Customer First Service Manual, Rev. B: Kodak Digital Science XP-535 LASER IMAGING FILM PROCESSOR

Agency, Regulatory and CE Marking Compliance
CUSTOMER FIRST SERVICE MANUAL, Rev. B

Kodak Digital Science XP-535 LASER IMAGING FILM PROCESSOR
Section 1 Introduction/Specifications
Section 2 Preventive Maintenance
Section 3 Troubleshooting
Section 4 Support Information
Revision History
Warnings and Cautions
874-5713
78-6970-7509-7
Revision History
1999 Rev. B
Kodak XP-535 Film Processor Customer First Service Manual
i
Revision History
The original issue and revisions of this manual are identified as follows:
Issue Date (Rev. A): 06/97, (Rev. B): 05/99
The conversion to Kodak content and format included in this revision has resulted in a complete reprint of
the existing Service Manual.
All pages are dated May, 1999.
1999 Rev. B
i
Read and Understand all instructions before operating the equipment.
THIS EQUIPMENT IS OPERATED WITH HAZARDOUS VOLTAGE THAT CAN SHOCK, BURN,
OR CAUSE DEATH
Always remove the wall plug or trip the supply circuit breaker before servicing the processor. (Grasp the
plug and pull to disconnect.) Do NOT operate the equipment with a damaged power cord or an extension
cord.
Ensure that the processor power source is properly grounded and that the power cord is positioned out of
the way so it will not be tripped over or trampled.
Do NOT perform any procedure or adjustment that requires the use of a screwdriver (to remove panels,
covers, etc.).
Connect this equipment to a grounded outlet.
1999 Rev. B
ii
Warnings and Cautions (continued)
THE DRYER LAMPS IN THE PROCESSOR ATTAIN TEMPERATURES THAT CAN CAUSE
SEVERE BURNS.
Avoid contact with the ends of the Dryer Lamps when servicing the processor.
The Fixer Chemistry can be irritating to the eyes.
Follow the instructions on the label attached to the fixer tank.
Hot Surface
Warning
(Front)
Hazardous
Voltage
Warning
Hot
Surface
Warning
(Rear)
Eye
Irritation
Caution
1999 Rev. B
iii
Warnings and Cautions (continued)
!
WARNING
This equipment can be an explosive hazard. Do not use in the presence of flammable
anesthetics, Oxygen, or Nitrous Oxide.
!
WARNING
For Continued Protection against Fire, Replace Fuses with only the Same Type and Fuse Rating.
!
WARNING
The electrical compartment of this device is not protected against ingress of liquids, including bodily fluids.
!
CAUTION
This equipment is intended to connect to other medical devices. Installation and service maintenance are
to be performed only by qualified service personnel. The equipment must be installed no closer than 1.8
meters from a patient bed or chair.
!
CAUTION
Do not substitute or modify any part of this equipment without approval of Eastman Kodak Company.
!
CAUTION
This equipment generates, uses, and can radiate radio frequency energy, and if not installed by qualified
service personnel and used in accordance with the User Guide, may cause interference to radio
communications and other electronic devices. Operation of this equipment in a residential area may
cause interference, in which case the user, at their own expense, will be required to take whatever
measures may be required to correct the interference.
!
CAUTION
General External Cleaning: This equipment may be cleaned with a damp cloth, using water with mild
detergent, or with commercial electronic equipment cleaner.
1999 Rev. B
iv
All agency, regulatory and CE marking information may be found in the User Guide for this model.
1999 Rev. B
1-1
1-1. Introduction
1-1-1. Purpose of this Manual
This manual is designed for trained in-service personnel who are responsible for customer-first service
of the Kodak 5535 (XP-535) Film Processor. The customer-first level of service includes basic machine
problem analysis and repair, as well as periodic preventive maintenance.
Special training is required to perform the service tasks described in this manual. Service attempts by
untrained personnel that result in damage to the system are the responsibility of the user. Training can be
provided at the user site by an experienced Kodak technician.
Note
For help with any machine problem not covered in this manual, call Kodak service.
1-1-2. Introducing the 5535 Film Processor
The 5535 is a compact, high performance film processor designed to be used in the 969 HQ Laser
Imager System. Its operations are controlled by microprocessor electronics, and it requires no operator
controls. The 5535 monitors it own functions and responds appropriately as conditions and film types
change. Features of the film processor are described in the following paragraphs.
1-1-2-1. Optional High Speed Processing
Special Kodak chemistry is available that significantly reduces development time. Film can be completely
processed, dry to dry, in 60 seconds. (This feature is not available in the U.S.)
1-1-2-2. Automatic Image Quality Control
The 5535 includes a densitometer as a permanent, in-line part of the processor. Density information is
taken from test patches on all processed film. This information is fed back to the laser imager, which uses
the feedback to automatically adjust for optimum image quality. (This feature is available only if Kodak film
is used.)
1-1-2-3. Optional Internal Replenishment Supply
Internal replenishment of the processing chemicals is available with the installation of an Internal
Replenishment Kit. This kit includes tanks of concentrated chemicals that are automatically mixed with
water in the correct proportions and pumped into the processor chemistry tanks as needed. (This feature
is not available in the U.S.)
1-1-2-4. Automatic Processing Parameter Changes
When it is docked to the 5535, the 969 Laser Imager automatically changes its programmed set of
exposure parameters when the film cartridge bar code indicates that a cartridge with a different film
emulsion number has been loaded. The system automatically prints a calibration sheet. Image quality is
also monitored by measuring the printed density of the density patch on each sheet of film. (This feature
is available only if Kodak film is used.)
1999 Rev. B
1-2
1-1-3. How the Film Processor Works
Figure 1-1 shows the locations of the major components of the processor, and Figure 1-2 shows the path
of film as it passes through the processor. The film moves successively through a developer section, fixer
section, wash section, and dryer section, and out into the exit tray. Film is transported by racks of rollers in
each of the sections, driven by a single, speed-controlled motor. The quality of the processed film is
enhanced by the smooth, uniform drive of the transport system. The staggered rollers ensure minimum
stress on the film.
Figure 1-1. Major Components of the Film Processor
1999 Rev. B
1-3
1-1-3-1. Developer Section
Rollers pass the film through a circulating developer bath of constant volume, temperature, and
chemical concentration.
The chemicals develop the latent image on the exposed film.
1-1-3-2. Fixer Section
Rollers pass the film through a circulating fixer bath of constant volume, temperature, and
concentration.
The fixer stops further development.
1-1-3-3. Wash Section
Rollers pass the film through a circulating bath of water to rinse it.
1-1-3-4. Dryer Section
Squeegee rollers remove excess water from the film.
Infrared lamps evaporate moisture left on the film and fans circulate the air to carry the moisture away.
A densitometer measures density and sends results back to the laser imager.
Figure 1-2. Film Path through the Processor
1999 Rev. B
1-4
1-2. Physical Specifications
1-2-1. Dimensions
Height: 1.28 m [50.4 in.] unpacked
1.51 m [59.4 in.] crated
Length: 690 mm [27.2 in.] unpacked
1.14 m [45.1 in.] crated
Width: 690 mm [27.2 in.] unpacked
910 mm [35.8 in.] crated
Weight: 156.8 kg [345 lb.] empty
212.8 kg [468.2 lb.] loaded
1-2-2. Tank Capacities
Developer: 12.4 liters [3.3 gal.]
Fixer: 12.2 liters [3.2 gal.]
Water 12.9 liters [3.4 gal.]
Internal Replenishment: 11 liters [2.9 gal.]
1-2-3. Electrical Requirements
Voltage: 200/220/230/240 vac + 10%, 50/60 Hz, single phase
Current: 10.9/11.7/12.7/14 amps
Note
All related local electrical codes must be observed when the processor is installed.
1-2-4. Plumbing
Water Supply Requirements
Volume: 3 liters (0.8 gal.]
Temperature: 10C [50F] (cold water supply)
Pressure: 66.2 psi [4.5 Bar] maximum
Note
A cold water kit is required. The 24 vac cold water solenoid is the rinse valve controlled by the
processor software.
1999 Rev. B
1-5
Drain Requirements
Volume: 10 liters [2.6 gal.] per minute (main drain)
5 liters [1.3 gal.] per minute (chemistry drains)
Size: 30 mm [1.5 in.] minimum (main drain)
25 mm [1.0 in.] minimum (chemistry drains)
Note
All connections must conform to local plumbing codes. If all drains from the processor empty into the
same drain, the volume of this drain must be at least equal to the sum of the individual drain
minimum volumes.
1-2-5. Environment
Temperature: 15 to 35C [59 to 95F] operating
35 to 60C [-31 to 140F] storage
Relative Humidity: 15 to 75% RH operating
10 to 90% RH storage
Heat Dissipation: 1440 BTU [1519 kilojoules] per hour standby
5100 BTU [5380 kilojoules] per hour processing
Magnetic Field: <30 gauss
Noise: 60 dBA during standby
70 dBA during print cycle
Vibration: 0.01 G operating
0.56 G storage
Ventilation: 10 cubic feet of air per minute [0.28 M
3
] must be removed from inside the
processor and exhausted outside the room at all times, whether or not the
processor is being used. (A fan inside the processor exhausts air through a
vent in the rear panel near the dryer.)
1999 Rev. B
2-1
2-1. The Value of Preventive Maintenance (PM)
In order to consistently produce the highest quality output, the film processor must receive periodic routine
maintenance. It is assumed that system operators will perform daily and bi-monthly maintenance. (These
procedures are described in paragraph 2-4.) The customer-first service technician is required to perform
preventive maintenance procedures at monthly and quarterly intervals. (See the checklists in paragraph
2-5.)
2-2. Supplies Required for PM
1. Cleaning pads, lintfree 78-8018-2802-7
2. White Scotchbritet pads
3. Algaecide agent
4. Developer and fixer chemistry, or
5. Replenishment chemistry (if replenishment tanks are used)
2-3. Replacement Parts Required for PM
Type C Cold Water Kit Filter (Box of 6) 78-8113-11561-9
Old Style Cold Water Kit Filter (Box of 10) 78-0439-5756-6
2-4. Operator Maintenance Tasks
The system operator must perform the following routine maintenance procedures on the film processor. If it
is evident from an inspection of the film processor that these routine tasks are not being performed
regularly, stress the importance of the procedures to the system operator. Do operator training as
necessary.
2-4-1. Operator Daily Procedure:
1. Turn off processor power.
2. Turn off the Cold Water Supply.
3. Open the top cover, and the front and left cabinet doors.
4. Tip the dryer rack far enough to the left to disengage the drive train, Prop the rack in this position.
5. Wipe the exposed rollers with a damp, lintfree cloth to remove any chemical deposits.
6. Pivot the rack back to its normal position, Make sure the latch at the rear of the dryer engages.
7. Close the top cover and cabinet doors to enable normal operation.
1999 Rev. B
2-2
2-4-2. OperatorTwice-a-Month Procedure:
1. Turn off processor power.
2. Turn off the cold water supply.
4. Tip the dryer rack far enough to the left to disengage the drive train. Prop the rack in this position.
Note
In the next step be careful not to splash or spill solution from one tank into another. Contamination
may result.
5. Carefully remove the developer, fixer, and wash racks from the processor.
6. Wash the racks under running water to remove any chemical deposits from the rollers, gears, and side
frames.
7. Empty and clean the wash water tank to eliminate any algae that may be present.
8. Check that all roller springs are tight.
9. Clean the main drive shaft and related gears.
10. Reinstall the racks.
11. Pivot the dryer rack back to its normal operating position. Make sure the latch at the rear of the dryer
engages.
12. Close the top cover and cabinet doors to enable normal operation.
13. Check the filter in the Cold Water Kit, and replace it if necessary.
14. If applicable, place new anti-algae agent in the second canister of the Cold Water Kit.
15. Turn on the cold water supply.
16. Apply power to the processor.
17. Check for developer and fixer replenishment operation by grasping the lines where they enter the
processor. You should be able to feel the solution running through the lines. If you cannot, check that
the replenishment pumps are working.
18. Allow the processor to reach operating temperature (Ready state).
19. Run a cleanup film through the processor.
1999 Rev. B
2-3
2-5. Customer-First Technician PM Checklists
Once a Month (or every 4,000 Films):
- 1. Clean the developer tank. (See paragraph 2-7.)
- 2. Inspect the fixer tank. Clean if necessary. (See paragraph 2-8.)
- 3. Clean all racks. Also inspect roller springs and clean main drive shaft and gears. (See paragraph
2-9.)
- 4. Check the cold water kit. As necessary, replace filter and add antialgae. (See paragraph 2-10.)
- 5. Do final system checks (ventilation, replenishment flow) and cleanup. (See paragraph 2-11.)
- 6. After completing the PM procedures, record the date and machine cycle count on a log sheet.
Every 3 Months (or every 12,000 Films):
- 1. Inspect and clean the cold water kit. (See paragraph 2-12.)
- 2. Inspect and clean the dryer. (See paragraph 2-13.)
- 3. Drain, clean, inspect, and refill the developer section. (See paragraph 2-14.)
- 4. Drain, clean, inspect, and refill the fixer section. (See paragraph 2-15.)
- 5. Drain, clean, inspect, and refill the wash section. (See paragraph 2-16.)
- 6. Inspect and clean the internal replenishment tanks (if used). (See paragraph 2-17.)
- 7. Add fresh processing chemistry and check processor operation. (See paragraph 2-18.)
- 8. Clean the cabinets. (See paragraph 2-19.)
- 9. After completing the PM procedures, record the date and machine cycle count on a log sheet.
1999 Rev. B
2-4
2-6. Processor CleaningGeneral Concepts
Using Spare Processor Racks
While the processor racks are being cleaned, the machine of course cannot be used to process film. If
processor down time is a critical issue, the user may wish to purchase spare processing racks. The spare
racks can replace those removed from the processor for cleaning, and film processing can continue. The
cleaned racks can in turn replace the racks in the processor at the next PM.
Cleaning Stainless Steel
When stainless steel is exposed to air, a protective layer of oxide forms on the surface of the steel. This
layer seals out elements that may attach to the stainless steel surface and cause rust or corrosion. Dirt,
dried chemicals, and other contaminants will prevent this protective layer from forming. Thus the
importance of keeping the stainless steel clean.
!
Caution
Use soap and water to keep stainless surfaces free of dirt and other contaminants. Do not use 3M
Scotchbrite pads, metal scrapers, or other abrasive tools. They may scratch the metal surface,
removing the protective layer of oxide and leaving an irregular surface that is susceptible to
corrosion.
2-7. Cleaning the Developer Tank (Monthly)
Required Supplies
Clean, lintfree cloths
Procedure
1. Power off the processor.
3. Drain the developer tank.
Note
Prepare a suitable place to set the rack before removing it from the tank. Chemistry will continue to
drip from the rack after it is removed, and will need to be absorbed.
4. Remove the developer rack.
5. Scrub the developer tank. (Do not use abrasives. Reference paragraph 2-6.) Take care not to
contaminate the fixer.
6. Flush the tank with running water until the drain water runs clean.
1999 Rev. B
2-5
2-8. Inspecting/Cleaning the Fixer Tank (Monthly)
Procedure
1. Make sure power is removed from the processor. (The top cover and cabinet doors should remain open
from the previous procedure.)
Note
Before removing a rack from its tank, make sure you have a suitable place to set it. Chemistry will
continue to drip from the rack after it is removed.
2. Remove the fixer and wash racks. Lift each rack slowly, allowing the chemistry to drain back into the
tank. (The racks will be cleaned, along with the other racks, as described in paragraph 2-9.)
3. Inspect the fixer tank.
4. If there are any deposits in the fixer tank, drain the tank and flush it with running water.
2-9. Cleaning and Inspecting the Racks (Monthly)
Required Supplies
White Scotchbrite
Procedure
1. Wipe and rinse the developer, fixer, and wash racks under running water to remove chemical deposits
from the rollers, gears, and side frames.
2. Wipe the rack rollers thoroughly with a clean, damp cloth, and check the surfaces for deposits or
defects. (Defective rollers must be replaced. Notify Kodak service.)
Note
White Scotchbrite pads can be used to remove deposits from roller surfaces. Rollers that cannot be
wiped clean with Scotchbrite should be replaced.
3. Check all roller springs for tightness, and bushings for wear. Defective parts should be replaced.
4. Clean the main drive shaft and related gears that drive the racks.
5. Tip the dryer rack far enough to the left to disengage the drive train, and prop the rack in this position.
6. Wipe the dryer rollers and rack with a clean, damp, nonabrasive pad or cloth.
7. Carefully return the racks to their proper tanks, making sure they are installed correctly.
8. Fill the tanks.
9. Pivot the dryer rack back to its normal position, making sure that the latch at the rear of the dryer
engages.
1999 Rev. B
2-6
2-10. Checking the Cold Water Kit (Monthly)
Required Supplies
Cold Water Kit filter
Antialgae agent
Procedure
1. Check the filter in the Cold Water Kit, and replace it if necessary.
2. If applicable, place new anti-algae agent in the second canister of the Cold Water Kit.
2-11. Final Checks and Procedures (Monthly)
1. Close the top cover and the cabinet doors.
2. Power on the processor.
Note
Proceed to step 3 immediately after power up, since the replenishment pumps run for only about 1
minute after power up.
3. Check for developer and fixer replenishment operation by grasping the lines where they enter the
processor. Solution should be flowing through the lines. If it is not, check that the replenishment pumps
are operating.
4. Verify that the processor ventilation system is operating by checking for blower sound near the vent at
the rear of the processor. Make sure that a trunk leading outside the area is securely connected to the
processor vent.
5. Allow the processor to reach operating temperature (Ready lamp lights).
6. Run a cleanup film through the processor.
Note
After completing the monthly PM procedures, record the PM on a log sheet and post the sheet near
the machine. A sample log sheet is shown at the end of this section, and log sheets are provided at
the end of the manual for your use.
1999 Rev. B
2-7
2-12. Inspecting and Cleaning the Cold Water Kit (Quarterly)
Required Supplies
Anti-algae tablets
Cold Water Kit filter
Procedure
1. Inspect the Cold Water Kit for leaks.
2. Check that the flow meter indicates a flow of 3 liters per minute during a processing cycle.
3. Service the antialgae module as follows:
Remove the canister and clean it.
Rinse the anti-algae tablets with fresh water to clean off any sediment that may have accumulated.
Fill the canister 1/3 full of anti-algae tablets, or replace the anti-algae pack.
Reinstall the canister.
4. Replace the filter in the Cold Water Kit.
2-13. Servicing the Dryer Section (Quarterly)
Required Supplies
White Scotchbrite
Procedure
1. Power off.
2. Open the top cover and the front and left cabinet doors.
3. Tip the dryer rack far enough to the left to disengage the drive train, and prop the rack in this position.
4. Wipe the dryer rollers and rack with a clean, damp, non-abrasive pad or cloth.
Note
White Scotchbrite pads can be used to remove deposits from roller surfaces. Rollers that cannot be
wiped clean with Scotchbrite should be replaced.
5. Check all roller bushings for wear.
6. Check for the presence and integrity of driven roller retaining springs.
1999 Rev. B
2-8
2-14. Servicing the Developer Section (Quarterly)
Required Supplies
White Scotchbrite
Procedure
1. Drain the tank.
2. Lift the rack out of the tank.
!
Caution
To prevent contamination, be careful not to splash or spill solution into another tank or onto other
surfaces inside the processor.
3. Carry the rack to a sink or floor drain for cleaning.
4. Wipe the rack and rollers under running water with a clean, non-abrasive pad or cloth. If deposits
cannot be removed with water, use an environmentally-acceptable cleaner or White Scotchbrite pads.
!
Caution
Systems cleaners are not recommended. If one is used, the rack and rollers must be flushed
thoroughly to avoid potential contamination of chemistry when processor operation is resumed.
5. Rinse the rack and rollers, and dry them with a clean cloth.
6. Check the surfaces of all rollers for deposits or defects. If the deposits cannot be removed or a roller is
defective, it must be replaced. (Notify Kodak service.)
7. Check all roller bushings for wear.
8. Check for the presence and integrity of driven roller retaining springs.
9. Wipe the tank and standpipe with a clean, non-abrasive pad or cloth.
10. Open the circulation pump drain valve and tighten the standpipe.
Note
It is good practice to check that the side frames of the rack are square before returning the rack to the
processor. If the rack is not square, the track of film passing through it will drift off center. Check for
squareness by inverting the rack and placing it on a flat surface. (Place the rack on something like a
tabletop, where it can hang over the edge slightly.)
11. Replace the rack in the processor tank.
1999 Rev. B
2-9
2-15. Servicing the Fixer Section (Quarterly)
Inspect and clean the fixer section by repeating steps 1 through 11 of paragraph 2-14.
2-16. Servicing the Wash Section (Quarterly)
Inspect and clean the wash section by repeating steps 1 through 11 of paragraph 2-14.
2-17. Inspecting and Cleaning the In-Line Replenishment Tanks (if Used) (Quarterly)
1. Slide the tray holding the replenishment tanks outside the processor (see Figure 2-1).
2. Remove the cap (A in Figure 2-1) from the replenishment tank (B) to which the float switch and
replenishment pump suction line are attached.
3. Inspect the float switch for crystallized chemical. Clean it as necessary.
4. Carefully lift the replenishment tank from the processor.
5. Dispose of any chemical in the tank in the appropriate drain.
6. Rinse the tank thoroughly with running water. Then drain it and return it to its place in the processor.
7. Replace the cap with the replenishment pump suction line and tank float switch.
8. Repeat the procedure for the other replenishment tank.
Figure 2-1. Replenishment Tanks
1999 Rev. B
2-10
2-18. Adding Fresh Chemistry and Checking Processor Operation (Quarterly)
1. Refill the replenishment tanks with the appropriate concentrated chemistry, or fill the processor tanks,
as appropriate.
!
Caution
When refilling the system, make sure to avoid air locks in the circulation pumps. If air is left in the
pumps, pump failure will occur.
2. Purge air from each replenishment pump by opening each drain valve and leaving it open until fluid
flows through the drain line. The valves are color-coded red for developer, blue for fixer, and green for
water.
3. Replace the chemistry and wash tank covers.
4. Pivot the dryer rack back into its normal position, making sure that the latch at the rear of the dryer
engages.
5. Hook the front dryer brace.
6. Close the top cover and cabinet doors.
7. Power on, allow the processor to warm up, and process several films that are the type normally used.
8. Check image quality.
1999 Rev. B
2-11
2-19. Cleaning the Processor Cabinet (Quarterly)
Clean the processor cabinet, inside and outside, with a damp, non-abrasive cloth or pad. A non-abrasive
cleaner may be used.
Note
After completing the quarterly PM procedures, record the PM on a log sheet and post the sheet near
the machine. Sample log sheets are shown on the next page, and log sheets are provided at the end
of the manual for your use.
1999 Rev. B
2-12
Customer First 5535 Preventive Maintenance Logsheet (Monthly
Procedures)
(Technician: Enter date and your initials at top of column. Check each procedure as it is completed.)
Procedures
Date
/ /
_____
Date
/ /
_____
Date
/ /
_____
Date
/ /
_____
Date
/ /
_____
Date
/ /
_____
Date
/ /
_____
Date
/ /
_____
1. Clean the Developer Tank.
2. Inspect/clean the Fixer Tank.
3. Clean and inspect the Racks.
4. Check the Cold Water Kit.
5. Check ventilation and replen-
ishment flow. Then clean up.
Customer First 5535 Preventive Maintenance Logsheet (3 Month Periods)

Procedures
Date
/ /
_______
Date
/ /
_______
Date
/ /
_______
Date
/ /
_______
Date
/ /
______
1. Inspect/clean the Cold Water Kit.
2. Service the Dryer Section.
4. Service the Developer Section.
5. Service the Fixer Section.
6. Service the Wash Section.
7. Inspect/clean Replenishment Tanks.*
8. Add fresh chemistry/check Processor.
9. Clean the Processor Cabinet.
* System option. Not available in the U.S.
1999 Rev. B
3-1
3-1. Local Panel and Keypad Message Types
The local panel and keypads display three types of messages, as described below.
3-1-1. Status Messages
Status messages are strictly informational and require no operator action.
3-1-2. Action Messages
Action messages indicate that some type of operator action is required before imager operation can
continue. If an action message does not clear after the indicated action has been performed, call for
service.
3-1-3. Error Messages
Error messages indicate an error condition within the imager. In some cases, error messages can be
cleared by operator action or firstline technician action, but in some cases a service call will be required.
An error message table is provided on the following pages. The table lists error messages that appear on
the local panel and the keypad, along with the actions that may clear the errors.
1999 Rev. B
3-2
3-2. Error Message Table
The following table lists all the local panel and keypad error message numbers. When an error message
is displayed, perform the operator action listed next to the message number.
Note
If the listed action does not clear the error message, call for Kodak service.
Local Panel Message Keypad Message Action
P501Processor
undocked.
K202Laser imager X is
not operational.
Cause: Over time, closing the supply drawer can
cause the imager to move away from the
processor.
Solution: Push the imager against the processor. If
the problem recurs, call for Kodak service.
P502No
communication with
processor. Processor
down or disconnected.
K221Processor X is
not functional.
(This message displays normally during a
processor power up routine, which takes about 2
minutes. At any other time, the message indicates
a problem.)
Problem 1: This error has displayed and processor
fan is not running:
Cause 1: The circuit breaker in the processor is
turned off.
Solution: Turn circuit breaker on.
Cause 2: No power from site source.
Solution: Check and fix site power problem. (Is site
circuit breaker off? Is there a wiring problem?)
Problem 2: This error has displayed and processor
fan is running.
Cause 1: The processor cover interlocks are not
working.
Solution: Open and close all processor covers to
reset interlocks.
Cause 2: Cable from imager to processor is loose
or disconnected.
Solution: Open front cover of processor and reseat
9-pin connector located in lower right hand corner.
(Note: The cable is friction fitted. It has no screws.)
1999 Rev. B
3-3
Local Panel Message Action Keypad Message
P508Processor
warning. Processor is
functional, but an error
has occurred.
K231Processor
warning. Check local
panel on laser imager
X.
The processor assumes the rinse valve is stuck on.
To determine the cause of the problem, check the
flow meter (part of the cold water kit mounted on
the wall) when the processor is in the idle state
(rollers not turning).
Cause 1: If the flow meter goes to zero during an
idle state and the error still occurs, algae is
probably plugging the weep hole in the standpipe
tube of the rinse tank.
Solution: Clean the tank and standpipe as follows:
1. Clean the weep hole.
2. Clean the wash tank and racks.
3. Clean the algaecide canister. Then add new
anti-algae tablets to 1/3 full.
4. Adjust the water flow to 3 liters per minute.
Cause 2: If the meter indicates constant water flow,
even when the processor is in an idle state, the
rinse valve is stuck on.
Solution: Replace the valve.
Workaround: Try tapping the rinse valve with a tool
to free it up.
P511Please wait XX
minutes for processor to
finish warming cycle.
K222Film processor is
not ready. Minutes to
ready: XXX
Problem: The error remains displayed for extended
periods.
Cause: Water flow is below specifications.
Solution: Adjust the flow control valve to obtain a
reading of 3 liters per second on the flow meter.
Related problems:
1. Check the Dev and Fix temperatures displayed
on the local panel. If they are below the set points
(Dev= 34.6, Fix = 34.0), the solutions may need
more time to warm up.
2. Check the developer and fix fluid levels. If they
are so low that the float switches are in the down
position, inspect the replenish supply and/or hoses
for kinks in the line or air locks.
P523Processor
malfunction.
K221Processor X is
not functional.
Developer heater is off. Power cycle the
processor. If problem remains call for Kodak
service.
P524Processor
malfunction.
K222Processor X is
ready: XXX
Temperature of developer is too high. Power cycle
the processor. If error does not clear, call for Kodak
service.
1999 Rev. B
3-4
P525Processor
malfunction.
K229A chemistry tank
on processor X is
empty.
Check the fluid level in the developer tank.
1. If the tank is full, call for Kodak service.
2. If the tank level is low, check the replenish
supply level, and check for kinks or air locks in the
supply line. If this does not solve the problem, call
for Kodak service.
P529Processor
malfunction.
K221Processor X is
not functional.
Problem 1: Temperature of the developer is below
10C (21F).
Solution: Wait until the room temperature increases
the temperature of the developer. (The heater will
then start and do a warmup cycle.)
Problem 2: Room is at normal temperature, the
error code is displayed, and the processor will not
accept film.
Solution: Power cycle the processor. If the problem
remains, call for Kodak service.
P532Processor
malfunction.
K221Processor X is
not functional.
Problem 1: Temperature of the dryer is below 10C
(21F).
the temperature of the dryer. (The heater will then
start and do a warmup cycle.)
accept film.
P533Processor
malfunction.
K221Processor X is
not functional.
Fixer heater is off. Power cycle the processor. If
problem remains, call for service.
P534Processor
malfunction.
K222Processor X is
ready: XXX
Temperature of the fixer is too high. Power cycle
the processor. If error does not clear, call for Kodak
service.
P535Processor
malfunction.
K229A chemistry tank
on processor X is
empty.
Check the fluid level in the fixer tank.
1. If the tank is full, call for Kodak service.
2. If the tank level is low, check the replenish
supply level, and check for kinks or air locks in the
supply line. If this does not solve the problem, call
for Kodak service.
1999 Rev. B
3-5
P539Processor
malfunction.
K221Processor X is
not functional.
Problem 1: Temperature of the fixer is below 10C
(21F).
the temperature of the fixer. (The heater will then
start and do a warmup cycle.)
accept film.
P542Jam in processor.
Remove jam.
K227Media is jammed
in processor X. Please
remove the media.
Problem 1: Jams in general.
Solution: Clear the jam as follows:
1. Visually inspect the processor to locate and
clear the jam. If the jam is not visible, proceed to
step 2.
Caution: When performing the following step, be
careful not to splash or drip fix solution into the
developer tank. This will contaminate the
developer and result in poor developing.
2. One by one, lift the racks just enough so that the
drive gears separate. Turn the gear. If it turns very
hard or not at all, the jammed film is probably in
that rack.
Problem 2: Film jams before the dryer.
Cause: The dryer assembly is not positioned
correctly, and the drive coupling is not engaging.
Solution: Reseat the dryer assembly, and check to
ensure that the dryer rollers are turning after the
processor covers are closed.
P567Processor
malfunction.
K221Processor X is
not functional.
The error should automatically clear. If it does not,
power cycle the 969. If the error does not clear,
then call for Kodak service.
P570Processor
malfunction.
K221Processor X is
not functional.
Problem: The processor transport motor is not
turning, probably because of a film jam.
Solution: Check the processor racks for a film jam
as follows:
1. Partially lift each rack and turn the drive gear by
hand. If the gear turns hard, the jam is probably in
that rack.
2. Clear the jam.
P571Processor
malfunction.
K221Processor X is
not functional.
Problem: The speed of the processor transport
motor is out of spec.
Solution: Same as for P570 above.
1999 Rev. B
3-6
P572Low water flow to
processor. Check water
flow.
K221 Processor X is not
functional.
To confirm the water flow problem, check the flow
meter on the cold water kit while the processor is
running (lights on, rollers turning). Flow rate should
be 3 liters per minute.
Problem 1: No water flow.
Solution: Ensure that all handle type control valves
are turned on. If necessary, tap the rinse valve with
a tool. This may free it up temporarily.
Problem 2: Low water flow.
Solution: Ensure that all handle type control valves
are turned fully on. The flow control valve on the
cold water kit can be adjusted. (Call Kodak service
for help.)
Workaround: If you cannot resolve the problem,
films can be directed to the receive magazine until
service help arrives. For keypad users this is done
by changing the Output setting on the Imager
menu. (All prints queued to the processor will have
to be reacquired and reprinted.)
P589Processor
malfunction.
K221Processor X is
not functional.
Problem: Processor NVRAM error at power up.
Solution: Power cycle the processor. If problem
P590Processor
malfunction. (P590 is
displayed for only an
instant. Then P502 is
displayed and remains
on the local panel.)
K221Processor X is
not functional.
Problem: The imager has shut down the processor
because: the developer, fixer or dryer temperature
is too high, or the transport motor is drawing too
much current.
Solution:
1. Power cycle both the processor and the imager.
If the error does not clear, power down both
machines.
2. Let the processor cool for 15 minutes. Then
power up both machines.
3. If the problem remains, call Kodak service.
1999 Rev. B
3-7
P632Automatic image
quality control OFF.
Automatic image quality
control OFF.
Densitometer feedback indicates that density or
contrast of calibration sheet is unacceptable.
Problem 1: Error has occurred but films appear
normal or near normal (slightly light or dark).
Solution: Press Calibrate on the local panel and
wait until a sheet exits the processor. If this does
not correct the problem, try a different supply
cartridge. If this does not work, have processor
maintenance change chemicals, check
replenishment volume, and check developer and
fixer temperatures.
Problem 2: Error has occurred and films are very
light (mirror imaged).
Solution: Try a different supply cartridge. (Film may
have been packaged emulsion side down at the
factory.)
Problem 3: Error has occurred and there is a milky
appearance in the clear areas of the film.
Solution: Call processor maintenance. (Fixer
solution is contaminated or weak.)
P633System operating
near calibration limits.
Check chemistry.
K230System operating
near calibration limits.
Check chemistry.
Refer to Action for P632.
1999 Rev. B
3-8
3-3. Film JamsGeneral
In general, four types of jams can occur:
Jams at the processor entrance.
Jams at the processor exit.
Jams inside the processor.
Jams in the film sorter (if one is used).
When a jam occurs, a message appears on the laser imager local panel (see Figure 3-1) and on the
remote keypad display. When this message displays, you must determine where the jam has occurred
and clear it.
Figure 3-1. Jam Message
1999 Rev. B
3-9
3-4. Locating the Jam
1. Power down the film processor.
2. Open the top cover and the left and front cabinet doors.
3. Remove the cover of the chemistry tanks.
4. Check for jammed film at the entrance to the developer rack. If a jam is visible, proceed to paragraph
3-5.
5. Check for jammed film in the dryer rack. If a jam is visible, proceed to paragraph 3-6.
6. Proceed to paragraph 3-7.
1999 Rev. B
3-10
3-5. Clearing a Jam at the Processor Entrance
!
Caution
Take extreme care when removing a rack from a filled tank that it does not drip or splash chemistry into
adjacent tanks. Contaminating the developer solution with fixer is especially critical.
1. Carefully lift the developer rack from the tank, and:
Rest it on the frame of the processor for a few seconds to drain into the tank.
Rinse the rack with clear water and place it in a clean, flat work area on some paper towels or
other absorbent material.
2. If the jammed film is in the developer rack, rotate the gears, pull against the springs to open the roller
nips, etc., as required to remove the film.
3. If the jammed film remains in the processor entrance, pull it out to clear the jam.
4. Inspect the rack and the processor for the cause of the jam.
5. Carefully replace the rack and chemistry cover, and restore the machine to operation.
1999 Rev. B
3-11
3-6. Clearing a Jam at the Processor Exit
1. Unhook the front dryer brace and release the latch at the rear. Tilt the dryer rack slightly to uncouple
the dryer drive train from the main drive.
2. Place the standpipe removal tool under the corner of the dryer to maintain the rack in this position.
3. Rotate the gear train, pull against the springs to open roller nips, etc., to remove the jammed film.
4. If the jam is behind the dryer lamp and fan assemblies, and it cannot be cleared, allow the dryer to
cool before proceeding.
5. Remove the lamp and fan assemblies blocking access to the jammed film as follows:
Loosen the thumbscrews (one on each side) securing the lamp and fan assemblies (see
Figure 3-2).
Figure 3-2. Thumbscrews for Lamp and Fan Assemblies
Unplug one end of the electrical cable connecting the two lamp and fan assemblies.
Pull the bottom of each assembly out and lift it free of the dryer rack. Be careful not to strain the
electrical connections.
6. Remove the jammed film.
7. After clearing the jam, inspect the rack for the cause of the jam.
8. Carefully reassemble the dryer rack and restore the machine to normal operation.
1999 Rev. B
3-12
3-7. Clearing a Jam within the Processor
Jams inside the processor can be located at any point between the entry and exit of the processor. They
may or may not be visible.
1. If the jam is visible, proceed as directed in either paragraph 3-5 or 3-6, depending on the location of
the jammed film.
2. Grasp the rod at the top of the dryer rack (see Figure 3-3) and carefully pivot the dryer rack to its
lowered position (see Figure 3-4).
Figure 3-3. Grasping the Dryer
3. Remove the cover of the wash tank (see Figure 3-4).
Note
If the jam is not visible, it is probably submerged in the developer, fixer, or wash tank. The racks must be
checked, one at a time, until the jam is located.
1999 Rev. B
3-13
Figure 3-4. Locating Jammed Film
4. Carefully examine the developer, fixer, and wash racks, one at a time, until the jammed film is located.
5. Refer to paragraph 3-5 (Clearing a Jam at the Processor Entrance). Complete steps 1 and 2 for the
rack containing the jammed film.
6. Carefully reassemble and restore the machine to normal operation.
1999 Rev. B
3-14
3-8. Inability to Locate Jammed Film
If you cannot locate the jammed film after trying the clearing procedures, reset the system and attempt to
run another film.
If the attempt is successful, resume normal operation.
If the attempt is not successful, call for Kodak service.
1999 Rev. B
4-1
Section 4 Support Informtation
4-1. Calling for Support
Once you have tried your best to repair the machine, but are unsuccessful, it is time to call for help. As a
rule, you should not spend more than 30 minutes diagnosing a down machine. If you know the machine is
going to need an Kodak techniciancall for Service. If you feel you could repair the machine with some
helpcall for Support. Use the phone numbers listed below. Be sure to have the machine model and
serial numbers available when you call.
Model Number M5535
Serial Number ______
Phone for Service 1-800-328-7754
Phone for Support 1-800-873-3000
Note
The serial number and complete model number of the film processor are located on an identification
plate mounted on the inside of the machines right side panel (see Figure 4-1).
Figure 4-1. Serial Number Location
1999 Rev. B
4-2
4-2. Maintenance Log
Date: Cycle Count:
Problem:
Cause:
Solution:
Date: Cycle Count:
Problem:
Cause:
Solution:
Customer First 5535 Preventive Maintenance Logsheet (3 Month Periods)

Procedures
Date
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1. Inspect/clean the Cold Water Kit.
2. Service the Dryer Section.
4. Service the Developer Section.
5. Service the Fixer Section.
6. Service the Wash Section.
7. Inspect/clean Replenishment Tanks.*
8. Add fresh chemistry/check Processor.
9. Clean the Processor Cabinet.
* System option. Not available in the U.S.
Customer First 5535 Preventive Maintenance Logsheet (Monthly Procedures)
Procedures
Date
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Date
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Procedures
Date
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Date
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