and pin 2 to check the level sensor (blue and green wire). Keep the level sensor in a upright position. The Ohmmeter should read almost 0Ohm because the reed contact should be closed with the float in the lower position. The Ohmmeter reading should show an infinite value when the float is moved up because the contact opens.
Heater / sensor support
Float
Circlip
Temperature sensor
blue green red red white t white black
b lu
1 2 3 4 5
re
Remount the sensor in the tank.
Master Lab / Master Lab+
After the check, connect the sensor again.
Close the cover of the cable duct. Close the side panel of thefilm processor.
Service Manual
251
Film processor
saml11023a
Temperature
Level
Heater ON/OFF ->
<- Level data
M802
MCB
5HSODFLQJ D WHPSHUDWXUH OHYHO VHQVRU
saml02036a
Remove the lid of the film processor.
saml02037a
Lift the cover of the film dryer
Master Lab / Master Lab+
Remove the light shield covering the tanks.
252
Service Manual
98.22.56 Edition 3
Film processor
saml14006a
98.22.56 Edition 3
Remove the side panel of the film processor
Cable duct
Remove the cover of the cable duct. Unplug the connector of the temperature / level sensor to be replaced.
:$51,1*
:KHQ HYHU \RX KDYH WR KDQGOH FKHPLFDOV SURWHFW \RXUVHOI ZLWK JORYHV DQG JRJJOHV 1HJOHFWLQJ WKLV SUHFDXWLRQ FRXOG OHDG WR VHYHU VNLQ LUULWDWLRQ DQGRU GDPDJHV WR \RXU H\HV ,Q WKH ZRUVW FDVH OHDGLQJ WR ORVV RI H\HVLJKW
Master Lab / Master Lab+
Remove the chemistry filters
saml11024a
Remove both screws of the heater / sensor cover and lift it off.
5?HAMI
Service Manual
253
Film processor
saml11004a
Heater / sensor support
1RWH
Float
%H YHU\ FDUHIXO QRW WR VSLOO FKHPLVWU\ LQWR RWKHU WDQNV RWKHUZLVH \RX FRQWDPLQDWH WKH FKHPLVWU\ LQ WKH RWKHU WDQN PDNLQJ LW XVHOHVV
Circlip
Insert the new temperature / level sensor as shown.
Temperature sensor
Connect the new temperature / level sensor.
Close the cable duct. Remount the cover of the heaters. Insert the chemistry filters. close the dryer cover. Close the side panel. Close the lid of the film processor.
5HSOHQLVKPHQW V\VWHP 0DQXDOO\ VZLWFKLQJ WKH UHSOHQLVKPHQW SXPSV
The replenishment pumps can be switched ON or OFF manually.
Master Lab / Master Lab+
,03257$17
'RQW OHW WKH UHSOHQLVKPHQW SXPSV UXQ WRR ORQJ \RX ZLOO RYHUUHSOHQLVK WKH EDWKV DQG ZDVWH JRRG FKHPLVWU\ Enter the menu 0$,17! )352& /,48,' 38036 5(3/
254
Service Manual
98.22.56 Edition 3
Remove the sensor by pushing it toward the racks.
Film processor
&KHFNLQJ WKH UHSOHQLVKPHQW UDWHV
98.22.56 Edition 3
:$51,1*
:KHQ HYHU \RX KDYH WR KDQGOH FKHPLFDOV SURWHFW \RXUVHOI ZLWK JORYHV DQG JRJJOHV 1HJOHFWLQJ WKLV SUHFDXWLRQ FRXOG OHDG WR VHYHU VNLQ LUULWDWLRQ DQGRU GDPDJHV WR \RXU H\HV ,Q WKH ZRUVW FDVH OHDGLQJ WR ORVV RI H\HVLJKW
saml02036a
Remove the lid over the film processor.
saml02035a
Fix a graduated plastic cylinder to each tank having a repleishment tube. Lift the replenishment tubes, turn them and place them into the cylinders.
100:1 in 20 C ml
100 90 80 70 60 50
100:1 in 20 C ml
100 90 80 70 60 50
100:1 in 20 C ml
100 90 80 70 60 50
100:1 in 20 C ml
100 90 80 70 60 50
,03257$17
$OZD\V XVH WKH VDPH JUDGXDWHG F\OLQGHU IRU WKH VDPH WDQN WR SUHYHQW GL OXWLQJ RU PL[LQJ XS WKH FKHPLVWU\ Select the menu: &200! )352& 0$15(3/
COMM F.PROC MANREPL Nominal Quantity per Test Cycle [ml] 41.4 DEV 9.2 BLEACH 59.2 FIX 71.6 STAB TEST
Master Lab / Master Lab+
Press the key below the word 7(67.
The Master Lab+ now delivers 20 pump strokes of replenisher per tank into the graduated cylinders. If no liquid is detected after 6 or 7 strokes an alarm message is displayed and the test is stopped.
Service Manual
255
Film processor
Check the quantity of replenisher in each graduated cylinder and compare it with the values displayed on the screen. Pour the replenisher into the charging hole of the corresponding tank. %H YHU\ FDUHIXO WR SRXU WKH UHSOHQLVKHU LQWR WKH ULJKW WDQN 2WKHU ZLVH \RX FRQWDPLQDWH WKH FKHPLVWU\ LQ WKH RWKHU WDQN PDNLQJ LW XVHOHVV
98.22.56 Edition 3 Master Lab / Master Lab+
1RWH
&KDQJLQJ WKH UHSOHQLVKPHQW UDWH IRU DOO FKHPLVWULHV WRJHWKHU
If the replenishment rate has to be changed proportional for every tank, it can be done by software because all pumps are mounted on one shaft. Select the menu: 6(7! )352& 5(35$7(
SET F.PROC REPRATE Replenishment Rate [ml/m] [20.7] DEV 4.6 BLEACH 29.6 FIX 35.8 STAB
Change the value for the developer (value in the brackets) to the desired rate. The values for bleach, fixer and stabilizer will be calculated automatically after confirming. Confirm with (17(5!.
&KDQJLQJ WKH UHSOHQLVKPHQW UDWH IRU RQH WDQN RQO\
If the replenishment rate for a particular tank has to be changed, the pump volume per stroke of that pump requires manual adjustment. The procedure is as follows: Set the replenishment rate for the particular tank with the menu: 0$,17! )352& /,48,' &$/3803
MAINT 48.8 21.7 DEV F.PROC 10.8 [4.8] BLEACH LIQUID 69.6 [31.0] FIX CALPUMP 80.4 [35.8] STAB [ml] [ml/m] TEST
The selectable range is for: bleach fixer stabilizer Always confirm with (17(5!.
1 ... 50ml/m 10 ... 100ml/m 10 ... 100ml/m
1RWH
)RU GHYHORSHU XVH WKH SURFHGXUH GHVFULEHG XQGHU &KDQJLQJ WKH UHSOHQLVKPHQW UDWH IRU DOO FKHPLVWULHV WRJHWKHU %XW EH DZDUH DOO Service Manual
256
Film processor
RWKHU UHSOHQLVKPHQW UDWHV PD\ QHHG D FRUUHFWLRQ LQ WKH RSSRVLWH GLUHFWLRQ ZLWK WKH SURFHGXUH MXVW EHLQJ GHVFULEHG
98.22.56 Edition 3
Calculate the difference between the old and the new value in %.
Now, the calculated diviation has to be adjusted mechanically at the particular replenishment pump.
saml11025a
1
% OF STROKE
100 75 50 25 0
2 3
Adjust the screw at the pump to the desired replenishment rate. Turn the screw () cw to increase or ccw to decrease the ratio.The stroke indicator () and the stroke scale () guide you in the right way.
Press the key below the word 7(67.
The Master Lab+ now delivers 20 pump strokes of replenisher per tank into the graduated cylinders. If no liquid is detected after 6 or 7 strokes an alarm message is displayed and the test is stopped. If the delivered quantity deviates from the 120,1$/ 48$17,7< 3(5 7(67 &<&/(, adjust the pump again and repeat the calibration.
5HSODFLQJ D EHOORZ RI WKH UHSOHQLVKPHQW SXPS
1RWH 7KH EHOORZ IRU WKH EOHDFK LV D LQFK EHOORZ DQG DOO WKH RWKHUV LQ WKH ILOP SURFHVVRU DUH EHOORZV
This procedure may be necessary if you have a defective bellow.
Master Lab / Master Lab+
Switch OFF the machine with the main switch. Remove the upper side panel of the film processor.
saml11047a
Remove both screws ($) holding the film replenishment pump assembly
Service Manual
257
Film processor
Carefully pull the assembly toward you until you have good access to the bellows.
98.22.56 Edition 3 Master Lab / Master Lab+
:$51,1*
%H DZDUH WKDW FKHPLFDO OLTXLG LV LQ WKH WXEHV DQGRU LQ WKH EHO ORZ :KHQ \RX GR WKH QH[W VWHSV WKLV OLTXLG ZLOO IORZ RXW HL WKHU LQWR WKH PDFKLQH RU RQWR \RXU FORWKHV ,W LV DGYLVDEOH WR KDYH D SLHFH RI JRRG DEVRUELQJ FORWK DW KDQG
Remove both elbow connectors of the bellow to be replaced. Remove both valves 'RQW ORRVH WKH JDVNHWV 2ULQJV
saml11026a
1RWH
Elbow connector Connector nut O-ring Valve assembly (red = bleach) (black = dev., fix., stab.)
Displacer Elbow connector O-ring
1)
Valve body
Valve assembly (red = bleach) (black = dev., fix., stab.)
displacer is mounted in the 3/4inch bellow only with the red valve assembly. All other valves have a black valve assembly
1)The
saml11048a
* *
Remove both screws (%) fixing the bellow to the pump.
Tilt down the bellow to be replaced. Turn the white body counterclockwise to remove it from the connecting rod.
Screw the new bellow clockwise to the connecting rod. 258 Fasten the bellow with both screws (%) to the pump. Service Manual
Film processor
Insert both valves with the gaskets. 1RWH
98.22.56 Edition 3
0DNH VXUH \RX UHDVVHPEOH WKHP WKH FRUUHFW ZD\
Remount both elbows. Reinstall the complete assembly. Verify the proper function and adjsutment as described in chapter &KHFNLQJ WKH UHSOHQLVKPHQW UDWHV, Page 255
7UDQVSRUW V\VWHP 0DQXDOO\ VZLWFKLQJ WKH PRWRU
The motor can manually be switched ON and OFF if no work cycle is in progress. Otherwise the command is ignored. Select the menu 0$,17! )352& 75$163 ),/0 02725
&KHFNLQJ WKH EHOW WHQVLRQ RI WKH WUDQVSRUW PRWRU
The transport motor is located under the dryer and to get access, you must remove the dryer rack first.
saml02036a
Remove the lid of the film processor.
Master Lab / Master Lab+
saml11019a
Lift the cover of the film dryer
Service Manual
259
Film processor
saml11027a
Fixing screws rack
Wire clamp Temperature sensor Dryer rack
Remove the temperature sensor from the wire clamp. Loosen both fixing screws. Remove the dryer rack by moving it upward.
saml04011a
5N
The correct belt tension gives a displacement of less than 5mm with a force of 5N (500gr).
saml11029a
"
If necessary adjust the belt tension by loosening the four screws (item 3) and moving the motor in the indicated direction. 1 = Main shaft 2 = Toothed belt 3 = Mounting screw 4 = Motor
5HPRYLQJ WKH PDLQ VKDIW
Switch OFF the machine with the keyboard first and then with the main switch. Remove the front panel of the Master Lab+. Remove the cover of the printer electronics Remove the film loading station as described in chapter 11.8.4
260
Service Manual
Master Lab / Master Lab+
Reassemble in reverse order.
98.22.56 Edition 3
5 mm
Film processor
saml11030a
98.22.56 Edition 3
# "
Loosen the set screw (item 5) of the pulley at the end of the shaft. Remove the pulley. Loosen the screws holding the three bearings (item 1) of the main shaft (item 3).
saml11031a
Worm gear (front view)
Safety clip
Remove the safety clips of the 8 worm gears driving the racks.
Groove (1 of 3)
Pull out the main shaft from the front of the Master Lab+.
,QVWDOOLQJ DQG DOLJQLQJ WKH PDLQ VKDIW
Master Lab / Master Lab+
Insert the main shaft from the front of the Master Lab+. Push the worm gears onto the shaft while inserting it. Remount the pulley. Fix the screw of the three bearings.
,03257$17
7KH IROORZLQJ VWHS KDV WR EH FDUULHG RXW DEVROXWH FRUUHFWO\ ,I WKH ZRUP JHDUV DUHQW FRUUHFWO\ DOLJQHG ILOPV ZLOO EH GHVWUR\HG
saml11032a
Make sure that on all worm gears the grooves with the hole for the safety clip are aligned.
Service Manual
261
Film processor
saml11031a
Worm gear (front view)
Safety clip
Groove (1 of 3)
Mount the toothed belt and adjust it as already described. If necessary, lubricate the bearings with TRI-FLOW. Remount the film loading station.
Start the machine and check the film transport with a leader card only. Remount all covers removed.
&KDQJLQJ WKH WUDQVSRUW VSHHG
The transport speed can be changed in the range of 190s to 200s which is the duration for the developing process. The nominal developing time is 195s. 1RWH )RU VWDQGDUG RSHUDWLRQ LW LV YHU\ PXFK DGYLVHG WR OHDYH WKH GHYHO RSHU WLPH DV LW LV VHW 7KLV LV WKH UHFRPPHQGHG VSHHG IURP WKH FKHPLVWU\ PDQXIDFWXUHU IRU & SURFHVV
For what ever reason it is necessary to change the speed do: Select the menu: 0$,17! )352& 6<67(0 '(97,0(
MAINT F.PROC SYSTEM DEVTIME Developer time [s] [195]
Press the key below the bracketed value and enter the new transport speed. Confirm with (17(5!.
)LOP ORDGLQJ VWDWLRQ 5HPRYLQJ WKH ILOP ORDGLQJ VWDWLRQ
Remove the front panel and the cover of the printer electronics.
262
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Secure the worm gears with the safety clip.
Film processor
98.22.56 Edition 3
Unplug the connectors of the film loading station for: o the knife solenoid o the cassette locking solenoid o the sensor board o the two micro-switches
saml11033a
Remove both mounting screws at the top front of the film loading station. Remove the film loading station.
Remount in reverse order.
5HSODFLQJ WKH NQLIH
Remove the film loading station as already described.
saml11034a
Remove the screws $ . Remove the knife support.
Master Lab / Master Lab+
&$87,21
%H YHU\ FDUHIXO ZKHQ KDQGOLQJ WKH NQLIH LW LV YHU\ VKDUS
C A U T I O N S H A R P B L A D E
<RX PD\ FXW \RXU ILQJHUV LI QRW FDUHIXO
Service Manual
263
Film processor
saml11035a
2 3
5
Carefully remove the circlips and the bushings (2). Remove the springs (3). Carefully remove the knife support assembly(4)
6
saml11036a
Film transport
Knife blade
When inserting the new knife support assembly ensure that the blade is positioned right as shown!
Reassemble in reverse order.
5HSODFLQJ WKH UROOHUV
Remove the film loading station as described
saml11037a
: :
:
Master Lab / Master Lab+
Remove the twelve (12) screws marked (;) to open the film loading station and access the rollers. Reassemble in reverse order.
5HSODFLQJ WKH VHQVRU ERDUGV
1RWH 7KH VHQVRU ERDUGV 0D DQG 0E DUH VXSSOLHG DV VHW RQO\
Remove the film loading station as described.
264
Service Manual
98.22.56 Edition 3
C A U T I O N S H A R P B L A D E
1 2 3 4 5 6
Knife blade Circlip and bushing Knife pressure spring Knife support Knife solenoid Manual film cutting lever
Film processor
saml11038a
98.22.56 Edition 3
Y
Sensor board
M805
Remove the four screws marked (<) to access the sensor board M805a. Proceed the same way on the lower side to access the M805b.
saml11039a
Film
These two boards in the film loading station read the film size in the loading station and detect the film length.
saml1140a
M805A
OP4
M805B OP1 OP2 OP3
There are four transmitters (M805a) and sensors (M805b) on the boards OP1 = track 1 (transmissive sensor) OP2 = track 2 (transmissive sensor) OP3 = track 3 (transmissive sensor) OP4 = track 4 (reflective sensor)
saml13020b
120 / 220
OP1
135 / 126
OP2
110
OP3
OP4
Master Lab / Master Lab+
The different film sizes are detected as follows: OP4 detects the leader card OP3 detects 110 film OP2 + OP3 detects 126 and 135 film OP1 + OP2 + OP3 detects 120 and 220 film
Service Manual
265
Film processor
saml11041a
M805A
M805B
M802
5DFNV 5DFNV LQ WKH SURFHVVRU
&$87,21
'RQW VZLWFK 21 WKH PDFKLQH DV ORQJ DV WKH UDFNV DUH UH PRYHG DQG WKH VXFWLRQ WXEH LV VWLOO LQ WKH DXWRPDWLF WRSRII WDQN 7KH DXWRPDWLF WRSRII V\VWHP ILOOV XS WKH WDQNV ZLWK ZDWHU DQG WKH FKHPLVWU\ ZRXOG EH GLOXWHG DQG XVHOHVV
saml02036a
Remove the lid of the film processor.
266
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Film processor
saml02037a
98.22.56 Edition 3
Lift the cover of the film dryer Remove the light shield covering the tanks.
9(5< ,03257$17
%H YHU\ FDUHIXO ZKHQ WDNLQJ RXW WKH UDFN WKDW \RX GRQW SRO OXWH WKH RWKHU FKHPLVWU\ ZLWK VSODVKHV 2WKHUZLVH WKH FKHP LVWU\ PD\ EH XVHOHVV
saml11017a
Metal bracket
Plastic locker
Remove the three screws holding the metal bracket. Remove the metal bracket. Press the plastic locker and carefully lift the rack out of the tank.
Reinsert a rack in the reverse order.
'U\HU UDFN
saml02036a
Master Lab / Master Lab+
Remove the lid of the film processor.
Service Manual
267
Film processor
saml02037a
Lift the cover of the film dryer Remove the light shield covering the tanks.
98.22.56 Edition 3 Master Lab / Master Lab+
saml11027a
Fixing screws rack
Take the temperature sensor out of the wire clamp. Remove both screws at the top of the rack. Lift out the rack.
Wire clamp Temperature sensor Dryer rack
Reinsert in reverse order.
2SHQLQJ D UDFN
1RWH 7KH IROORZLQJ SURFHGXUH LV DEVROXWHO\ 127 UHFRPPHQGHG IRU UH SDLUV LQ WKH ILHOG :H UHFRPPHQG WR H[FKDQJH D GHIHFWLYH UDFN LQ WKH ILHOG ,W UHTXLUHV D YHU\ VNLOOHG ILHOG HQJLQHHU WR KDQGOH DOO WKH UROOHUV DQG JHDUV ZKHQ WKH UDFN KDV WR EH UHDVVHPEOHG
The following procedure is described at the example of the bleach rack. Before you disassemble the rack, clean it thoroughly with water.
saml11042a
Remove both circlips on each axle of the gears. Remove the screw at the plastic locker.
268
Service Manual
Film processor
saml11043a
98.22.56 Edition 3
To remove the cross under of the rack press on the two plastic clips with screw drivers and slightly twist the cross under. Turn the rack and repeat the same at the other side. Remove the cross under.
saml11044a
Remove both plastic guides at each side by carefully pressing a screw driver between the rack frame and the guide.
Remove a side wall of the rack. Remove the roller or rollers to be replaced.
The satellite gear (the gear without a roller) can easily be removed by pressing a 6mm nut to the fixing point of the gear. For detailed drawings of each rack please refer to the Spare parts list Master Lab+ P/N 98.22.15
5HDVVHPEOLQJ D UDFN
Master Lab / Master Lab+
Place all the rollers at the correct position of one side wall. Remount the second side wall of the rack. Remount the cross under. There is only one way to mount it as it is coded with four pins. Make sure that the clips of the cross under did snap-in! Remount both guides. There is only one way to mount them as they are also coded. To reinstall the gears, refer to the next chapter.
Service Manual
269
Film processor
$OLJQLQJ WKH JHDUV
1RWH $OLJQLQJ WKH JHDUV KDV WR EH GRQH HYHU\ WLPH D UDFN KDV EHHQ RSHQHG DQG ZKHQ D JHDU ZKHHO KDV EHHQ UHSODFHG 7KLV LV YDOLG IRU HYHU\ UDFN LQ WKH ILOP SURFHVVRU DV ZHOO DV IRU WKH GU\HU UDFN
saml11045a
To align the main gear with the small gear below, the two marks on the gear must match as shown.
saml11046a
The gears on the opposite side of the rack have to be aligned as shown. 7KH PDUN RQ DOO JHDUV GULY LQJ D UROOHU KDV WR ORRN WKH VDPH ZD\ 7KH PDUN RQ WKH VDWHOOLWH JHDUV GRHVQW PDW WHU
Satellite gear
1RWH
Secure all the gears with the circlips. Manually turn the main gear in both directions and check if all rollers turn smoothly. If necessary lubricate all bearings with: o TRI-FLOW for racks in the tanks o pure silicon oil for the dryer rack
Master Lab / Master Lab+
Insert a leader card and manually transport it forward and backward by turning the main gear. Ensure the leader card doesnt jam or catch anywhere on its way through the rack. Reinstall the rack. In the processor, ensure that the plastic lockers did correctly snap-in. In the processor, secure the racks with the metal bracket Start the machine to check the film transport. 7KH WUDQVSRUW VWRSV DXWRPDWLFDOO\ ZKHQHYHU WKH OLG LV UHPRYHG DQG WKH HUURU PHVVDJH 7UDQVSRUW $ODUP LQ )LOP 3URFHVVRU LV GLV SOD\HG Service Manual
1RWH
270
98.22.56 Edition 3
Film processor
saml11018a
98.22.56 Edition 3
Disable the safety stop by turning the screw 90 counterclockwise (service position). Press (17(5! to clear the error. If a work cycle was in progress, the transport starts again.
Feed a leader card only through the film processor to check the film transport. If the transport works ok, close all the covers removed.
Master Lab / Master Lab+
Service Manual
271
Film processor
6FKHPDWLFV
Scheda M805A (circuit diagram) Scheda M805A (layout drawing) Scheda M805B (circuit diagram) Scheda M805B (layout drawing) Scheda M806 (circuit diagram) Scheda M806 (layout drawing)
17322.017.2 15333.082.4 17322.018.0 15333.083.1 17333.085.1 15333.077.1
1 1 1 1 1 1
272
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
7LWOH
'UDZLQJ
3DJHVVKHHWV
98.22.56 Edition 3
3DSHU SURFHVVRU DQG $76
2YHUYLHZ DQG IXQFWLRQDO GHVFULSWLRQ
12
Following the exposure in the printer, the prints are fed to the paper processor. The paper processor has five tanks:
q q q
the first tank is for the developer the second tank is for the bleachfix the remaining three tanks are for the stabilizer.
$JLWDWLRQ SXPS
Each tank has an agitation pump to stir the liquid while replenishment is done by a multi-head pump (1 head for each type of chemistry). The liquid in the tanks is heated by electrical heaters and temperature sensors monitor the temperature. The liquid level in each tank is monitored by a sensor. When the prints leave the last stabilizer tank, they are transported to the dryer. After drying, the prints are collected in the print collector. A sorter arm in the ML+ X40 collects and distributes the prints to a separate stacker.
6RUWHU
Master Lab / Master Lab+
Service Manual
273
Paper processor and ATS
saml12001a
! " # $ % & "
#
$ ' !
1 3 5 7 9 11 13 15
Dryer Dryer heating 1 (230V / 450W) Dryer heating 2 (230V / 450W) Speedometer of transport motor Stabilizer tank 3 Stabilizer tank 1 Developer tank Print collector
2 4 6 8 10 12 14 16
Temperature sensor of dryer Dryer fan 1 Dryer fan 2 Transport motor Stabilizer tank 2 Bleachfix tank Transport switch Water tank (auto top-off system)
6SHFLILFDWLRQV
Transport system Minimal format Maximal format Transport speed Selectable temperature range Measurable temperature range Temperature accuracy single sheet with rollers 9 x 9cm (3.5 x 3.5) 21 x 30.5cm (8.25 x 12) 635mm / min.
Master Lab / Master Lab+
30.1 ... 50.0oC for the chemistry 40.1 ... 79.9oC for the dryer 0.0 ... 102.3oC +/- 0.05oC in the range of 0 ... 50oC +/- 0.10oC in the range of 50 ... 102.3oC 40 ... 50s developer time developer 70 ... 290ml / m2 bleachfix 100 ... 300ml / m2 stabilizer 100 ... 700ml / m2
Selectable transport speed Selectable replenishment rates
274
Service Manual
98.22.56 Edition 3
Paper processor and ATS
The following two tables give specific process data for two types of processes: o table 1 for RA-4 and o table 2 for Prime
98.22.56 Edition 3
Values for RA-4 7LPH >VHF@ Developer 45 -1/+3 Bleachfix 45 Stabilizer 1 35 Stabilizer 2 35 Stabilizer 3 35 Dryer 74 %DWK Values for Prime 7LPH 7HPS >VHF@ >o&@ Developer 45 -1/+3 38 +/-0.15 Bleachfix 45 35 +/-3.0 Stabilizer 1 35 35 +/-3.0 Stabilizer 2 35 35 +/-3.0 Stabilizer 3 35 35 +/-3.0 Dryer 74 60 +/-5.0 %DWK $ODUP >o&@ +/- 0.3 +/- 3.0 +/- 3.0 +/- 3.0 +/- 3.0 +/- 5.0 5HSO UDWH 3XPS IORZ 7DQNV >PO P2@ >O PLQ@ >O@ 162 2.4 - 3.6 5.49 108 2.4 - 3.6 5.59 360 2.5 - 3.7 4.47 360 2.5 - 3.7 4.38 360 2.5 - 3.7 4.38 ------7HPS >o&@ 35 +/-0.3 35 +/-3.0 35 +/-3.0 35 +/-3.0 35 +/-3.0 60 +/-5.0 $ODUP >o&@ +/- 0.3 +/- 3.0 +/- 3.0 +/- 3.0 +/- 3.0 +/- 5.0 5HSO UDWH 3XPS IORZ 7DQNV >PO P2@ >O PLQ@ >O@ 162 2.4 - 3.6 5.49 214 2.4 - 3.6 5.59 360 2.5 - 3.7 4.47 360 2.5 - 3.7 4.38 360 2.5 - 3.7 4.38 -------
and the corresponding replenishment tanks are:
saml12002a
RA-4
110mm
Stabilizer
Bleach
Developer
200mm
Prime
122mm
90mm
Master Lab / Master Lab+
110mm
Stabilizer
Bleach
Developer
250mm
80mm
120mm
&KHPLVWU\ Developer Bleachfix Stabilizer
3ULPH >OLWHU@ 4.5 3.0 10.0
5$ >OLWHU@ 3.4 4.4 7.4
Service Manual
275
Paper processor and ATS
+HDWLQJ HOHPHQWV
+HDWLQJ V\VWHP 3DSHU SURFHVVRU KHDWLQJ V\VWHP
Each tank has a heating element made of stainless steel AISI. The heating element is driven by the M803 board and is powered by 220V / 150W (for details refer to chapter 13.4). Each element has a built-in thermal-lag switch that switches the power OFF at 50C +/-5C.
saml12003a
Ground 220VAC
1 2 3
Heating wire 360kOhm Sand Thermal-lag switch
7HPSHUDWXUH DQG OHYHO VHQVRUV
Each tank has a combined liquid level and temperature sensor, but the temperatures are measured in three tanks only: o the developer tank o the bleachfix tank and o the last stabilizer tank.
Master Lab / Master Lab+
saml12004a
Heater / sensor support
Float
Circlip
Temperature
sensor
276
Service Manual
98.22.56 Edition 3
Paper processor and ATS
The processor board MCB compares the measured values of the temperature sensors with the preset values and calculates the required heating.
98.22.56 Edition 3
The resistance of the temperature sensors is at: o 20C = 1.97kOhm o 35C = 2.10kOhm The level sensor part monitors the liquid level of each tank. A reed contact is switched by the float. If the liquid level is too low the automatic top-off system is activated. In Master Lab without automatic top-off system, the corresponding LED under the paper processor cover is lighting up and a warning appears on the display.
'U\HU VHFWLRQ
The heater in the dryer section consists of two fans with directly mounted heaters. Each heater has a power of 450W at 220V. A built-in protective bimetal thermal switch cuts OFF the power if the temperature exceeds 85C. .
saml12005a
! " # $
Master Lab / Master Lab+
1 2 3 4 5 6
Dryer cover Temperature sensor Heater 1 Fan 1 Heater 2 Fan 2
The actual temperature is monitored by a sensor. If there is no work cycle in process, the dryer temperature is maintained at 40oC standby temperature. If a work cycle starts, the temperature is increased to the setup value. The dryer fan is always switched on.
+HDWLQJ PDQDJHPHQW
A heating management is necessary to ensure that the temperatures raise as fast as possible without exceeding the maximum rated line power and to keep the temperatures stable after reaching the setup values.
Service Manual
277
Paper processor and ATS
The dryer is switched on after all temperatures of the different baths are at the setup values. The heater in the tanks are also switched ON and OFF in time slices with different power. The temperature management knows three phases to handle the temperature: 1 Warm up phase: Definition: (actual temperature) = (setup temperature) - (warm up trigger value). Keep temperature phase: Definition: (actual temperature) = (setup temperature) - (thermostat trigger value). Cool down phase: Definition: (actual temperature) > (setup temperature)
98.22.56 Edition 3 Master Lab / Master Lab+
The different triggers are defined as follows: %DWK Developer Bleachfix Stabilizer Dryer :DUP XS (setup) - 0.2oC (setup) - 1.9oC (setup) - 2.9oC ---7KHUPRVWDW (setup) - 0.15oC (setup) - 1.0oC (setup) - 1.5oC (setup) - 0.5oC $ODUP (setup) +/- 0.3oC (setup) +/- 3.0oC (setup) +/- 3.0oC (setup) +/- 5.0oC
The heating power for each tank in the different phases is as follows; %DWKV Developer Bleachfix Stabilizer 1 Stabilizer 2 Stabilizer 3 Dryer 1 Dryer 2 0D[ KHDWLQJ SRZHU 150W 150W 150W 150W 150W 450W 450W :DUP XS SKDVH 112W 112W 84W 84W 84W 0W 0W .HHS WHPS SKDVH 75W 84W 19W 19W 84W 450W 450W FRRO GRZQ SKDVH 0W 0W 0W 0W 0W 0W 0W
5HSOHQLVKPHQW V\VWHP
To replenish a chemical bath means to regenerate it with fresh chemicals. Three pumps are mounted on one crank shaft driven by a 220V motor and controlled by the M803 board (for details refer to chapter 13.4). There is one pump for each type of chemistry bath. The three stabilizer tanks have one replenishment pump only. The replenishment is fed into tank 3 and then flows to the remaining two tanks as the three tanks are cascaded. The overflow is in stabilizer tank 1.
278
Service Manual
Paper processor and ATS
98.22.56 Edition 3
A vacuum sensor monitors the chemical flow of the developer replenishment. This sensor is used to detect an empty replenishment tank. As the machine works with proportional replenishment tanks it is assumed that all other tanks are empty at the same time as the developer is empty therefore only the developer is monitored.
saml12006a
4
Stabilizer
Bleach
Dev.
230V~ L1 Phase 5
F4
M803
230V~ L2 Phase Fuse F3: 4A fast blow (L2) Fuse F4: 4A fast blow (L1)
F3
220Vac
Fuse resistor
6 2
3 GND
L14: Developer, Bleach and Stabilizer replenishment pumps
+5V
Drive circuit
Fuse resistor
Indicator LED
Input to heater
1 3 5
Replenishment pump assembly Paper replenishment tanks Vacuum sensors
2 4 6
Chemical filters (three) Working tanks Microswitch
%DWK Developer Bleachfix stabilizer
Master Lab / Master Lab+
)ORZ UDWH VWURNH RA-4 Prime 1.90ml 1.90ml 2.55ml 1.28ml 4.25ml 4.25ml
7XEH FRORU blue red yellow
)ORZ VHQVRU YDFXXP VHQVRU
The flow of replenishment is checked in one tank with a flow sensor. If there is not enough flow, the message :$51,1* &+$1*( 5(3/(1,6+0(17 appears in the display of the Master Lab. In Master Labs (up to serial number 100749) the level is checked in the stabilizer replenishment tank with a float. In the Master Lab+ (as of serial number 100750) the flow is checked in the developer tube with a vacuum sensor.
Service Manual
279
Paper processor and ATS
The Master Lab 120, 140, 220 and 240 have no vacuum sensor. Every replenishment and recovery tank is equipped with a level sensor. If the level of one of the tanks is too high a warning is displayed. The level sensors are connected to the MCB board by the same RCB board that is also used for the replenishment console (see chapter 14.4)
98.22.56 Edition 3 Master Lab / Master Lab+
5HSOHQLVKPHQW PDQDJHPHQW
Different phases are considered for the control of the replenishment pumps. The phases are as follows: 1 The paper processor pump is enabled when 0.1m2 of paper has been entered. The pumps make 20 strokes in the commands: o manual replenishment and o test cycle. During start-up, when the machine is switched ON by the keyboard 21! key, the machine makes 4 strokes to check the flow of replenishment. If no flow of replenishment is detected by the vacuum sensor, the remaining number of strokes is stored and executed after vacuum sensor detects replenisher again.
5HFLUFXODWLRQ V\VWHP
The recirculation pumps are required to assure the stability of the chemicals in the working tanks. Recirculation is done by a single centrifugal pump for each working tank.The pumps are located under the tanks and have an input filter.
saml12007a
"
1 2 3 4 5
Stabilizer 3 recirculation pump Stabilizer 2 recirculation pump Stabilizer 1 recirculation pump Bleachfix recirculation pump Developer recirculation pump
The pumps are activated if a work cycle is in process or if any of the heaters is powered. If there is no work cycle in process, the pumps are periodically switched ON for 20s and OFF for 80s.
280
Service Manual
Paper processor and ATS
saml12008a
98.22.56 Edition 3
1 2 3
!
Recirculation pumps Chemical filters Developer overflow tank
saml12009a
230V~ L1 Phase
Stabilizer 3 Stabilizer 2 Stabilizer 1 Bleachfix Developer
F4
M803
230V~ L2 Phase Fuse F3: 4A fast blow (L2) Fuse F4: 4A fast blow (L1)
F3
GND
L9: Developer pump L10: Bleach pump L11: Stabilizer 1-2-3 pump Drive circuit
+5V 220Vac
Fuse resistor
Fuse resistor
Indicator LED
Input to heater
5HFLUFXODWLRQ PDQDJHPHQW
The pumps are enabled at the following conditions:
Master Lab / Master Lab+
1 2 3
In the standby mode all pumps are OFF. In the warm-up mode all pumps are ON In the normal mode are two conditions to be observed: o During a work cycle the pumps are ON. o Without a work cycle the pumps are continuously switched ON for 10s and switched OFF for 90s In the shutdown mode all pumps are OFF if any work cycle is finished.
Service Manual
281
Paper processor and ATS
7RSRII V\VWHP
$XWRPDWLF WRSRII V\VWHP
The automatic top-off system reduces the work load of the operator by automatically refilling the tanks with water to compensate for evaporated water. It therefore reduces the risk of chemistry overconcentration. It also cleans the film squeegee rollers.
saml12010a
)65
On/Off button green lamp red lamp
All the automatic top-off functions are controlled by the ALMLPLUS board.
saml13016a
Electro Pump valves Replenishment consol
J86
J87
J76
J85 Power supply 220VAC Input (not used) J93
8 4 C 4
8 4 C
8 C
SW1 SW2 SW3
J94 Output (not used)
ATS
ALMLPLUS Board
J89 J90
J84
J88
J75
Tank sensor MCB Board
The ALMLPLUS board acts as the direct interface between the MCB board and the automatic top-off system elements (electro valves, pump and sensors). It receives the status information of the tank level sensors and the machine work cycle from the MCB. According to this information the ALMLPLUS board acti-
282
Service Manual
Master Lab / Master Lab+
Power supply 24VDC
98.22.56 Edition 3
Paper processor and ATS
vates the pump and the electro valves for the quantities set with the rotary switches SW2 and SW3.
98.22.56 Edition 3
The replenishment console interface is a completely independent section on the board and acts as a level sensor interface.
$XWRPDWLF WRSRII PDQDJHPHQW
With the manual switch ON the automatic top-off system is activated. The pump and the valves are switched according to the following phases: 1 Top-off phase (paper and film tanks together) Activated when the machine is switched ON by the timer on the MCB board or manually by the main switch (not more than once every 12 hours). The added water quantity represents the average night evaporation. The nominal quantity may be adjusted by switch SW2 from 20% to 320%. Evaporation phase (paper and film tanks) Activated every two hours, if during this time no work cycle occurred. The added water quantity represents the average evaporation in two hours. The nominal quantity may be adjusted by switch SW3 from 20% to 320%. Level phase (independent for every tank) Activated if a tank level is low and there is no work cycle in progress. The quantity inserted in a tank is the maximum quantity to be inserted before an overflow occurs. The level phase can only be activated twice per tank. This precaution is necessary to save the machine in case of a chemical loss due to a leak (time-out for the level control is 1 minute). An alarm condition is indicated if the red lamp is continuously ON accompanied by an audible buzzer. The alarm can be reset by switching OFF the automatic top-off system with the switch. If the alarm condition does not disappear after 5 minutes, the Printer displays the message /2: /(9(/ $/$50.
:DWHU TXDQWLW\
Default values for each tank
Master Lab / Master Lab+
7DQN Developer Bleachfix Stabilizer 1 Stabilizer 2 Stabilizer 3
/HYHO SKDVH 117 117 82 82 90
7RSRII SKDVH 6: WR 57 27 40 37 45
(YDSRUDWLRQ SKDVH 6: WR 23 12 17 17 25
Service Manual
283
Paper processor and ATS
The water quantity is adjustable with selector SW2 and SW3 3RVLWLRQ 0 1 2 3 4 5 6 7 8 9 A B C D E F 7RSRII SKDVH (YDSRUDWLRQ SKDVH VZLWFK 6: VZLWFK 6: 20% 20% 40% 40% 60% 60% 80% 80% 100% 100% 120% 120% 140% 140% 160% 160% 180% 180% 200% 200% 220% 220% 240% 240% 260% 260% 280% 280% 300% 300% 320% 320%
7UDQVSRUW V\VWHP
The transport system is driven by a 24Vdc motor with speed control and regulation done by the M803 board and the MCB board. The motor drives the main shaft via a toothed belt. The worm gears on the main shaft drive the gears of the different racks.
saml12011a
"
"
#
1 3 5 7
Motor 2 Toothed belt Main shaft 4 Friction bearing Ball bearing 6 Worm gears driving the racks Worm gear driving the distributor / conveyer
284
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Paper processor and ATS
6SHHG FRQWURO
98.22.56 Edition 3
3ULQFLSOH RI VSHHG FRQWURO
A slotted disk is mounted to the shaft of the motor. While turning, this disk interrupts a light barrier. The pulses of the light barrier are counted and compared with the preset value. If the speed is different to the preset value, the pulse-width of the driving electronic is either increased or decreased depending on the direction of the difference
saml12012a
"
!
1 2 3 4 5
Motor Light barrier on M806 board Slotted disk Toothed belt Main shaft
%ORFN GLDJUDP RI VSHHG FRQWURO
saml13006a
M803 (Paper)
MCB
or M802 (Film)
slotted disk
light barrier
0RWRU HQHUJL]LQJ
The motor is energized by 24Vdc by a pulse-width modulated supply. A pulse is generated every 10ms with a pulse-width between 0.8ms and 9.2ms depending on the load.
saml11012a
t = 0.8 ... 9.2ms 24Vdc
Master Lab / Master Lab+
t = fix 10ms
Service Manual
285
Paper processor and ATS
5DFNV
Six racks are installed in the paper processor, 1 rack in each working tank and 1 rack in the dryer. These racks are of four different types: o a rack type for developer and bleachfix o a rack type for stabilizer 1 and 2 o a rack type for stabilizer 3 o a rack type for the dryer. Every rack has several rollers driven by gears. The prints are transported between the rollers.
saml12013a
1 2 3 4 5
" #
Upper squeegee roller Lower squeegee roller Rollers (pressed against the upper roller) Lower roller Crossunder
All racks in the tanks are locked with a metal bracket and two screws ($). The dryer rack is screwed to the rear wall.
saml12014a
metal bracket
Screws A
Master Lab / Master Lab+
The crossover assembly is mounted on top of the racks and fixed with two plastic screws.
286
Service Manual
98.22.56 Edition 3
Paper processor and ATS
saml12015a
98.22.56 Edition 3
6RUWHU
6RUWHU
The sorter collects the prints leaving the dryer and moves them to the collecting bin. The sorter is driven by a 24Vdc motor and a toothed belt. The different positions of the sorter arm are monitored by light barriers.
saml12016a
1 2 3 4
Switch for big prints Sorter arm Motor Pulley
"
saml12017a
5 6 7 8
Master Lab / Master Lab+
&
SQ5 = Sorter in right position (home) SQ6 = Sorter position for large prints (not in Master Lab+) SQ7 = Sorter in final position SQ8 = Sorter in left position (order separation)
5HSODFHPHQWV DQG DGMXVWPHQWV +HDWLQJ V\VWHP 0DQXDOO\ VZLWFKLQJ WKH KHDWHUV
Each heater in the paper processor and the dryer can be switched ON or OFF.
Service Manual
287
Paper processor and ATS
:$51,1*
98.22.56 Edition 3 Master Lab / Master Lab+
6ZLWFK 2)) WKH KHDWHU DIWHU RQH PLQXWH WR DYRLG RYHUKHDWLQJ WKH FKHPLVWU\ For the various heaters use the menu: 0$,17! 3352& 7(03 +($7(5 0$,17! 3352& 7(03 +($7(5 0$,17! 3352& 7(03 +($7(5 0$,17! 3352& 7(03 +($7(5 0$,17! 3352& 7(03 +($7(5 0$,17! 3352& 7(03 +($7(5
'(9 %/($&+ 67$% 67$% 67$% '5<(5
1RWH
7KH KHDWHU FRPPDQGV IRU WKH GU\HU LV LJQRUHG LI D ZRUN F\FOH LV LQ SURJUHVV
9LHZLQJ WKH WHPSHUDWXUHV
Enter the menu: &200! 3352& ',63703
The following display shows the temperatures
COMM [ C] Nom : Act : P.PROC DEV. 35.0 35.0 DISPTMP BLEACH 35.0 34.9 STAB 35.0 35.1 DRYER 60.0 36.4
1RWH
7KH GU\HU KHDWV RQO\ ZKHQ D ZRUN F\FOH LV LQ SURJUHVV
&KHFNLQJ FDOLEUDWLQJ WKH WDQN WHPSHUDWXUH
:$51,1*
:KHQ HYHU \RX KDYH WR KDQGOH FKHPLFDOV SURWHFW \RXUVHOI ZLWK JORYHV DQG JRJJOHV 1HJOHFWLQJ WKLV SUHFDXWLRQ FRXOG OHDG WR VHYHU VNLQ LUULWDWLRQ DQGRU GDPDJHV WR \RXU H\HV ,Q WKH ZRUVW FDVH OHDGLQJ WR ORVV RI H\HVLJKW Display the temperatures as told before. Wait until the nominal and the actual values on the display dont vary more than 0.2C.
288
Service Manual
Paper processor and ATS
1RWH
'RQW FKHFN WKH GU\HU WHPSHUDWXUH EHFDXVH WKH GU\HU KHDWV RQO\ ZKHQ D ZRUN F\FOH LV LQ SURFHVV 2WKHUZLVH WKH KHDWHU VWD\V SUH KHDWHG DW o&
98.22.56 Edition 3
saml02042a
Remove the lid of the paper processor. :KHQHYHU WKH OLG LV UH PRYHG WKH WUDQVSRUW VWRSV DXWRPDWLFDOO\ DQG WKH HUURU PHVVDJH 75$163257 $/$50 ,1 3$3(5 352&(6625 DS SHDUV LQ WKH GLVSOD\
1RWH
saml12018a
Disable the safety stop by turning the screw in the dryer 90o counterclockwise (service position). Press (17(5! to clear the error. If a work cycle was in process, the transport starts again.
saml02043a
Lift the cover of the paper dryer.
saml02044a
Master Lab / Master Lab+
Turn the two fasteners on the crossover and remove it.
saml02045a
Unlock the lower part of the paper dryer and tip it up.
Service Manual
289
Paper processor and ATS
:$51,1*
98.22.56 Edition 3 Master Lab / Master Lab+
:KHQ HYHU \RX PHDVXUH WKH WHPSHUDWXUH LQ GLIIHUHQW WDQNV YHU\ SURSHUO\ FOHDQ WKH WKHUPRPHWHU 2WKHUZLVH \RX FRQWDP LQDWH WKH FKHPLVWU\ LQ RWKHU WDQNV DQG WKH\ PD\ HYHQ EH XVH OHVV DIWHUZDUGV
saml02046a
Take a precision thermometer (e.g. a mercury type).
Measure the temperature of each bath close to the float of the level sensor (the place closest to the temperature sensor). 1RWH Write the measured value on a piece of paper.
7KH WHPSHUDWXUH VHQVRU WR PHDVXUH WKH WHPSHUDWXUH RI DOO VWDELOL] HUV LV ORFDWHG LQ VWDELOL]HU WDQN 7KH VHQVRUV LQ WDQN DQG DUH QRW FRQQHFWHG
In a consecutive way enter the menus: 0$,17! 3352& 7(03 &$/703 '(9 0$,17! 3352& 7(03 &$/703 %/($&+ 0$,17! 3352& 7(03 &$/703 67$% to compare the measured values for every bath with the corresponding values in the menu. Correct any difference of more than 0.2C by correcting the corresponding value in brackets with the measured value.
MAINT P.PROC TEMP Actual Temperature [ C] [34.9] CALTMP DEV
Confirm with (17(5!. Wait a few minutes to allow the bath to adapt the temperature Repeat the whole procedure again until the difference is less than 0.2C between the measured and the displayed values.
290
Service Manual
Paper processor and ATS
saml02047a
98.22.56 Edition 3
Tip the lower part of the paper dryer down and lock it.
saml02048a
Remount the crossover and turn both fasteners.
saml02049a
Lower the cover of the paper dryer.
saml02050a
Close the lid of the paper processor.
Master Lab / Master Lab+
&DOLEUDWLQJ WKH GU\HU WHPSHUDWXUH
1RWH 7R FDOLEUDWH WKH GU\HU WHPSHUDWXUH \RX QHHG DQ HOHFWURQLF WKHU PRPHWHU WR PHDVXUH WKH DLU WHPSHUDWXUH $Q RUGLQDU\ PHUFXU\ WKHUPRPHWHU FDQQRW EH XVHG LW LV WRR VORZ
Remove the lid of the paper processor. Open the cover of the dryer. Place the sensor of your (electronic) thermometer near the temperature sensor and fix it.
Service Manual
291
Paper processor and ATS
Close the cover of the dryer. Ensure that the temperature in the chemistry tanks is correct. Make sure a working cycle is in progress. Otherwise the heater will not heat correctly to its nominal value. If the reading of the thermometer is beyond the tolerance of +/-5C select the menu: 0$,17! 3352& 7(03 &$/703 '5<(5 Correct any difference of more than +/-5C by correcting the corresponding value in brackets with the measured value.
MAINT P.PROC TEMP CALTMP DRYER Actual Temperature [C] [58.3]
Confirm with (17(5!.
Repeat the measuring sequence until the value is within the tolerance.
&KDQJLQJ WKH VHWWLQJ RI WKH WHPSHUDWXUH
To change the nominal value of the temperature proceed as follows: Select the menu: 6(7! 3352& 7(03 7KH PHQX 6(7! QHHGV D SDVVZRUG WR EHFRPH DFWLYH
1RWH
SET
P.PROC Temperature [ C] [35.0] DEV [35.0] BLEACH
TEMP
[35.0] STAB
[60.0] DRYER
Confirm with (17(5!.
&KHFNLQJ WHPSHUDWXUH VHQVRU OHYHO VHQVRUV
Remove the side panel of the paper processor. Remove the cover of the cable duct. Disconnect the connector of the temperature / level sensor to be checked.
292
Service Manual
Master Lab / Master Lab+
Change the value in brackets of the desired chemistry to the new value.
98.22.56 Edition 3
Paper processor and ATS
Take the sensor out of the tank as described in chapter Replacing the temperature / level sensor, page 294. %H YHU\ FDUHIXO QRW WR VSLOO FKHPLVWU\ LQWR RWKHU WDQNV RWKHUZLVH \RX FRQWDPLQDWH WKH FKHPLVWU\ LQ WKH RWKHU WDQN PDNLQJ LW XVH OHVV
saml12019a
98.22.56 Edition 3
1RWH
Connect an Ohm-Meter to pin 3 and pin 4 (red and white wire) to check the temperature sensor. Measure the resistance of the sensor (type Siemens KTY). It should read at 20C: 1.97kOhm at 35C: 2.10kOhm Now connect the Ohm-Meter to pin 1 and pin 2 (blue and green wire) to check the level sensor. Keep the level sensor in an upright position. The reed contact has to be closed when the float is in the lower position.
Heater / sensor support
Float
Circlip
Temperature sensor
blue green red red white t white black
b lu
re
1 2 3 4 5
The reed contact has to be open when the float is moved to the upper position. Remount the sensor in the tank.
After the check, connect the sensor again. Close the cover of the cable duct.
Master Lab / Master Lab+
Close the side panel of the paper processor.
Service Manual
293
Paper processor and ATS
Temperature
M803
MCB
<- Heater ON/OFF Level data ->
5HSODFLQJ WKH WHPSHUDWXUH OHYHO VHQVRU
Remove the lid of the paper processor Tilt up the cover of the dryer. Remove the side panel of the paper processor. Remove the cover of the cable duct. Disconnect the temperature / level sensor to be replaced.
:$51,1*
:KHQ HYHU \RX KDYH WR KDQGOH FKHPLFDOV SURWHFW \RXUVHOI ZLWK JORYHV DQG JRJJOHV
Master Lab / Master Lab+
1HJOHFWLQJ WKLV SUHFDXWLRQ FRXOG OHDG WR VHYHU VNLQ LUULWDWLRQ DQGRU GDPDJHV WR \RXU H\HV ,Q WKH ZRUVW FDVH OHDGLQJ WR ORVV RI H\HVLJKW Remove the chemistry filters.
294
Service Manual
98.22.56 Edition 3
Level
Paper processor and ATS
saml12021a
98.22.56 Edition 3
5?HAMI ) *
saml12004a
Remove both screws $ of the heater / sensor cover Remove the cover % .
Heater / sensor support
Remove the sensor by pushing it toward the racks. %H YHU\ FDUHIXO QRW WR VSLOO FKHPLVWU\ LQWR RWKHU WDQNV RWKHUZLVH \RX FRQWDPLQDWH WKH FKHPLVWU\ LQ WKH RWKHU WDQN PDNLQJ LW XVHOHVV
1RWH
Float
Circlip
Insert the new sensor as shown.
Temperature
sensor
Reassemble in reverse order.
5HSOHQLVKPHQW V\VWHP 0DQXDOO\ VZLWFKLQJ WKH UHSOHQLVKPHQW SXPSV
The replenishment pumps can be switched ON and OFF manually.
Master Lab / Master Lab+
,03257$17
'RQW OHW WKH UHSOHQLVKPHQW SXPSV UXQ WRR ORQJ \RX ZLOO RYHUUHSOHQLVK WKH EDWKV DQG ZDVWH JRRG FKHPLVWU\ Enter the menu: 0$,17! 3352& /,48,' 38036 5(3/
Service Manual
295
Paper processor and ATS
&KHFNLQJ WKH UHSOHQLVKPHQW UDWHV
:KHQ HYHU \RX KDYH WR KDQGOH FKHPLFDOV SURWHFW \RXUVHOI ZLWK JORYHV DQG JRJJOHV 1HJOHFWLQJ WKLV SUHFDXWLRQ FRXOG OHDG WR VHYHU VNLQ LUULWDWLRQ DQGRU GDPDJHV WR \RXU H\HV ,Q WKH ZRUVW FDVH OHDGLQJ WR ORVV RI H\HVLJKW Remove the lid over the paper processor.
saml02041a
100:1 in 20 C ml 100:1 in 20 C ml 100:1 in 20 C ml
Fix a graduated cylinder to each tank having a replenishment tube. Lift the replenishment tube of each tank, turn it and place it into the corresponding cylinder.
100 90 80 70 60 50 40 30 20 10
100 90 80 70 60 50 40 30 20 10
100 90 80 70 60 50 40 30 20 10
,03257$17
$OZD\V XVH WKH VDPH JUDGXDWHG F\OLQGHU IRU WKH VDPH WDQN WR DYRLG FRQ WDPLQDWLRQ RI RWKHU WDQN FRQWHQW
Select the menu &200! 3352& 0$15(3/
COMM P.PROC MANREPL Nominal Quantity per Test Cycle [ml] 38.2 DEV 50.4 BLEACH 84.8 STAB TEST
Press the key below the word 7(67.
The Master Lab+ now delivers 20 pump strokes of replenisher per tank into the graduated cylinders. If no liquid is detected after 6 or 7 strokes, an alarm message is displayed and the test stops. Check the quantity of replenisher in each graduated cylinder, compare it with the values displayed on the screen. Pour the replenisher back into the charging hole of the corresponding tank.
296
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
:$51,1*
Paper processor and ATS
1RWH
%H FDUHIXO WR SRXU WKH UHSOHQLVKPHQW EDFN LQWR WKH ULJKW WDQN 2WKHUZLVH \RX FRQWDPLQDWH WKH FKHPLVWU\ LQ WKH RWKHU WDQN PDNLQJ LW XVHOHVV
98.22.56 Edition 3
&KDQJLQJ WKH UHSOHQLVKLQJ UDWH IRU DOO FKHPLVWULHV WRJHWKHU
If the replenishing rate has to be changed proportional for every tank it can be done by software because all pumps are mounted on the same shaft. Select the menu: 6(7! 3352& 5(35$7(
SET P.PROC REPRATE 2 Replenishment Rate [ml/m ] [162] DEV 215 BLEACH 360 STAB
Change the value for the developer (value in brackets) to the desired rate.The values for bleachfix and stabilizer are calculated automatically after confirming. Confirm with (17(5!.
&KDQJLQJ WKH UHSOHQLVKLQJ UDWH IRU RQH WDQN RQO\
If the replenishment rate for a particular tank has to be changed, the pump volume per stroke of that pump requires manual adjustment. The procedure is as follows: Set the replenishment rate for the particular tank with the menu: 0$,17! 3352& /,48,' &$/3803
MAINT 38.2 162 DEV P.PROC 50.4 [215] BLEACH LIQUID 84.8 [360] STAB CALPUMP [ml]
2 [ml/m ]
TEST
Master Lab / Master Lab+
The selectable range is:
for bleachfix for stabilizer
100 ... 300ml/m2 100 ... 700ml/m2
Always confirm with (17(5!. )RU GHYHORSHU XVH WKH SURFHGXUH GHVFULEHG XQGHU &KDQJLQJ WKH UHSOHQLVKPHQW UDWH IRU DOO FKHPLVWULHV WRJHWKHU %XW EH DZDUH DOO RWKHU UHSOHQLVKPHQW UDWHV PD\ QHHG D FRUUHFWLRQ LQ WKH RSSRVLWH GLUHFWLRQ ZLWK WKH SURFHGXUH MXVW EHLQJ GHVFULEHG
1RWH
Calculate the difference between the old and the new value in %.
Service Manual
297
Paper processor and ATS
Now, the calculated deviation has to be adjusted mechanically at the particular replenishment pump.
98.22.56 Edition 3 Master Lab / Master Lab+
saml11025a
1
% OF STROKE
100 75 50 25 0
2 3
Adjust the screw to the desired replenisher rate. Turn the screw cw to increase or ccw to decrease the rate. The stroke indicator and the stroke scale guide you in the right way.
Press the key below the word 7(67.
The Master Lab+ now delivers 20 pump strokes of replenisher per tank into the graduated cylinders. If no liquid is detected after 6 or 7 strokes, an alarm message is displayed and the test stops. If the delivered quantity deviates from the 120,1$/ 48$17,7< 3(5 7(67 &<&/(, adjust the pump again and repeat the calibration.
5HSODFLQJ D EHOORZ RI WKH UHSOHQLVKPHQW SXPS
This procedure may be necessary if you need to change the paper processor from RA-4 chemistry to Prime chemistry or when you have a defective bellow. Switch OFF the machine with the main switch. Remove the upper side panel of the paper processor.
saml12022a
Remove both screws $ holding the paper replenishment pump assembly.
Carefully pull the assembly toward you until you have good access to the bellows.
298
Service Manual
Paper processor and ATS
:$51,1*
98.22.56 Edition 3
%H DZDUH WKDW FKHPLFDO OLTXLG LV LQ WKH WXEHV DQGRU LQ WKH EHO ORZ :KHQ \RX GR WKH QH[W VWHSV WKLV OLTXLG ZLOO IORZ RXW HLWKHU LQWR WKH PDFKLQH RU RQWR \RXU FORWKHV ,W LV DGYLVDEOH WR WDNH D SLHFH RI JRRG DEVRUELQJ FORWK
Remove both elbow connectors of the bellow to be replaced.
saml12023a
Remove both valves 'RQW ORRVH WKH JDVNHWV 2 ULQJV
1RWH
saml12024a
B B
Remove both screws (%) fixing the bellow to the pump.
Tilt down the bellow to be replaced. Turn the white body counterclockwise to remove it from the connecting rod.
Take the new bellow and remove it as well from the connecting rod.
Master Lab / Master Lab+
Screw the new bellow clockwise to the old connecting rod.
Fasten the bellow with both screws (%) to the pump.
Service Manual
299
Paper processor and ATS
saml12025a
Insert both valves together with the gaskets. 1RWH 0DNH VXUH WR UHDVVHPEOH LW FRUUHFWO\ DV VKRZQ
Remount both elbow connectors. Reinstall the complete assembly. Verify the proper function and adjustment as described in chapter 12.9.2
7UDQVSRUW V\VWHP 0DQXDOO\ VZLWFKLQJ WKH PRWRU
The motor can manually be switched ON or OFF if no work cycle is in progress. Otherwise the command is ignored. Select the menu 0$,17! 3352& 75$163 3$3(5 02725
&KHFNLQJ DGMXVLQJ WKH EHOW WHQVLRQ RI WKH WUDQVSRUW PRWRU
Remove the lid of the paper processor.
) *
Open the dryer cover. Remove the temperature sensor from the cable clamp. Remove the dryer rack as shown. Lift it first ($), then move the top to the front (%).
300
Service Manual
Master Lab / Master Lab+
saml12026a
98.22.56 Edition 3
Paper processor and ATS
The transport motor is located below the dryer.
saml04017a
98.22.56 Edition 3
5 mm
5N
The correct belt tension gives a displacement of less than 5mm with a force of 5N (500gr).
saml11029a
"
If necessary, adjust the belt tension by loosening the four screws (item 3) and moving the motor in the indicated direction. 1 = Main shaft 2 = Toothed belt 3 = Mounting screw 4 = Motor
5HPRYLQJ WKH PDLQ VKDIW
Switch OFF the machine with the keyboard first and then with the main switch. Remove the front panel of the Master Lab+. Remove the left side panel. Remove the distributor / conveyer as described in chapter 10.3.17
saml12027a
Master Lab / Master Lab+
"
1 3 5
Set screw M4 x 10 Bearing Worm gear conveyer.
2 4 6
Pulley Main shaft Worm gear driving the distributor/
Loosen the set screw (item 1) of the pulley at the end of the shaft. Remove the pulley (item 2).
Service Manual
301
Paper processor and ATS
Loosen the screws holding the three bearings (item 3) of the main shaft (item 4).
98.22.56 Edition 3 Master Lab / Master Lab+
saml11031a
Worm gear (front view)
Safety clip
Remove the safety clips of the six worm gears driving the racks.
Groove (1 of 3)
Pull out the main shaft from the front of the Master Lab+
,QVWDOOLQJ DQG DOLJQLQJ WKH PDLQ VKDIW
1RWH 2SSRVLWH WR WKH ILOP SURFHVVRU WKH ZRUP JHDUV LQ WKH SDSHU SUR FHVVRU WUDQVSRUW GRQW QHHG DQ\ DOLJQPHQWV
Insert the main shaft from the front of the Master Lab+. Mount the worm gears to the main shaft while inserting the shaft. Remount the pulley. Fix the screws of the three bearing.
saml11031a
Worm gear (front view)
Safety clip
Secure the worm gears with the safety clips.
Groove (1 of 3)
Mount the toothed belt and adjust it as described in chapter . Lubricate the bearings with TRI-FLOW. Start the Master Lab+ and check the paper transport.
&KDQJLQJ WKH WUDQVSRUW VSHHG
The transport speed can be changed between 40s and 50s as the duration for the developing process. The nominal development time is 45s. To change the speed proceed as follows:
302
Service Manual
Paper processor and ATS
Select the menu: 0$,17! 3352& 6<67(0 '(97,0
MAINT P.PROC SYSTEM [s] DEVTIM Developer time [45]
98.22.56 Edition 3
Press the key below the value in brackets and enter the new transport speed. Confirm with (17(5!. )RU VWDQGDUG RSHUDWLRQ OHDYH WKH GHYHORSHU WLPH DV LW LV VHW ,W LV D UHFRPPHQGHG VSHHG IURP WKH FKHPLVWU\ PDQXIDFWXUHU IRU 5$ SURFHVV
1RWH
5DFNV 5DFNV LQ WKH SURFHVVRU
&$87,21
'RQW VZLWFK 21 WKH PDFKLQH DV ORQJ DV WKH UDFNV DUH UH PRYHG DQG WKH VXFWLRQ WXEH LV VWLOO LQ WKH DXWRPDWLF WRSRII WDQN 7KH DXWRPDWLF WRSRII V\VWHP ILOOV XS WKH WDQNV ZLWK ZDWHU DQG WKH FKHPLVWU\ ZRXOG EH GLOXWHG DQG XVHOHVV
saml02042a
Master Lab / Master Lab+
Remove the lid of the paper processor.
saml02043a
Lift the cover of the dryer.
Service Manual
303
Paper processor and ATS
saml02044a
saml02045a
Unlock the lower part of the dryer with the two knurled screws and tip it up.
saml12014a
metal bracket
Screws A
Remove both screws ($) holding the metal bracket. Remove the metal bracket.
9(5< ,03257$17
%H YHU\ FDUHIXO ZKHQ WDNLQJ RXW WKH UDFN WKDW \RX GRQW SRO OXWH WKH RWKHU FKHPLVWU\ ZLWK VSODVKHV 2WKHUZLVH WKH FKHP LVWU\ PD\ EH XVHOHVV Carefully lift the rack out of the tank. Reinsert the rack in reverse order.
Master Lab / Master Lab+
'U\HU UDFN
saml02042a
Remove the lid of the paper processor.
304
Service Manual
98.22.56 Edition 3
Turn both fasteners on the crossover unit left, then lift the unit and remove it.
Paper processor and ATS
saml02043a
98.22.56 Edition 3
Lift the cover of the dryer.
saml02044a
Turn both fasteners on the crossover unit left, then lift the unit and remove it.
saml02045a
Unlock the lower part of the dryer with the two knurled screws and tip it up.
saml12026a
) *
Remove the temperature sensor from the cable clamp. Remove the dryer rack as shown. Lift it first ($), then move the top to the front (%).
Master Lab / Master Lab+
Reinsert in reverse order.
2SHQLQJ D UDFN
1RWH 7KH IROORZLQJ SURFHGXUH LV DEVROXWHO\ 127 UHFRPPHQGHG IRU UH SDLUV LQ WKH ILHOG :H UHFRPPHQG WR H[FKDQJH D GHIHFWLYH UDFN LQ WKH ILHOG ,W UHTXLUHV D YHU\ VNLOOHG ILHOG HQJLQHHU WR KDQGOH DOO WKH UROOHUV DQG JHDUV ZKHQ WKH UDFN KDV WR EH UHDVVHPEOHG
The following procedure is described at the example of the stabilizer rack.
Service Manual
305
Paper processor and ATS
Before you disassemble the rack, clean it thoroughly with water.
saml12028a
Remove the circlip from the axles of the gears and pull out the axle.
saml12029a
Remove the bracket of the rack by pressing a screw driver between the bracket () and the rack at the places shown.
Remove the bracket on the other side of the rack. Remove one side of the rack and take out the rollers to be replaced.
For detailed drawings of each rack please refer to the Spare parts list Master Lab+ P/N 98.22.15.
5HDVVHPEOLQJ WKH UDFN
Place all rollers into the correct position of one side wall.
saml12030a
4 2 3
Mount the other side () of the rack.
Master Lab / Master Lab+
Remount the bracket (). 0DNH VXUH WKDW WKH FOLSV GLG VQDS LQ
1 Bracket 2 Main gear 3 Side of the rack 4 Clips
1RWH
Reinsert the axle and secure the main gear with the circlip. 7KHUH LV QR DOLJQPHQW QHFHVVDU\ IRU WKH UDFNV LQ WKH SDSHU SURFHV VRU
1RWH
Manually turn the main gear to check if all rollers turn smoothly in both directions. If necessary lubricate the bearings with: o TRI-FLOW for the racks in the tanks o pure silicon oil for the dryer rack.
306
Service Manual
98.22.56 Edition 3
Paper processor and ATS
Insert a print by manually turning the main gear and check for correct transport of the print. Carefully reinsert the rack in the tank. Secure the rack with the metal bracket. Remount the crossover and the dryer.
98.22.56 Edition 3
Start the machine to check the paper transport. 1RWH 7KH WUDQVSRUW VWRSV DXWRPDWLFDOO\ ZKHQHYHU WKH OLG LV UHPRYHG DQG WKH HUURU PHVVDJH 7UDQVSRUW $ODUP LQ 3DSHU SURFHVVRU LV GLVSOD\HG
saml12018a
Disable the safety stop by turning the screw 90 counterclockwise (service position).
Press (17(5! to clear the error. If a work cycle was in progress, the transport starts again.
6RUWHU &KHFNLQJ WKH EHOW WHQVLRQ
Open the cover of the paper dryer. Remove the cover under the sorter.
saml04018a
Master Lab / Master Lab+
8 mm 2.5 N
The correct tension gives a displacement of less than 8mm under a force of 2.5N (250gr).
Service Manual
307
Paper processor and ATS
6FKHPDWLFV
Scheda M806 (circuit diagram) Scheda M806 (layout drawing)
17333.085.1 15333.077.1
1 1
308
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
7LWOH
'UDZLQJ
3DJHVVKHHWV
98.22.56 Edition 3
:HW SDUW FRPSXWHU V\VWHP
2YHUYLHZ
13
The film and paper processor are controlled by the same CPU board. Each processor has its own driver board for pumps, heaters and so on. The film processor drivers are on the M802 and the paper processor drivers are on the M803 board. Most wet part computer system boards are located in the drawer under the film processor dryer.
saml13001a
SCSB Sorter
Film Sensor M805
M802 Film
MCB Wet section CPU
Speed control M806 Paper proc.
M803 Paper
Speed control M806 Film proc.
Master Lab / Master Lab+
Console RCB*
Main switch
Line filter
Power supply Printer
Top-off system ALMLPLUS
Battery
)LJ
:HW SDUW HOHFWURQLFV EORFN GLDJUDP
The optional console RCB board is used to control an external replenishment console. This option is for Master Lab only! In he Master Lab+, the place is used for the ALMLPLUS board. This board controls the top-off system and an optional external replenishment console.
Service Manual
309
Wet part computer system
saml13002a
M803
ALMLPLUS
M802
)LJ
%RDUG ORFDWLRQ LQ WKH GUDZHU
Not in the drawer are the two speed control boards M806 and the SCSB board. The control boards M806 are found in the transport systems of each processor. The SCSB board is found in the sorter. The M805 boards (a and b) are located in the film loading station.
0&% ERDUG 2YHUYLHZ
The MCB board is a general purpose microcontroller board designed around the HD6303 microcontroller from Hitachi. This board consists of o a 32kB EPROM o a 8kB RAM o a 16 channel analog / digital converter o a real time clock o a buzzer for acoustic alarm and o a BCD rotary switch for different machine and software versions. A nickel-cadmium battery powers a circuit responsible to retain the data in the microcontroller RAM.
310
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Wet part computer system
saml13003a
Voltage reference
Input circuit
98.22.56 Edition 3
Printer
Serial interface
A/D converter
Timers interface
Real time clock
CPU
Power and reset logic
Code memory
Data memory
Backup supply
)LJ
%ORFN GLDJUDP RI 0&% ERDUG
The MCB board receives the power failure and battery low signals from the power supply on one side. On the other side it sends commands to the power supply to change to battery operation, to supply the printer with dc current and to test the transport battery. This board also receives analog signals from the temperature sensors, pulses from both M806 to determine the paper and film transport speed. The driver boards M802 and M803 are controlled by the MCB and the dialogue with the printer part is made via a serial interface.
Master Lab / Master Lab+
)XQFWLRQDO XQLWV 3URFHVVRU
Processor type Clock rate Address range Hitachi HD63B03Y microcontroller, 8 bit 4.9152 MHz 64kBytes
&RGH PHPRU\
The code memory a EPROM stores the machine program. The storage capacity is 32kBytes. This EPROM is plugged in socket U10.
Service Manual
311
Wet part computer system
'DWD PHPRU\
The data memory stores the setup parameters of the wet part. It is a static RAM with a capacity of 8kBytes. It is plugged in socket U3. A battery backup supply holds the data when the power of the machine is switched off.
98.22.56 Edition 3 Master Lab / Master Lab+
%DFNXS VXSSO\
The responsibility of this unit is to maintain a certain voltage level (S +5V) after shutdown of the regular power to the data memory to prevent the loss of stored information. This buffering is limited to the +5V supply of the storage memory.
saml13004a
+5V S + 5V
Testpoint +VBat 3.6V 100mAh
)LJ 1LFNHO&DGPLXP
%DWWHU\ FRQQHFWLRQ GLDJUDP
The source of the backup voltage is a rechargeable battery. It is of the nickelcadmium type with a capacity of 100mAh. The charging current is ~2.5mA. The battery has an average lifetime of 5 years but it may fall down to a minimum of 11 month, depending on tolerances of the used components. If you encounter the error message %DWWHU\ ORZ , immediately save your data on a memory card and replace the battery (see chapter 13.7.2).
6HULDO LQWHUIDFH
The serial interface is the communication link to the printer part. It is integrated into the microcontroller. The transfer rate is 19200 bits / second (Baud).
$QDORJ WR GLJLWDO FRQYHUWHU
This converter is used to make sensor data understandable for the microcontroller. The analog data from the sensors in the film and paper processor are converted into digital data for the microcontroller.
312
Service Manual
Wet part computer system
saml13005a
Data bus
Temperature sensor (5)
F-Sensors
Low pass filter Film
Address bus
98.22.56 Edition 3
Film processor
Control bus
Ref. Voltage Circuitry
A/D HD46508PA
MCU HD6303Y
Temperature sensor (4) Paper processor
P-Sensors
Low pass filter Paper
)LJ
%ORFN GLDJUDP RI $' FRQYHUWHU
It is a 10 bit converter with 16 inputs. Each of the inputs has a low pass noise filter between the sensor and the converter. The reference voltage for the converter is +5V.
7LPHUV LQWHUIDFH
This circuit controls the transport speed of the film and paper processor. The input information are the pulses generated by the slotted disk on the transport motor and the light barrier on the M806 board.
saml13006a
M803 (Paper)
MCB
or M802 (Film)
slotted disk
light barrier
)LJ
Master Lab / Master Lab+
3ULQFLSOH RI VSHHG FRQWURO
3RZHU DQG UHVHW ORJLF
This circuit is used to initialize the hardware and to check the different supply voltages such as the battery voltage (low battery) and the 19.5Vac (power fail). The reset signal is triggered either by hardware or by software.
Service Manual
313
Wet part computer system
5RWDU\ VZLWFK SRVLWLRQV DQG MXPSHUV
saml13007a
MCB
U2 Microcontroller
Rotary switch
Reset button
Buzzer
J2 +
Battery J1
)LJ
0&% MXPSHU DQG VZLWFKH SRVLWLRQV
5RWDU\ VZLWFK SRVLWLRQV
Position 0: Position 1: Position 2: without sorter with sorter (also for single track machines) 1 track machine with ext. replenishment console (ML+120 and ML+220) Position 3: 2 track machine with ext. replenishment console (ML+140 and ML+240) Position 4 to 9: not used
-XPSHUV
Jumper Default setting Option - Closed Battery on Open Battery off closed Serial interface in normal Open Serial interface in test - mode mode
314
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Wet part computer system
7HVW SRLQWV DQG LQGLFDWRUV
saml13008a
98.22.56 Edition 3
MCB
U2 Microcontroller
Rotary switch
Reset button
TP1 +5V
GND
GND Buzzer L2 L1
J2 +
Battery
TP2 +24V TP3 VBATT J1
)LJ
0&% WHVW SRLQW DQG LQGLFDWRU SRVLWLRQ
7HVW SRLQWV
Test point GND: Test point 1: Test point 2: Test point 3:
Master Lab / Master Lab+
Ground +5V +24V Battery voltage (nominal 3.6Vdc)
,QGLFDWRUV
/(' / / :KHQ 21
Board receives +5Vdc Board receives +24Vdc
Service Manual
315
Wet part computer system
0 ERDUG
1RWH 7KLV GULYHU ERDUG LV XVHG LQ PDFKLQHV ZLWK ILOP SURFHVVRU RQO\
98.22.56 Edition 3 Master Lab / Master Lab+
2YHUYLHZ
The M802 board drives all components of the film processor. It is controlled by the MCB board.
saml13009a
From/to MCB
From sensors
Low pass filter
Buffers / logic
Solenoid drivers 24Vdc
Heater drivers 220V ac
T ransport motor driver 24Vdc
Motor drivers 220V ac
)LJ
%ORFN GLDJUDP RI WKH 0 ERDUG
It receives data from the sensors of the film processor and sends these signals to the MCB board. Commands from the MCB board activate the various loads in the film processor with the drivers on the M802 board. The drivers are for: o bath and dryer heaters o dryer fan o agitation and aeration pumps o replenishment pumps o film cutting knife solenoid o film cassette locking solenoid o film transport motor Received sensor data are: o replenishment pump microswitch and developer vacuum sensor o optical reader in the film loading station (M805) detecting the presence of different film types o cassette present microswitch and film end microswitch in the film loading station to activate the film cutting knife o tank level sensors checking low level in the tanks. 316 Service Manual
Wet part computer system
)XQFWLRQDO XQLWV ,QSXW FLUFXLWU\
98.22.56 Edition 3
All signals coming from the MCB are passing a low pass filter and are buffered to reduce noise.
6ROHQRLG GULYHUV
The solenoid drivers are power transistors switching 24Vdc. Each driver input has an indicator LED showing the status (see 13.3.4).
+HDWHU GULYHUV 9DF
The 220Vac heaters are switched on and off by triacs. These switching elements are protected by two fuse resistors each. During an overload of a fuse resistor, it changes its resistive value to R =
:$51,1*
8QGHU 12 FLUFXPVWDQFHV UHSODFH H GHIHFWLYH IXVH UHVLVWRU ZLWK D QRUPDO UHVLVWRU <RX ORVH WKH SURWHFWLRQ RI WKH GULYHU
saml13010a
220V ac Fuse resistor +5V Fuse resistor Indicator LED Input to heater
Master Lab / Master Lab+
)LJ
&LUFXLW GLDJUDP RI KHDWHU GULYHU
The signal driving the triac is isolated by an opto isolator. Each driver input has an indicator LED showing the status (see 13.3.4).
0RWRU GULYHUV 9DF
These drivers are exactly the same as the drivers for the heaters.
7UDQVSRUW PRWRU GULYHU 9
The driver for the transport motor is a power FET.
Service Manual
317
Wet part computer system
)XVHV RQ WKH 0 ERDUG
saml13011a
M802
F3 F4 F2 F1
)LJ
)XVHV RQ 0
)XVH F1 F2
9DOXH >$@ 8 8
7\SH F F
'LPHQVLRQ >PP@ 6.3 x 32 6.3 x 32
3DUW QXPEHU
3URWHFWHG SDUWV
F3 F4
4 4
F F
6.3 x 32 6.3 x 32
1) F = quick acting fuse (fast blow) T = surge resisting fuse (slow blow)
318
Service Manual
Master Lab / Master Lab+
0028-759-85 220Vac phase 0028-759-85 220Vac neutral Used for: Heater developer, film Heater bleach, film Heater fixer, film Heater stabilizer, film Heater dryer, film 0028-759-81 220Vac phase 0028-759-81 220Vac neutral Used for: Bleach aeration pump, film Dryer fan, film Replenishment pump, film Spray pump developer, film Recirculation pump dev., film Recirculation pump bleach, film Recirculation pump fixer, film Recirculation pump stabi., film
98.22.56 Edition 3
Wet part computer system
,QGLFDWRUV RQ WKH 0 ERDUG
saml13012a
98.22.56 Edition 3
L 23
L 20
L 15
L 10
L5
)LJ
,QGLFDWRUV RQ 0
/(' L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L23
:KHQ 21 Developer heater powered Bleach heater powered Fixer first heater powered Second fixer heater powered First stabilizer heater powered Second stabilizer heater powered Dryer heater powered Dryer fan powered not used not used Bleach aeration pump powered Developer recirculation and spray pump powered Bleach recirculation pump powered Fixer recirculation pump powered Stabilizer recirculation pump powered not used Developer, bleach, fixer and stabilizer multiple replenishment pump powered not used not used not used not used Film cutter solenoid powered Cassette locking solenoid powered
Master Lab / Master Lab+
Service Manual
L1
M802
319
Wet part computer system
0 ERDUG
This board is used for the paper processor. Therefore it is found in every machine.
2YHUYLHZ
The M803 board drives all components of the paper processor. In addition it drives all fans in the entire wet part of the machine. It also switches the power for the printer part.
saml13013a
From/to MCB
From sensors
Low pass filter
Buf fers / logic
Sorter drivers 24Vdc
Heater drivers 220V ac
Transport motor driver 24Vdc
Motor drivers 220V ac
Supply printer part 220V ac
)LJ
%ORFN GLDJUDP RI WKH 0 ERDUG
It receives data from the sensors of the paper processor and sends these signals to the MCB board. Commands from the MCB board activate the various loads in the paper processor with the drivers on the M803 board. The drivers are for: o bath and dryer heaters o agitation pumps o replenishment pumps o pump cooling fan o exhaust fan o printer part power (220Vac) o two way sorter motor o paper transport motor Received sensor data are: o replenishment pump microswitch and developer vacuum sensor o tank level sensors checking low level in the tanks o lost liquid sensor o optical reader indicating the sorter position o microswitch indicating large format prints o sensor on the SCSB indicating prints coming out of the dryer.
320
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Wet part computer system
)XQFWLRQDO XQLWV ,QSXW FLUFXLWU\
98.22.56 Edition 3
All signals coming from the MCB are passing a low pass filter and are buffered to reduce noise.
6RUWHU GULYHU
The sorter driver is capable to change the polarity of the 24Vdc to move the sorter in both directions
+HDWHU GULYHUV 9DF
The 220Vac heaters are switched on and off by triacs. These switching elements are protected by two fuse resistors each. During an overload of a fuse resistor, it changes its resistive value to R =
:$51,1*
8QGHU 12 FLUFXPVWDQFHV UHSODFH H GHIHFWLYH IXVH UHVLVWRU ZLWK D QRUPDO UHVLVWRU <RX ORVH WKH SURWHFWLRQ RI WKH GULYHU
saml13010a
220V ac Fuse resistor +5V Fuse resistor Indicator LED Input to heater
)LJ
Master Lab / Master Lab+
&LUFXLW GLDJUDP RI KHDWHU GULYHU
The signal driving the triac is isolated by an opto isolator. Each driver input has an indicator LED showing the status (see 13.3.4).
0RWRU GULYHUV 9DF
These drivers are exactly the same as the drivers for the heaters with one exception: The driver for the exhaust fan has a different fuse resistor. The fuse resistor R63 is 120Ohm / 1W instead of 68Ohm / 0.5W as for all the others.
Service Manual
321
Wet part computer system
3ULQWHU VXSSO\ 9DF
This driver is the same as the driver for the exhaust fan. The fuse resistor R67 is 120Ohm / 1W.
7UDQVSRUW PRWRU GULYHU 9
The driver for the transport motor is a power FET.
)XVHV RQ WKH 0 ERDUG
saml13014a
F2 F1
F4
M803
F3
)LJ
)XVHV RQ 0
)XVH F1 F2
'LPHQVLRQ 9DOXH 3DUW QXPEHU 7\SH >PP@ >$@ 8 8 F F 6.3 x 32 6.3 x 32
3URWHFWHG SDUWV
1) F = quick acting fuse (fast blow) T = surge resisting fuse (slow blow)
322
Service Manual
Master Lab / Master Lab+
F3 F4
4 4
F F
6.3 x 32 6.3 x 32
0028-759-85 220Vac phase 0028-759-85 220Vac neutral Used for: Heater developer, paper Heater bleach, paper Heater stabilizer, paper Heater dryer, paper 0028-759-81 220Vac phase 0028-759-81 220Vac neutral Used for: Exhaust fan Dryer fan, paper Replenishment pump, paper Cooling fan pump Recirculation pump dev., paper Recirculation pump bleach, paper Recirculation pump stabi., paper Main power for the printer part
98.22.56 Edition 3
Wet part computer system
,QGLFDWRUV RQ WKH 0 ERDUG
saml13015a
L10
98.22.56 Edition 3
M803
)LJ
,QGLFDWRUV RQ 0
/(' L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19
:KHQ 21 Developer heater powered Bleach heater powered First stabilizer heater powered Second stabilizer heater powered Third stabilizer heater powered First dryer heater powered Second dryer heater powered Dryer fan powered Developer recirculation pump powered Bleach recirculation pump powered Stabilizer recirculation pump powered not used not used Developer, bleach and stabilizer multiple replenishment pump powered Pump cooling fan powered Bath exhaust fan powered 220Vac power line feeds printer part Not used not used
Master Lab / Master Lab+
Service Manual
L15
L1
L5
L19
323
Wet part computer system
$/0/3/86 ERDUG 2YHUYLHZ
This board controls the automatic top-off system of the Master Lab+. This system adds water to the different tanks in the film as well as in the paper processor to compensate for evaporated liquid during the night.
saml13016a
Electro Pump valves Replenishment consol
J86
J87
J76
J85 Power supply 220VAC Input (not used) J93
8 4 C 4
8 4 C
8 C
SW1 SW2 SW3
J94 Output (not used)
ATS
ALMLPLUS Board
J89 J90
J84 Power supply 24VDC J88 J75
Tank sensor MCB Board
)LJ
&RQQHFWLRQ GUDZLQJ
It also adds water in case a tank level is too low during production but just as much as is necessary before an overflow occurs. Finally it cleans the squeegees of the film stabilizer 2 in a standby mode of the film processor.
3XPS GULYHU
The 220Vac pump is switched on and off by a triac. This switching element is protected by two fuse resistors. During an overload of a fuse resistor, it changes its resistive value to R =
324
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Wet part computer system
:$51,1*
98.22.56 Edition 3
8QGHU 12 FLUFXPVWDQFHV UHSODFH D GHIHFWLYH IXVH UHVLVWRU ZLWK D QRUPDO UHVLVWRU <RX ORVH WKH SURWHFWLRQ RI WKH GULYHU
saml13017a
+5V
Fuse resistor
Fuse 2A Fuse resistor to pump
220V ac Input 0V
)LJ
&LUFXLW GLDJUDP RI SXPS GULYHU
The signal driving the triac is isolated by an opto isolator. Each driver input has an indicator LED showing the status (see 13.3.4).
)XVHV RQ WKH $/0/3/86 ERDUG
saml13018a
.
& + " "
& + "
& +
Master Lab / Master Lab+
)LJ
)XVHV RQ WKH $/0/3/86
)XVH F1 F2
9DOXH 'LPHQVLRQ 7\SH 3DUW QXPEHU >$@ >PP@ 1.25 2 F F 5 x 20 5 x 20
3URWHFWHG SDUWV +24V Auto level pump (220Vac)
1) F = quick acting fuse (fast blow) T = surge resisting fuse (slow blow)
Service Manual
325
Wet part computer system
,QGLFDWRUV RQ WKH $/0/3/86 ERDUG
saml13019a
EV1 EV2 EV3 EV4 EV5 EV6 EV7 EV8 EV9 EV10 EV1 1
8 4 4 C 0 8 4 C 0 8 C 0
ALAR +24V +5V ACT PUMP MAIN ON TANK BUZZ.
Electro valve film developer Electro valve film bleach Electro valve film fixer 1 Electro valve film fixer 2 Electro valve film stabilizer 1 Electro valve film stabilizer 2 Electro valve paper developer Electro valve paper bleach Electro valve paper stabilizer 1 Electro valve paper stabilizer 2 Electro valve paper stabilizer 3 Level phase alarm Power supply +24V Power supply +5V The board is running (flashing with 1Hz) Top-Of f pump Maintenance mode Manual switch activated (green lamp) Level empty (red lamp) Buzzer
)LJ
,QGLFDWRUV RQ WKH $/0/3/86 ERDUG
6&6% ERDUG
This board has to detect prints coming out of the dryer and to determine the correct sorter position.
saml13023a
)LJ
/D\RXW RI 6&6%
The detection is made by two IR light barriers. Each light barrier consists of a transmitter and a receiver on the other side. The signals are sent to the MCB.
326
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Wet part computer system
$FFHVVLQJ $GMXVWLQJ UHSODFLQJ WKH ZHW SDUW HOHFWURQLF ERDUGV 7KH 0&% 0 0 5&% RU $/0/3/86 ERDUGV
saml01001a
98.22.56 Edition 3
POWER
ATS
Switch OFF the Master Lab+ with the main circuit breaker.
saml113021a
POWER
ATS
Loosen the cap socket screw in the drawer.
saml13002a
M803
ALMLPLUS
M802
Pull out the drawer and you have access to the MCB, M802, M803, RCB or ALMLPLUS
Master Lab / Master Lab+
To close the drawer proceed in reverse order.
5HSODFLQJ WKH EDWWHU\ RQ WKH 0&%
To replace the battery on the MCB proceed as follows: If not already done, make a backup of the data. Switch OFF the machine and open the drawer as described in chapter 13.7.1 Unplug all connectors. Remove the MCB Board. 327
Service Manual
Wet part computer system
saml13027a
Desolder the battery Solder the new battery. :DWFK WKH SRODULW\
*=JJAHO
1RWH
&$87,21
,I D EDWWHU\ KDV WR EH UHSODFHG GRQW WKURZ WKHP LQWR WKH ZDVWHSDSHU EDVNHW RU GXVW ELQ %H DZDUH WKDW \RX GLVSRVH WKH EDWWHU\ VWULFWO\ LQ DFFRUGDQFH ZLWK WKH ORFDO UHJXODWLRQ IRU WKH SURWHFWLRQ RI WKH HQYLURQPHQW 7KH\ KDYH WR EH WUHDWHG DV VSHFLDO UHIXVH Switch ON the machine Restore the previously written backup with the machine data from the memory card to the printer as described in chapter 6.8.2. Set the internal clock as described in chapter 2.5.6.
Set the timer as described in chapter 2.5.5
7KH 6&6% ERDUG
To adjust or replace the board proceed as follows:
saml02043a
Lift the cover of the paper dryer. Make sure the cover locks on both sides.
328
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Wet part computer system
saml13024a
98.22.56 Edition 3
The SCSB board is located inside the cover of the dryer.
saml13025a
, 4
3 4
, 4!
3 4"
Measure the voltage across R2 respectively R4 without any paper present between the sensors. Use a digital voltmeter with a minimal impedance of 1MOhm / Volt. The voltage has to be higher than 35mV
saml13026a
, ,
4"
4
3
4! 4
If the voltage is less, adjust the sensors mechanically until you have the highest voltage (35mV to 200mV)
To close the cover of the dryer, proceed in reverse order.
Master Lab / Master Lab+
Service Manual
329
Wet part computer system
6FKHPDWLFV
Overview schematics Schema a blocci MCB (block diagram MCB) Scheda MCB (circuit diagram MCB) Scheda MCB/N (layout drawing) Scheda MCB 4S (layout drawing) Scheda M802 (circuit diagram) Scheda M802 (layout drawing) Scheda M803 (circuit diagram) Scheda M803 (layout drawing) Scheda ALMLPLUS (circuit diagram) Scheda ALMLPLUS 4S (layout drawing) Scheda SCSB (circuit diagram) Scheda SCSB (layout drawing) Drawer, layout overview Drawer, internal wiring Wiring 220V Wiring 220V, pumps Wiring 230V, dryer Wiring 24V / 45V Fuseboard, schematics Fuseboard, layout Wiring signal level Wiring signal level, dryer Wiring signal level, replenishment console
17519.021.0 17433.004.0 17319.013.3 14074.207.1 15356.099.7 17322.014.3 15313.045.4 17333.088.2 15313.044.3 17344.252.2 15356.149.5 17333.095.1 15335.004.2 14064.682.8 18720.230.8 18720.231.9 17233.270.1 15399.283.5 15399.288.5 17322.016.0 15311.016.0 15399.289.6 15399.274.7 15399.302.1
1 to 25 1 1 to 5 1 1 1 1 1 1 1 to 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1
330
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
7LWOH
'UDZLQJ
3DJHVVKHHWV
98.22.56 Edition 3
2SWLRQV
&XVWRPL]HU
14
The Customizer provides an attractive possibility of customizing products using existing conventional equipment. Complex prints are exposed onto regular photographic paper in a short time. For further details refer to: o Service Manual Customizer Master Lab+ P/N 98.29.02 and o Spare parts list Customizer Master Lab+ P/N 98.29.14 and o Operating Manual Customizer Master Lab+ P/N 98.29.15
Master Lab / Master Lab+
)LOP FOHDQHU
*HQHUDO
The film cleaner discharges any static electricity by means of ionized air and cleans the film with brushes.
Service Manual
331
Options
,QVWDOODWLRQ
98.22.56 Edition 3 Master Lab / Master Lab+
,03257$17
7KH IROORZLQJ GHVFULSWLRQ DERXW WKH LQVWDOODWLRQ LV IRU 9DF ILOP FOHDQ HUV RQO\ 9DF W\SHV PXVW KDYH D ORFDO FRQQHFWLRQ DQG VKDOO 127 EH FRQQHFWHG WR WKH 32',6 ,I FRQQHFWHG WR WKH 32',6 WKH\ ZLOO EXUQ RXW Switch OFF the machine first at the keyboard followed by the main switch.
saml14032a
Remove the light shaft and the film deck. Remove the four screws holding the black cover of the lamp house. Remove the black aluminum cover.
Remove the side panel of the printer electronics. Tilt down the electronic unit (CPU / CBO). Remove the aluminum plate behind the electronic unit to access to the PODIS. Position the film cleaner under the keyboard and lead the power cable into the lamp house, through the hole in the table into the cable duct and finally to the PODIS.
saml14033a
P/S
Film Cleaner
N PE
Power Distributor PODIS
Connect the cable to the corresponding terminal on the PODIS.
Remount the aluminum plate behind the electronic unit. Tilt up the electronic unit (CPU / CBO).
332
Service Manual
Options
Remount the side panel of the printer electronics. Remount the black aluminum plate to the lamp house.
98.22.56 Edition 3
Insert the light shaft and the film deck. Switch ON the machine again.
Master Lab / Master Lab+
Service Manual
333
Options
5HPRWH FRQWURO LQWHUIDFH
*HQHUDO
The remote interface and the corresponding software package (SW 1.xx R on CBO2, position U71) in the Master Lab+ allows you or read via modem the setup data, production statistics and quality control data from a remote location. On the other side you may transmit setup data to a remote Master Lab+. It is also possible to perform certain maintenance and tests with the <MAINT> menu from a remote position. 1RWH )RU VDIHW\ UHDVRQ WKH UHPRWH IXQFWLRQV ZLWK WKH PHQX 0$,17! GRQW DOORZ DQ\ RSHUDWLRQV ZKLFK PRYH SDUWV VXFK DV WXUQLQJ WKH IHHGHU PRYLQJ WKH NQLIH DQG VR RQ 7KH VRIWNH\ DQG WKH (17(5! NH\ DUH EORFNHG IRU VXFK RSHUDWLRQV DQG DQ HUURU PHVVDJH LV GLV SOD\HG
98.22.56 Edition 3 Master Lab / Master Lab+
Quality Control Production Statistics Setup Data
The modem is connected between the phone line and the Master Lab+. At the other end of the phone line is a computer (PC) with a software supplied by GRETAG IMAGING AG. Communication is always started by the computer and never by the Master Lab+.
saml14001a
Setup
Modem
SETUP
Language Phone Line Setup Data Quality Control Production Statistics
LANGUAGE
M M R CR E O Y AD
Modem
Spreadsheet or Database Program
334
Service Manual
M M R CR E O Y AD
Options
98.22.56 Edition 3
,QVWDOODWLRQ
For detailed information about installation and use of the remote control interface refer to the Operating Manual MASTER CONTROL Program 1.60, P/N 98.27.40 and for MASTER CONTROL Program 2.4x P/N 98.29.56.
0DVWHU /DE GLUHFWO\ FRQQHFWHG WR D 3&
saml14002a
Master Lab
+
RS 232
PC PC labeling e.g. COM 1 2 3 4 5 TD RD RTS CTS
Master Lab labeling: Modem TXD RXD RTS CTS GND DTR 2 3 4 5 7 20
7 GND 20 DTR
Connect the PC with a standard 1 to 1 (25 line) cable to the Master Lab+. Should the COM port on your PC be a 9 pin Sub-D connector, you need a gender changer from 25 pin to 9 pin.
0DVWHU /DE FRQQHFWLRQ YLD PRGHP
saml14003a
Master Lab
+
RS 232
Modem
Auto answer mode Modem
2 3 4 5 7 20 6
Modem
RS 232
PC PC labeling
Master Lab labeling:
Modem TXD RXD
2 3 4 5 7 9 20
Modem TD RD RTS CTS DSR GND CD DTR RI
2 3 4 5 6 7 8 20 22
e.g. COM 1
2 3 4 5 6 7 8 20 22
TD RD RTS CTS GND DTR DSR
TD RD RTS CTS DSR GND CD DTR RI
Master Lab / Master Lab+
RTS CTS GND +12V DTR
Connect your PC to the modem with a standard 1 to 1 (25 line) cable. Should your COM port on your PC be a 9 pin Sub-D connector, you need a gender changer from 25 pin to 9 pin. The cable between Master Lab+ and modem requires special wiring.
Service Manual
335
Options
5HSOHQLVKPHQW FRQVROH
*HQHUDO
1RWH 7KH UHSOHQLVKPHQW FRQVROH LV QRW DYDLODEOH IRU 0DVWHU /DE 0/ [[ DQG 0/ [[
98.22.56 Edition 3 Master Lab / Master Lab+
The replenishment console replaces the small internal replenishment tanks with larger units placed in an external console providing all the necessary hydraulic and electrical connections. This kit is suitable for all Master Lab models with a film processor, increasing their working autonomy. The installation kit contains a small electronic board called RCB required in older Master Labs to manage the level sensors in the tanks of the console. The dimensions of the console are: Width: 78cm (30.7) Height: 118cm (46.5) Depth: 43cm (17) The system is made of an external console placed on feet that can be placed just behind the Master Lab+. The console contains 14 tanks: o 7 for replenishment and o 7 for recovery. The capacity of each tank is 13 liters. Pipes to connect the tanks to the Master Lab+ are provided. Another collecting tray at the bottom of the Master Lab is necessary to feed the pipes from the console to the replenishment pumps and to the tanks. Two systems are possible to monitor the levels in the tanks of the console: o An electronic board (called RCB), part of the kit for older Master Labs to be installed in the electrical panel of the wet part o Function included in the ALMLPLUS board in Master Lab+
,QVWDOODWLRQ
For the installation proceed as follows: Switch OFF the machine first at the keyboard followed by the main switch. Remove the replenishment and recovery tanks for the film and the paper processor. Open the bottom side panels.
336
Service Manual
Options
)LOP VLGH
saml14004a
3DSHU VLGH
saml14005a
98.22.56 Edition 3
Remove the upper covers
saml14006a
saml14007a
Master Lab / Master Lab+
Remove the draw-off units
saml14008a
saml14009a
Service Manual
337
Options
Remove the replenishment tanks from the machine.
saml02011a
saml02016a
Close and remove the recovery tanks from the machine.
saml14010a
saml14011a
saml14012a
Remove the overflow connection pipes at the working tanks.
Disconnect the replenishment pipes at the filters coming from the draw-off unit.
338
Service Manual
Master Lab / Master Lab+
Remove the tank tray and support for the recovery tanks (4 screws)
98.22.56 Edition 3
)LOP VLGH
3DSHU VLGH
Options
,03257$17
98.22.56 Edition 3
/LIW WKH ORVW OLTXLG VHQVRU EHIRUH \RX SXOO RXW WKH ROG WDQN WUD\ RU LQVHUW WKH QHZ WDQN WUD\ RWKHUZLVH WKH VHQVRU ZLOO EUHDN RII
saml14013a
Lost liquid sensor
Remove the lower tank tray. Lift it on the opposite side of the lost liquid sensor and carefully pull it out while lifting the lost liquid sensor.
Remount the new tank tray (with holes).
,03257$17
:KLOH FRQQHFWLQJ WKH SLSHV PDNH VXUH WKDW WKH ULJKW SLSH LV FRQQHFWHG WR WKH ULJKW ILOWHU RU WDQN DQG GRQW EXFNOH WKH SLSHV Connect the replenishment pipes from the console to the filters. Connect the overflow pipes to the working tanks. Secure them with the new clamps supplied in the kit. Pull out the drawer at the rear of the Master Lab/Master Lab+ carrying the wet part electronics.
2OGHU 0DVWHU /DEV
saml14014a
0DVWHU /DE
saml14015a
Master Lab / Master Lab+
Cable duct
Cable duct
J76
Cable duct
Cable duct
J76
RCB Board
Cable duct Cable duct Cable duct
ALMLPLUS bo
ard
Cable duct
J75
Cable duct
MCB Board
Cable duct
MCB Board
Service Manual
339
Options
Mount the RCB board to the electrical panel using the lock spacers (6 pieces). Connect J75 of the RCB board to J74 on the MCB board (cable is included). Connect the replenisher console D Connect the replenisher console to J76 on the RCB board (cable is to J76 on the ALMLPLUS board included). (cable is included).
98.22.56 Edition 3 Master Lab / Master Lab+
saml14016a
1 0 9
4 5
MCB
Set the BCD-switch on the MCB board to the following positions: o Pos. 2 for ML without sorter but with replenisher console. o Pos. 3 for ML with sorter and replenisher console
)LOP VLGH
saml14017a
3DSHU VLGH
saml14018a
Cable duct
Cable duct
Open the cable ducts and unplug connector J32 (film side) and J33 (paper side). If a vacuum-switch is installed, disconnect it at the microswitch on the replenishment pump.
340
Service Manual
Options
saml14019a
98.22.56 Edition 3
J32 /J33
Connect the replenishment pump with cable P/N 15399.332.0 to the respective connector J32 (film side) and J33 (paper side). 1RWH 7KH IORZPHWHU RU YDFXXP VZLWFKHV UHPDLQ GLVFRQ QHFWHG
P/N 15339.332.0
Repl. pump microswitch
Close the cable ducts and all covers you have removed.
1 2
Master Lab / Master Lab+
Service Manual
341
Options
/LQH SULQWHU
9(5< ,03257$17
7KH OLQH SULQWHU GRHVQW ZRUN DQ\PRUH DV RI PDLQ VRIWZDUH YHUVLRQ [[
98.22.56 Edition 3 Master Lab / Master Lab+
*HQHUDO
Depending on the Master Lab (Master Lab or Master Lab+), the kind of information to be printed with the line printer is different: o With a Master Lab, all setup parameters, production statistics, photographic statistics, scanner values and results of exposure time calculations can be printer with the line printer. o With a Master Lab+, only the scanner values of a negative can be printed with the line printer. The reason is the remaining memory capacity. The information to be printed is selected with the menu &200! /,67 ;;;; The line printer is connected to the Master Lab/Master Lab+ at the serial interface which is located at the lower left rear corner of the machine. The connector is marked with /LQH 3ULQWHU Be aware, the line printer interface at the Master Lab/Master Lab+ is a serial interface, unlike most line printers which are for parallel interface only. For this reason, the line printer supplied by GRETAG IMAGING is equipped with an external serial/parallel converter.
6HWWLQJ XS WKH OLQH SULQWHU
Two DIP switches on the control circuit board in the line printer allow the selection of certain functions. The following configuration has to be set: o 9600 Baud o 8 Data Bit o 1 Stop Bit o No parity To set the configuration proceed as follows: Turn OFF the main switch of the line printer.
342
Service Manual
Options
saml14020a
98.22.56 Edition 3
Remove the cover on the rear of the line printer.
saml14021a
ON OFF
ON
DS1
ON
DS2
The DIP switches are now visible.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10
The DIP switches have the following setting possibilities:
',3 VZLWFK '6
This is a 8 switch unit.
6ZLWFK 1R 1 2 3 4 5 6 7 8
)XQFWLRQ Print mode Zero character Character table Printer commands Printer quality International character set
21 Compressed Graphics IBM Mode NLQ
2)) Pica 0 Italics EPSON Mode Draft
,QWHUQDWLRQDO FKDUDFWHU VHW &RXQWU\ USA France Germany England Denmark Sweden Italy Spain 6ZLWFK 1R ON ON ON ON OFF OFF OFF OFF 6ZLWFK 1R ON ON OFF OFF ON ON OFF OFF 6ZLWFK 1R ON OFF ON OFF ON OFF ON OFF
Master Lab / Master Lab+
',3 VZLWFK '6
This is a 10 switch unit
Service Manual
343
Options
6ZLWFK 1R 1 2 3 4 5 6 7 8 9 10
)XQFWLRQ Paper select Paper length Skip perforation Automatic line feed Code unit C.G. font select Paper-end detector Print mode Bidirectional
21 Active 12 ON CR + LF 7 units ATARI / IBM2 Inactive Emphasized Factory set
2)) Inactive 11 OFF CR only 8 units ATARI / IBM1 Active Standard 'RQW FKDQJH
5HFRPPHQGHG VZLWFK VHWWLQJ
The recommended DIP switch setting should look as follows:
saml14022a
DS 1 ON OFF ON OFF
DS 2
6HWWLQJ WKH VHULDO SDUDOOHO FRQYHUWHU
The serial to parallel converter receives serial data from the Master Lab and converts them to parallel data for the line printer. The converter has a DIP switch and jumpers for a correct configuration.
saml14023a
OFF ON 1 2345 6 DIP-Switch
Jumpers
',3 VZLWFK
1 2 3 4 5 6 ON OFF ON ON OFF OFF 9600 Baud 9600 Baud 9600 Baud 8 Data Bits Parity: none Parity: none
344
Service Manual
Master Lab / Master Lab+
The right settings to connect the Riteman line printer is as follows:
98.22.56 Edition 3
Options
-XPSHUV '7( VHOHFWLRQ
saml14024a
98.22.56 Edition 3
Front view
&RQQHFWLRQ FDEOH OLQH SULQWHU 0DVWHU /DE0DVWHU /DE
The interconnecting cable is a serial cable with a 25 pin male Sub-D connector on both sides. The cable is available under P/N 36.13.64.
saml14025a
Master Lab/Master Lab+
25 Pin male, Sub D DTR - DSR 20 TxD - RxD 3 GND 7 CTS - RTS 4
Line printer
25 Pin male, Sub D
20
Master Lab / Master Lab+
Service Manual
345
Options
3DVVSRUW OHQV :DOOHW OHQV
*HQHUDO
With the optional passport lens (lens code 9) you have the possibility to print from a 135 film negative four equal images with the size of 40mm x 60mm (~1.6 x ~2.4) on 3.5 paper. The passport lens can be ordered under P/N 34.85.42. With the optional wallet lens (lens code 10) you have the possibility to print from a 135 film negative two equal images with the size 63mm x 89mm (~2.5 x 3.5) on 5 paper. The wallet lens can be ordered under P/N 34.85.40.
98.22.56 Edition 3 Master Lab / Master Lab+
,QVWDOODWLRQ
The installation of the passport lens or wallet lens is similar to the installation of a regular lens (see chapter 2). A special self-adhesive shielding bracket (P/N 36.12.34) included in the passport lens kit only, has to be fixed to the optic box below the 135 film deck to avoid reflections. Proceed as follows: Remove the film deck from the machine. Remove the protective foil from the adhesive tape on the shielding bracket.
saml14026a
Filmdeck Optic box Shielding bracket P/N 36.12.34
Stick the bracket to the recess on the optic box as shown. Press it well to the optic box.
Set up a corresponding format channel.
$GMXVWPHQW
1RWH 7KH DGMXVWPHQW LV GHVFULEHG IRU WKH SDVVSRUW OHQV EXW LW LV LGHQWL FDO IRU WKH ZDOOHW OHQV
$OLJQLQJ WKH OHQV
346 Select the menu &200! 35,17(5 6(7/(16 6(7=220 Press the key below 67$57. Open the front cover. Service Manual
Options
saml14027a
98.22.56 Edition 3
Check the alignment of the four prints on the paper.
saml14028a
Loosen the set screw at the lower end of the lens.
5AJ I?HAM
saml14029a
Turn the insert carrying the four lenses until the prints are correctly aligned. 7KH SULQWV PD\ EH RII FHQ WHU UHIHU WR WKH QH[W FKDS WHU
1RWH
Tighten the set screw again.
Master Lab / Master Lab+
Service Manual
347
Options
&HQWHULQJ WKH SULQWV RQ WKH SDSHU
Remove the light shaft and the film deck.
98.22.56 Edition 3
saml14030a
Turn the screws in the flange ring of the lens in the desired direction.
Reinsert the film deck and the light shaft. Check the position with the menu: &200! 35,17(5 6(7/(16 6(7=220. Press the key below 67$57.
saml14031a
Ensure that the position of the prints is as much in the center as possible. Otherwise repeat step 1 to 5.
348
Service Manual
Master Lab / Master Lab+
Options
98.22.56 Edition 3
*UHHWLQJ FDUG DWWDFKPHQW
*HQHUDO
The greeting card option allows you to print an additional subject to the regular print size of 3.5 and 4. This option only works as of main software version 2.00.
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description 36.16.60 BV supplied with the greeting card attachment and is also found at the end of this chapter.
&RQYHUVLRQ DQG XSJUDGH NLWV
Several upgrade kits allow an improvement of productivity and/or possibilities.
(QODUJHPHQW NLW (
*HQHUDO
This enlargement kit (P/N 34.65.07 for Master Lab and Master Lab+) converts a single format machine into a multi format machine. It converts: o a Master Lab+ 120 to a Master Lab+ 220 o a Master Lab+140 to a Master Lab+ 240 o a Master Lab / Master Lab+ 320 to a Master Lab / Master Lab+ 520 o a Master Lab / Master Lab+ 340 to a Master Lab / Master Lab+ 740
,QVWDOODWLRQ
Master Lab / Master Lab+
For the installation and setup procedure refer to the corresponding description 34.65.07 BV supplied with the upgrade kit.
6SHHGXS NLW ,
*HQHUDO
There are two speedup kits available: o with P/N 34.65.08 for Master Lab o with P/N 36.46.76 for Master Lab+
Service Manual
349
Options
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description 34.65.08 BV / 36.46.76 BV respectively supplied with the upgrade kit.
6SHHGXS NLW ,,
*HQHUDO
The speedup kit II (P/N 34.28.79) does the same as the speedup kit I but is without sorter. It converts: o a Master Lab / Master Lab+ 220 to a Master Lab / Master Lab+ 240 o a Master Lab / Master Lab+ 520 to a Master Lab / Master Lab+ 540
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description 34.28.79 BV supplied with the upgrade kit.
'LJLWDO XSNLW
*HQHUDO
This upgrade (P/N 36.43.56 for Master Lab+ only!) allows printing of electronic images on photographic paper. The kit contains a CRT, the optics for prints up to 4, the necessary electronics and a plug-in for the Photo Shop software to calibrate it to the CRT. This upkit can be installed into any multi format machine (Master Lab+ 220 / 240 / 520 or 740)
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description 36.43.56 BV supplied with the upgrade kit. Further information are also found in: o Service Manual Master Lab Digital P/N 98.27.15 and o Spare parts list addendum Master Lab Digital P/N 98.27.16
350
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
This upgrade kit converts a machine with 200 prints/hour to a machine with 400 prints/hour. It also contains a sorter. It converts: o a Master Lab+ 120 to a Master Lab+ 140 o a Master Lab / Master Lab+ 320 to a Master Lab / Master Lab+ 340
Options
98.22.56 Edition 3
)LOP SURFHVVRU XSJUDGH
*HQHUDO
The film processor upgrade kit P/N 18988.243.0 is for every Master Lab / Master Lab+ without the possibility to develop film. This upgrade converts: o a Master Lab / Master Lab+ 120 to a Master Lab / Master Lab+ 320 o a Master Lab / Master Lab+ 140 to a Master Lab / Master Lab+ 340 o a Master Lab / Master Lab+ 220 to a Master Lab / Master Lab+ 520 o a Master Lab / Master Lab+ 240 to a Master Lab / Master Lab+ 740
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description supplied with the upgrade kit
8SJUDGLQJ WKH SURFHVVRU WR .2'$. 60
The Master Lab SM wet part uses Kodak patented LVTT (/ow-9olume 7hin 7ank) technology with direct replenishment chemicals delivered from Kodak SM Processing Units (cartridges). The Kodak Processing Units contain the concentrated chemicals which are mixed with water directly in the working tanks of the machine. Two SM Processing Units (P1, P2) are used for the paper processor and two SM Processing Units (F1, F2) are used for the film processor. A built-in water tank delivers water for the mixing of the replenishment and for the automatic top-off system. For operation the SM Processing Units (cartridges) are inserted by the operator into the appropriate support and are easily exchanged when empty. The water tank has to be filled up separately. Finally 4 multi-head pumps (one for each Processing Unit) are used to bring the concentrated replenishment chemicals and the water into the working tanks. Further information is also found in: o Service Manual Master Lab+ SM P/N 98.27.91 and o Spare parts list addendum Master Lab+ SM P/N 98.27.86
Master Lab / Master Lab+
$XWRPDWLF 'HQVLWRPHWHU $'0
*HQHUDO
The automatic Densitometer P/N 34.90.98 upgrades a Master Lab+ which was originally delivered with Densitometer D188. This densitometer allows automatic reading of film and paper test strips by simply inserting them into the entry slot. This is an optional component within the concept to upgrade a Master Lab to a Master Lab+
Service Manual
351
Options
Handling, maintaining and servicing the automatic Densitometer is described in the Operating Manual and the Service Manual supplied with the equipment.
98.22.56 Edition 3 Master Lab / Master Lab+
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description 34.90.98 BV supplied with the upgrade kit.
/DPS KRXVH XSJUDGH NLW
*HQHUDO
The lamp house upgrade kit P/N 34.29.66 simplifies the setup procedure by means of a testfilter installed in the lamp house of a Master Lab+ operating with main software 3.00 or higher. In addition, the power supply for the cooling fan is now taken directly from the 24Vdc.
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description 34.29.66 BV supplied with the upgrade kit.
$36 ,QGH[ NLW
General This upgrade is intended for Master Lab+ which are of the multi format type, such as ML+ 520 / 740 or 220 / 240. Such upgraded machines allow printing and processing normal negatives (135 film) in the conventional printing mode, as well as formats (C-, H- and P-formats) of APS film. It also allows the production of index prints from APS film and 135 film. As an option, all other film formats may be printed and processed too. Several kits are available to upgrade the different Master Lab+: o upgrade kit P/N 37.06.40, upgrading Master Lab+ 220 for APS and Index print o upgrade kit P/N 37.06.41, upgrading Master Lab+ 240 for APS and Index print o upgrade kit P/N 37.06.42, upgrading Master Lab+ 520 for APS and Index print o upgrade kit P/N 37.06.43, upgrading Master Lab+ 740 for APS and Index print An optional 135 film deck allows you to produce index prints from 135 film. This optional film deck is available for all the above mentioned Master Lab+.
352
Service Manual
Options
,QVWDOODWLRQ
For the installation and setup procedure refer to the corresponding description 37.06.40 IA supplied with the upgrade kit. Further information are also found in: o Operating Manual Addendum Master Lab+ Advanced Photo System P/N 98.27.43 and o Service Manual Addendum Master Lab+ Advanced Photo System P/N 98.27.42 and o Spare parts list Addendum Master Lab+ Advanced Photo System P/N 98.27.41
98.22.56 Edition 3
.LW GHVFULSWLRQV
7LWOH
Greeting card
.LW
36.16.60 BV
3DJHVVKHHWV
1 to 6
Master Lab / Master Lab+
Service Manual
353
354
98.22.56 Edition 3
Options
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
%LEOLRJUDSK\ JORVVDU\ DQG LQGH[
%LEOLRJUDSK\
D 6DIH KDQGOLQJ RI 3KRWRJUDSKLF 3URFHVVLQJ &KHPLFDOV Kodak Catalog # CAT 832 1713) Pub. # J-98A
15
Learn how to safely handle photoprocessing chemicals and to recognize and avoid potential hazards E ,QGRRU $LU 4XDOLW\ 9HQWLODWLRQ LQ 3KRWRJUDSKLF 3URFHVVLQJ )DFLOLWLHV
Kodak Catalog # CAT 184 9298) Pub. # J-314 Learn about the rol and proper use of ventilation systems in the workplace to help minimize employee exposure to photographic processing chemicals.
*ORVVDU\
$36
Master Lab / Master Lab+
Abbreviation for $dvanced 3hoto 6ystem. A new film format developped by Kodak. This film format has several advantages compared with the former film formats such as easier handling, several negative formats on the same film and the possibility to strore special information with every negative. $'0 Abbreviation for $utomatic 'ensito0eter. Built-in equipment for automatic measurement of the colors on a test strip or test negative, $76 Abbreviation for $utomatic 7op-off 6ystem. A system in the wet part of the machine responsible to compensate the los of liquide due to evaporation.
Service Manual
355
Bibliography, glossary and index
%&' Abbreviation for %inary &oded 'ecimal. Methode to use decimal figures in a computer based system. (3520 Device containing a software program which is resident on a PBA to control and /or monitor the function of a particular sub-unit. ,QGH[ SULQW This is an overview print containing all negatives of the film as little thumbnail pictures marked with the frame number. This allows the customer to reorder prints withoput handling the negatives. /&' Abbreviation for /iquid &ristal 'isplay. Type of man-machine interface. /(' Abbreviation for /ight (mitting 'iode. A semiconductor device emitting light when current is passed through the element. 06'6 Abbreviation for 0aterial 6afety 'ata 6heet. An informative paper provided by the supplyer of chemicals explaining the characteristics, possible risks under defined conditions, protection and first aid measures 3%$ Abbreviation for 3rinted %oard $ssembly. Indicating a printed circuit board which has components mounted on it. PCB would be the bare printed circuit itself. 5$0
Master Lab / Master Lab+ 98.22.56 Edition 3
Abbreviation for 5andom $cess 0emory. An electronic storage chip allowing the access of an individual position ion the storage area.
356
Service Manual
98.22.56 Edition 3
,QGH[
A
Adjusting Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196, 221, 300 Exposure position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Paper cassette to different paper widths . . . . . . . . . . . . . . . . . . . . . . . . . 215 Paper position in X-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Paper position in Y-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Pressure solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Sensors on panorama feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Aeration pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Agitation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Aligning the lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Analog/Digital converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Automatic top-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282, 324
B
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57, 106, 114 Disposing old batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115, 143, 146, 328 Lithium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123, 141 Memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Nickel-Cadmium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Rechargeable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Replacing on MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Belt Adjusting tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196, 221, 300 Checking tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259, 300, 307 Bridges (see jumpers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Master Lab / Master Lab+
C
Cable Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Calculate Focal length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Calibrating Film dryer temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Paper dryer temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Tank temperatures in film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Tank temperatures in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Calibration strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Service Manual
357
Checking Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259, 300, 307 Distributor power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 DX-Code diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Knife sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Light barriers on distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Replenishment rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255, 296 Sensors of paper extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Sensors on feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Tank temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246, 288 Temperature sensors / level sensors . . . . . . . . . . . . . . . . . . . . . . . . 250, 292 Chemistry types in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Cleaning Lamp house . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Recommended liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 90 Code Film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 For film insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Paper cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Color dots to identify chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48, 49, 50, 51 Compensate temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Conventions used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Conversion kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Customizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
D
Densitometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104, 351 Detection DX-Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 190 Documentation / Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Drivers Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317, 321 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Dryer heater In film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 In paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 DX-Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
358
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
E
98.22.56 Edition 3
Electrical Programmable Logic Device (EPLD) . . . . . . . . . . . . . . . . . . . . . . . . 125 Electronic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Environmental guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 115, 143, 146, 328 Exhaust fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F
Fan Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Lamp cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 150 Pump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Fibre optic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Film cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Film cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Replacing the knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Film deck code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Film density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Filter wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 151, 171 First aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Floor Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Flow sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237, 279 Focal length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Focus test film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162, 164 Frame scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110, 112, 318, 322, 325
G
Graduated cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Grain finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162, 163 Greeting card attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Master Lab / Master Lab+
H
Hazardous vapors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Heating Elements in film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Elements in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Home position On universal film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Zoom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service Manual
359
I
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113, 315, 319, 323, 326 Installation Film cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 Passort lens / Wallet lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Remote control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Replenishment console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Interface Man-machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124, 140, 312 Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
98.22.56 Edition 3 Master Lab / Master Lab+
J
Jumpers CPU configutation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Machines without lens turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 On MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Voltage selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
K
Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
L
Labels in the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Lamp power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Leader card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 LED (Light emitting diode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 317 Lens Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Passport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Wallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Lens code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Level sensor Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Light attenuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 152 Light shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Line printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
360
Service Manual
M
Main shaft film processor side Installing/aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Main shaft paper processor side Installing/aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Mains Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Supplies of various types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Manuals / Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Master Lab family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Measuring box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170, 175, 177 Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
98.22.56 Edition 3
O
Optic box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
P
Paper cassette Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Different paper width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Paper transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Passport lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Phases of automatic top-off management . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Phases of heating management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Position Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191, 197 Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Paper in X-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Paper in Y-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Power supply for electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 for lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 for stepper motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Power supply for distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Pressure solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Prime chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Pump bellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257, 298
Master Lab / Master Lab+
Service Manual
361
R
RA-4 chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Racks Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286, 303 Reading Lens code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Replenishment console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Replenishment pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236, 278 Replenishment rate Changing for all chemistries together . . . . . . . . . . . . . . . . . . . . . . . . 256, 297 Changing for one tank only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256, 297 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255, 296 Reset logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Room Aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
S
Safe handling of chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 30 Safety stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247, 289, 307 Scanning the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Sensors Automatic top-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Film detection in film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Flow or vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234, 276 Lost liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Measuring the resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Overview of paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Panorama feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Paper extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234, 276 Shipping kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
362
Service Manual
Master Lab / Master Lab+
98.22.56 Edition 3
Pumps Aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Agitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Automatic top-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Manually switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238, 280 Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Site Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Transport to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273, 287 Specification Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 technical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Wet part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Spray pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
98.22.56 Edition 3
T
Temperature Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175, 234 Viewing values in film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Viewing values in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Test points on MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Tools Required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 178 Spirit level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Top-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282, 324 Transport Belts on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 In film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 In paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240, 285 Triac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Master Lab / Master Lab+
U
Upgrade kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
V
Vacuum cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Vacuum sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237, 279 Vapors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Service Manual
363
W
Wallet lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
98.22.56 Edition 3 Master Lab / Master Lab+
Z
Zoom drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Zoom home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
364
Service Manual
Althardstrasse 70, CH-8105 Regensdorf, Switzerland, Telephone ++41 1 842 11 11, Telefax ++41 1 842 21 00
GRETAG IMAGING AG 98.22.56 SA en 2000/11 Printed in Switzerland
You might also like
- The Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good LifeFrom EverandThe Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good Life4/5 (6458)
- The Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You AreFrom EverandThe Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You Are4/5 (1175)
- Never Split the Difference: Negotiating As If Your Life Depended On ItFrom EverandNever Split the Difference: Negotiating As If Your Life Depended On It4.5/5 (1005)
- Hidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space RaceFrom EverandHidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space Race4/5 (1022)
- The Hard Thing About Hard Things: Building a Business When There Are No Easy AnswersFrom EverandThe Hard Thing About Hard Things: Building a Business When There Are No Easy Answers4.5/5 (361)
- The World Is Flat 3.0: A Brief History of the Twenty-first CenturyFrom EverandThe World Is Flat 3.0: A Brief History of the Twenty-first Century3.5/5 (2289)
- Devil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New AmericaFrom EverandDevil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New America4.5/5 (280)
- A Heartbreaking Work Of Staggering Genius: A Memoir Based on a True StoryFrom EverandA Heartbreaking Work Of Staggering Genius: A Memoir Based on a True Story3.5/5 (233)