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98.22.56Edition 3

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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, CH—8105 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

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1.1.1 About this documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.1.2 Conventions used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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1.2.1 Symbols used in this manual only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Symbols used on or inside the machine and in this manual . . . . . . . . . . . . . 20Symbols on transport boxes, crates and other packing material . . . . . . . . . . 21

1.2.2 Safe handling of photographic chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2.3 Sealed screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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1.3.1 The Master Lab+ family of products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Master Lab+ 520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Master Lab+ 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Master Lab+120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Master Lab+ 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Master Lab+ 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Master Lab+ 740 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Master Lab+ 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Master Lab+ 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.3.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Film processor side (ML+ 320, ML+ 340, ML+ 520 and ML+ 740) . . . . . . . . 26Film processor side (ML+ 120, ML+ 140, ML+ 220 and ML+ 240) . . . . . . . . 26Front view: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Paper processor side (ML+ 320, ML+ 340, ML+ 520 and ML+ 740) . . . . . . . 27Paper processor side (ML+ 120, ML+ 140, ML+ 220 and ML+ 240) . . . . . . . 28

1.3.3 Labels on the Master Lab+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.3.4 Safety and operating overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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1.4.1 Master Lab+ system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.4.2 Printer part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.4.3 Wet part, film processor (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.4.4 Wet part, paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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1.5.1 Printer part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.5.2 Wet part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

��* + ��#�Film cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Remote control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Passport and wallet lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37External replenishment console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Line printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Greeting card attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Various conversion kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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2.2.1 Floor space requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.2.2 Room height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.2.3 Floor load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.2.4 Site illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.2.5 Room temperature and humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.2.6 Air conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.2.7 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.2.8 Room aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.2.9 Mains socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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2.3.1 Checking for shipping damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.3.2 Transport to installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.3.3 Tools required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.3.4 Unpacking the Master Lab+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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2.4.1 Film processor tanks (not valid for ML+120 to ML+240) . . . . . . . . . . . . . . . . 47

2.4.2 Filling the paper processor tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.4.3 Mechanical configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.4.4 Voltage setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.4.5 Mains cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.4.6 Preparing the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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2.4.7 Connecting the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Voltage / current ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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2.5.1 Check the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.5.2 Check the film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.5.3 Checking the paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.5.4 Concluding checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.5.5 Setting the wake-up times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.5.6 Setting time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.5.7 Master setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.5.8 Saving the data of the initial setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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3.2.1 Maintenance menu for the paper processor. . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.2.2 Maintenance menu for the film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.2.3 Maintenance menu for the other system parts . . . . . . . . . . . . . . . . . . . . . . . . 79

3.2.4 Maintenance menu for optical index printer . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.2.5 Maintenance menu for Customizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

3.2.6 Debug menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

3.2.7 Maintenance functions on the ALMLPLUS board . . . . . . . . . . . . . . . . . . . . . 83

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4.3.1 Optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.3.2 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

4.3.3 Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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4.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

4.4.2 Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.4.3 Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.4.4 Concluding procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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5.2.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.2.2 Backup batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.2.3 Fuses in the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Old version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107New version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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5.3.1 Electronic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.3.2 Lamp power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.3.3 34V Terminal regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.3.4 Fuses in the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Rack with old PODIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Rack with new PODIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Fuse board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

5.3.5 Indicators in the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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5.4.1 Wet part power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

5.4.2 Checking the backup batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

5.4.3 Printer part power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5.4.4 Electronic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

5.4.5 Supply for the exposure lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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5.5.1 Wet part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.5.2 Printer part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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6.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

6.2.2 The processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

6.2.3 Reset circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

6.2.4 Code memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

6.2.5 Data memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

6.2.6 Backup supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

6.2.7 Serial communication interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

6.2.8 Parallel interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.2.9 A/D Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.2.10 Memory card interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.2.11 General purpose input port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.2.12 General purpose output port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.2.13 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.2.14 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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6.4.1 Software version below 3.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

6.4.2 Software version 3.0 and higher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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6.6.1 Overview CBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

6.6.2 Overview CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

6.6.3 Block diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132CBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

6.6.4 Fuses on CBO and CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Fuses on CBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Fuses on the CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

6.6.5 Indicators on the CBO and the CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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6.7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6.7.2 Special connection of keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6.7.3 Special key combination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6.7.4 Block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

6.7.5 LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6.7.6 LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

6.7.7 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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6.8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

6.8.2 Restoring data from the memory card.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Restoring a film channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Restoring all data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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6.9.1 Adjustments on the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

6.9.2 Replacing the CPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

6.9.3 Replacing the backup battery on the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . 143

6.9.4 Clearing the RAM’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

6.9.5 Adjusting the CBO / CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

6.9.6 Replacing the CBO / CBO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

6.9.7 Contrast adjustment for the LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

6.9.8 Replacing the backup battery in the memory card . . . . . . . . . . . . . . . . . . . . 145

*��/ ��&�� %�

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7.1.1 Lamp house . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

7.1.2 Filter wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

7.1.3 Block diagram and timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

7.1.4 Light attenuator, testfilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

7.1.5 Light shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

7.1.6 Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

7.1.7 Lens turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

7.1.8 Lens code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.1.9 Calculation of focal length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.1.10 Zoom drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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7.2.1 Replacing the exposure lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

7.2.2 Adjusting the lamp voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

7.2.3 Adjusting filter wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

7.2.4 Adjusting the lens turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

7.2.5 Lens code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

7.2.6 Zoom lens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Preparing the focus adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Adjusting with grain finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Adjusting without grain finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

7.2.7 Setting the home position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

7.2.8 Focusing a fixed-focus lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

7.2.9 Adjusting the optical axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

7.2.10 Automatic Densitometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

��# ��&�� *"

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8.1.1 Optic box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

8.1.2 Measuring box with measuring board (scanner) . . . . . . . . . . . . . . . . . . . . . 172

8.1.3 Film positioning and DX-Code detection . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

8.1.4 Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

8.1.5 Measuring board (MESY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

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8.3.1 135 film. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

8.3.2 120 film. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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8.4.1 Special tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

8.4.2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

"�' ��(��&��"/

8.5.1 Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

8.5.2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

"�* ��&�� "�

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9.1.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

9.1.2 Positioning diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

9.1.3 Viewing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

9.1.4 Scanning position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

9.1.5 Exposure position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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9.3.1 Automatic 135 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

9.3.2 Automatic 135 film deck for Fuji code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

9.3.3 Automatic 110 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

9.3.4 Universal film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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9.4.1 135 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

9.4.2 110 film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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9.5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

9.5.2 Inserts coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

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9.6.1 Checking and positioning the DX-Code diodes . . . . . . . . . . . . . . . . . . . . . . 193

9.6.2 Adjusting exposure / viewing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

9.6.3 Adjusting the pressure solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

9.6.4 Adjusting the belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

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9.7.1 Adjusting home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

9.7.2 Adjusting the exposure position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

,�" ��&�� ,"

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10.1.1 Paper cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.2 Paper extractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.1.3 Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.1.4 Backprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.1.5 Paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.1.6 Feeder / Panorama feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.1.7 Distributor (ML X40 models only!) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

10.1.8 Timing diagrams of paper path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

�/� �� $�� /

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10.3.1 Loading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

10.3.2 Coding the paper cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

10.3.3 Adjusting the paper cassette to different paper widths. . . . . . . . . . . . . . . . . 215

10.3.4 Checking the sensors of the paper extractor . . . . . . . . . . . . . . . . . . . . . . . . 218

10.3.5 Removing the paper extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

10.3.6 Checking the knife function and its sensors . . . . . . . . . . . . . . . . . . . . . . . . . 219

10.3.7 Replacing the lower knife blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

10.3.8 Replacing the rolling knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

10.3.9 Removing the paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

10.3.10 Adjusting the tension of the transport belts . . . . . . . . . . . . . . . . . . . . . . . . . 221

10.3.11 Adjusting the sidewise paper position (Y-axis). . . . . . . . . . . . . . . . . . . . . . . 222

10.3.12 Adjusting the longitudinal paper position (X-axis) . . . . . . . . . . . . . . . . . . . . 223

10.3.13 Changing the type of feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

10.3.14 Adjusting the sensors in the panorama feeder. . . . . . . . . . . . . . . . . . . . . . . 225

10.3.15 Checking the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

10.3.16 Manually moving the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

10.3.17 Removing the distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

10.3.18 Checking the distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Checking the light barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Mechanical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

�/�% ��&�� #/

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11.1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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11.2.1 Film processor heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

11.2.2 Temperature / level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

11.2.3 Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

11.2.4 Heating management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

��# ;��&��!�� #*

11.3.1 Flow sensor / vacuum sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

11.3.2 Replenishment management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

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11.4.1 Recirculation management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

��' ��!�� %/

11.5.1 Principle of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240Block diagram of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

11.5.2 Motor energizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

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11.6.1 M805 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Old version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244New version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

�� ;��)�� %%

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11.8.1 Heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246Manually switching the heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246Viewing the temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246Checking / calibrating the tank temperatures . . . . . . . . . . . . . . . . . . . . . . . . 246Calibrating the dryer temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Changing the temperature setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Checking temperature sensors / level sensors . . . . . . . . . . . . . . . . . . . . . . 250Replacing a temperature / level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

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11.8.2 Replenishment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254Manually switching the replenishment pumps . . . . . . . . . . . . . . . . . . . . . . . 254Checking the replenishment rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255Changing the replenishment rate for all chemistries together . . . . . . . . . . . 256Changing the replenishment rate for one tank only . . . . . . . . . . . . . . . . . . . 256Replacing a bellow of the replenishment pump . . . . . . . . . . . . . . . . . . . . . . 257

11.8.3 Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259Manually switching the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259Checking the belt tension of the transport motor . . . . . . . . . . . . . . . . . . . . . 259Removing the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260Installing and aligning the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261Changing the transport speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

11.8.4 Film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Removing the film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Replacing the knife. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263Replacing the rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Replacing the sensor boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

11.8.5 Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Racks in the processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Dryer rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267Opening a rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268Reassembling a rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269Aligning the gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

��, ��&��

� � -��+�� #

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12.1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

� � @��(��!�� *

12.2.1 Paper processor heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

12.2.2 Temperature and level sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

12.2.3 Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

12.2.4 Heating management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

� �# ;��&��!�� "

12.3.1 Flow sensor / vacuum sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

12.3.2 Replenishment management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

� �% ;��!�� "/

12.4.1 Recirculation management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

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12.5.1 Automatic top-off management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

12.5.2 Water quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

� �* ��!�� "%

12.6.1 Principle of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285Block diagram of speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

12.6.2 Motor energizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

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12.9.1 Heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287Manually switching the heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287Viewing the temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Checking / calibrating the tank temperature. . . . . . . . . . . . . . . . . . . . . . . . . 288Calibrating the dryer temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Changing the setting of the temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Checking temperature sensor / level sensors . . . . . . . . . . . . . . . . . . . . . . . 292Replacing the temperature / level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . 294

12.9.2 Replenishment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Manually switching the replenishment pumps . . . . . . . . . . . . . . . . . . . . . . . 295Checking the replenishment rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296Changing the replenishing rate for all chemistries together . . . . . . . . . . . . . 297Changing the replenishing rate for one tank only. . . . . . . . . . . . . . . . . . . . . 297Replacing a bellow of the replenishment pump . . . . . . . . . . . . . . . . . . . . . . 298

12.9.3 Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300Manually switching the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300Checking / adjusing the belt tension of the transport motor . . . . . . . . . . . . . 300Removing the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Installing and aligning the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Changing the transport speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

12.9.4 Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303Racks in the processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303Dryer rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304Opening a rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305Reassembling the rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

12.9.5 Sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307Checking the belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

� ��/ ��&�� #/"

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�#� 3��!�� #/,

�#�� 4 �� $ ��#/,

�#� �17�� #�/

13.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

13.2.2 Functional units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Code memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Data memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Backup supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Analog to digital converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Timers interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313Power and reset logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

13.2.3 Rotary switch positions and jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Rotary switch positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

13.2.4 Test points and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Test points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

�#�# �"/ �� #�*

13.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

13.3.2 Functional units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Input circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Solenoid drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Heater drivers (220Vac). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Motor drivers (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Transport motor driver (24V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

13.3.3 Fuses on the M802 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

13.3.4 Indicators on the M802 board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

�#�% �"/#�� # /

13.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

13.4.2 Functional units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Input circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Sorter driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Heater drivers (220Vac). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Motor drivers (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Printer supply (220Vac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Transport motor driver (24V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

13.4.3 Fuses on the M803 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

13.4.4 Indicators on the M803 board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

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13.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

13.5.2 Pump driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

13.5.3 Fuses on the ALMLPLUS board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

13.5.4 Indicators on the ALMLPLUS board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

�#�* �1�7�� # *

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13.7.1 The MCB, M802, M803, RCB or ALMLPLUS boards. . . . . . . . . . . . . . . . . . 327

13.7.2 Replacing the battery on the MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

13.7.3 The SCSB board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

�#�" ��&�� ##/

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14.2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

14.2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

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14.3.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

14.3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Master Lab+ directly connected to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Master Lab+ connection via modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

�%�% ;��&�� ##*

14.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

14.4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

�%�' �� #%

14.5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

14.5.2 Setting up the line printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342DIP switch DS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343DIP switch DS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Recommended switch setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

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14.5.3 Setting the serial / parallel converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344DIP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344Jumpers (DTE selection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

14.5.4 Connection cable line printer - Master Lab/Master Lab+ . . . . . . . . . . . . . . . 345

�%�* -��3�� #%*

14.6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

14.6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

14.6.3 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Aligning the lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Centering the prints on the paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

�%�� 2��(��&��#%,

14.7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

14.7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

�%�" 1�� (��)��#%,

14.8.1 Enlargement kit E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

14.8.2 Speedup kit I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

14.8.3 Speedup kit II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

14.8.4 Digital upkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

14.8.5 Film processor upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

14.8.6 Upgrading the processor to KODAK - SM . . . . . . . . . . . . . . . . . . . . . . . . . . 351

14.8.7 Automatic Densitometer (ADM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

14.8.8 Lamp house upgrade kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

14.8.9 APS / Index kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

�%�, :�� #'#

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�'� 7��(��&!?�(��!��B�� #''

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�'�# ��B ��#'�

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�� 1

�&��(� ��&��&�� (��&��

��

This manual is part of the service training and given to trained service engineers only!

C��D ��!?�$��)�!��&�!�� &��4��(��&��

Please read and observe the safety rules provided later in this chapter.

�� +��&��

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. Fur-thermore, 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.

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The Master Lab+ documentation includes four manuals:� Operating Manual� Operating Manual Program 3 SETUP (further called Setup Manual)� Service Manual (the manual your are reading now)� Spare parts list

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.

�� 1�� &��

�� The following convention apply throughout this manual:

� 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. E4;��;F

� All softkeys (keys with different meanings depending on the menu) are printed in boldface e.g. -�-;41

�� !��

�� Please observe the following rules for safe operation of the Master Lab+:

� 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.

� Observe all relevant local, national and/or international safety regulations regarding the handling of electric/electronic equipment and chemicals.

��

� Always ��&�� and dispose of according to the instructions of the manufacturer of chemicals and legal environmental guidelines and procedures.

� C� �� &��!��$�(��!��&��.��G

� Keep new and used chemicals out of the reach of unauthorized persons. Store chemicals in a lockable room.

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� Always wear protective cloth (gloves, goggles, apron) when handling chemicals.

� Ask the supplier of the chemicals for the relevant MSDS (�aterial �afety �ata �heet) 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. Inter-ruption of the protective conductor inside or outside the machine, or discon-necting 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.

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� Never carry out any working steps if you are uncertain about the effect. If in doubt, consult your local GRETAG representative

ATS

POWER

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�� !��&��!

�!��&��&��&��

3+;C�C2GIf instructions marked with this sign are not carried out correctly, mal-function of the machine may result or personnel may be hurt.

��H��-+;��GThis sign is used in the manual only! Always switch off the machine before working on electrical parts. Not following the instruction endan-gers your life!

@�+HI�-+;��GThis 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!

��-4��4>�7+��;��-;4-�;�I�Batteries should be exchanged by trained specialists only. Used bat-teries must be disposed of properly in accordance with the local reg-ulations 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.

��H��-+;��C��GAlways switch off the machine before opening or removing a cover!

@�+�GWait until the part marked with the heat sign has cooled down other wise you may burn your fingers!

��1�;4��+��1��1@+;2�GDon’t touch such parts with bare fingers or ungrounded tools! Electro-static discharges can destroy delicate electronic circuits or compo-nents!

;4�+��C2�-+;��GWait until all rotating parts (fan, motor, etc.) stops turning otherwise injury on your fingers may result!

3�+;�-;4��1��H��2�4H��GWhenever 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!

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�!��B��?��&��)��(��

3�+;�2422��GWhenever you work with chemistry, wear goggles. Splashes in your eyes must be washed out immediately with water! Immediately get medical advice!

:��-�@+C��4>>GBe careful not to hurt your hands when you close a part (e.g. a heavy lid or cover)

�@+;-�7�+��GTake special care when you are working with parts marked with this sign. You may get hurt if you disregard this sign!

� � � � � � � � � � � � �

� � � � � � �

� � � � � � � �

:��!GStore the equipment in a dry place (storage temperature not lower than 0° centigrade)!

�&��GAlways place transport boxes such that the arrows point upwards. Don’t overturn the boxes when transporting, loading, unloading, stor-ing, packing or unpacking.

>��(��GThe 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!

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22 Service Manual

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��# �� $

�� 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 cor-responding dryers and the sorter on the paper side. The wet part is an indepen-dent 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 spe-cial functions in operation or in service mode.

��#�� &��!��

The Master Lab+ family comprises the eight models:� Master Lab+ 120� Master Lab+ 320� Master Lab+ 140� Master Lab+ 340� Master Lab+ 520� Master Lab+ 740� Master Lab+ 220� Master Lab+ 240

The basic layout is the same for all machines. However, they differ in that single assemblies will be added or omitted.

��' /

The Master Lab+ 520 is a basic model of the family.

Film processor

Paper processor

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

Film sizes 110,126,135,120 and APSCapacity 21 film per hour (based on 135 film with 24 exposures)

Paper width 3.5” to 8.25”Capacity 200 Prints per hour (based on 10 x 15cm /4” x 6” prints)

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the paper cassette the format is defined and the computer checks whether the remaining parts of the configuration are correct.

��# /

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.

�� /


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 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 scan-ner measures the next frame. The paper sorter collects the prints from both paper tracks and separates consecutive orders.

Paper processor

��%/


It has no film processor.


Paper width 3.5” to 8.25”Capacity 400 Prints per hour (based on 10 x 15cm /4” x 6” prints)

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To achieve this capacity it features a shutter and a paper distributor.

��%/

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.

�� /


It has no film processor, instead it has larger replenishment and recovery tanks installed.

�� %/

The Master Lab+ 240 provides the same layout as the Master Lab+ 220 but has twice the processing capacity.

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��#� 4 �� $

>��8��# /?��#%/?��' /��%/9saml01002a

>��8�� /?��%/?�� /�� %/9saml01003a

1 Printer 4 Replenishment tanks for film proces-sor

2 Film dryer 5 Overflow tanks for film processor3 Film outlet station 6 Printer control system

7 Automatic Densitometer (ADM)

2

3

5

4

6

7

1

1 Printer 4 Overflow tanks for paper processor2 Cover 5 Replenishment tanks for paper processor3 Print stacker 6 Printer control system

7 Automatic Densitometer (ADM)

2

3

6

1

5

4

7

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>�� $D

-��8��# /?��#%/?��' /��%/9saml01006a

��# /?��#%/?��' /��%/

�� /?��%/?�� /�� %/

saml01004a saml01005a

13 Exhaust connection14 Wet part control system

15 Bleach air pump

13

14

15

13

14

14 Paper dryer 19 Connector for peripherals:15 Print stacker � Densitometer (D188/D19C)16 Overflow tanks for paper proces-

sor� Modem

17 Repl. tanks for paper processor � Line printer18 Mains socket � Aux 1, Aux 2

20 Lost liquid sensor21 Water tank for autom. top-off system

14

15

18

1916

17

20

21

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-��8�� /?��%/?�� /�� %/9saml01007a

��#�# ��&��

All together are five labels in a Master Lab+

saml01008a

14 Paper dryer 19 Connector for peripherals:� Densitometer (D188)� Modem� Line printer� Aux 1, Aux 2

15 Print stacker 20 Lost liquid sensor18 Mains socket 21 Water tank for autom. top-off system

14

15

18

19

20

21

1 Printer serial number 4 Wet part status label2 Printer status label 5 Master Lab+ serial number3 Wet part serial number

1

2

3

4

5

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� 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

The circled or crossed out number on the status label indicates which modifica-tion has been installed.

When several modifications are installed in the field or in the factory then the cor-responding 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.

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�� !��&��!��&��(��&��&��!�$�!��$&��&��&� ��!��&��&��&��$��&��&��!��(��&��G

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1

11

21

31

41

2

12

22

32

42

3

13

23

33

43

4

14

24

34

44

5

15

25

35

45

6

16

26

36

46

7

17

27

37

47

8

18

28

38

48

9

19

29

39

49

10

20

30

40

50

GRETAGSAN MARCO

1

11

21

31

41

2

12

22

32

42

3

13

23

33

43

4

14

24

34

44

5

15

25

35

45

6

16

26

36

46

7

17

27

37

47

8

18

28

38

48

9

19

29

39

49

10

20

30

40

50

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��#�% ��!��(�� $saml01010a

1 Exhaust tube connector 12 Paper dryer cover locking screw2 Main electric box 13 Master Lab+ serial number3 Mains transformer 14 Manufacturer model number4 Voltage selector (XT) 15 Status label of wet part5 Terminal block (X2) 16 Electrical rating marking6 Mains inlet 17 Film cutting knife blade7 Mains cable terminal (X3) 18 Safety switch, paper processor8 Line filter 19 Safety switch, film processor9 Voltage setup instruction 20 Indicator “Power on”10 Label of factory voltage setup 21 Mains switch11 Protective earthing terminal

112

2, 3, 4, 5

13

17

14,15, 162120

9,10

11

6, 7, 8

19

18

Film processorside view

Paper processorside view

Top view Front view

17

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��% ��&��

��%�� !��

Dimension system Width 780mm (2.56ft.)Length 1226mm (4.02ft.)Height 1700mm (5.6ft.)

packed Width 1070mm (3.5ft.)Length 1400mm (4.6ft.)Height 1960mm (6.4ft.)

System footprint 1m2 (78 x 123cm)10.3sq.ft. (2.56 x 4.02ft.)

Weights ML+ 320 320kg / 393kg(dry / operational) ML+ 340 328kg / 401kg

ML+ 520 326kg / 399kgML+ 740 334kg / 407kgML+ 220 280kg / 345kgML+ 240 288kg / 353kgML+ 120 274kg / 339kgML+ 140 282kg / 347kg

Mains voltage 1 phase 200/208/220/230/240Vac +/- 10%, 50/60Hz3 phase 220Vac +/- 10%, 50/60Hz3 phase 380Vac +/- 10%, 50/60Hz

Power consumption ML+ 320 - 740 max. 3300VA; average: 2450VAML+ 120 - 240 max. 2800VA; average: 2000VA

Stray power ML+ 320 - 740 max. 7700kJ; average: 5800kJML+ 120 - 240 max. 6000kJ

Ambient conditionsTemperature operational +15oC to +30oC

non-operational -25oC to +60oC

Humidity operational 30% to 75% (not condensing)non-operational 10% to 90% (not condensing)

Ambient light max. 1000 Lux

Noise level operational max. 70dB(A)standby max. 60dB(A)

Exhaust tube length max. 2.5m (8.2ft.)diameter 50mm (1.97”)

Exhaust fan air flow rate 1.6m3 / min1)

�9 ��!��!?��&��&�� &��&��&��&��G�>��&��

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��%� -��

Negative formats ML+ 320 / 340 135 onlyML+ 520 / 740 135, 110, 126, 120, 220, Disc, APSML+ 220 / 240 135, 110, 126, 120, 220, Disc, APSML+ 120 / 140 135 only

Paper size ML+ 320 / 340 4” onlyML+ 520 / 740 3.5”, 4”, 5”, 6”, 7”, 8”, 8.25”ML+ 220 / 240 3.5”, 4”, 5”, 6”, 7”, 8”, 8.25”ML+ 120 / 140 4” only

Print size ML+ 320 / 340 4” x 6” onlyML+ 520 / 740 3.5” x 3.5” to 8.25” x 12”

Panorama. PassportML+ 220 / 240 3.5” x 3.5” to 8.25” x 12”

Panorama. PassportML+ 120 / 140 4” x 6” only

Capacity ML+ 320 / 120 200 (4”)(prints / hour) ML+ 340 / 140 400 (4”)

ML+ 520 / 220 225 (3.5”), 200 (4”), 160 (5”), 100 (8”)ML+ 740 / 240 450 (3.5”), 400 (4”), 160 (5”), 100 (8”)

Paper loading Daylight cassette for 175m paper rollsAutomatic paper loading

Film transport 135 Automatic with DX-Code reader110 Automatic126 Manual120 / 220 ManualDisc Semi automaticAPS Automatic with DX-Code and MOF reader

Light system Halogen lamp 24V / 250WAdditive filter system

Lens system ML+ 120 / 140 Fix lensML+ 320 / 340 Fix lensML+ 520 / 740 Zoom lens (motor driven), single lenses

optionalML+ 220 / 240 Zoom lens (motor driven), single lenses

optional

Measuring system True color scannerApprox. 96 pixels x 3 colors (135 FF)

Serial interface for Densitometer (D188/D19C)Line printerModemAuxiliary 1, 2

Data backup Memory card (RAM-card) 32kBytes

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��%�# 3��?��8��9

Chemical process C-41 RANP

Transport system Short leader (by leader cards)

Film formats 110, 126, 135, 120, 220, APS

Processing time (dry to dry) 8 minutes 40 seconds (135 film, 24 exposures)

Processing speed 478mm / minute

Processing capacity 21 films / hour (135 film, 24 exposures)

Replenishment system Automatic, from integrated tanks(external tanks optional)

Evaporation compensation Automatic, from integrated water tank

Capacity of working tanks DEV 11.84 L(racks installed) BL 2.60 L

FIX 1 2.69 LFIX 2 2.58 LSTAB 1 2.70 LSTAB 2 2.58 L

Capacity of replenishment tanks DEV 1.95 LBL 0.45 LFIX 2.77 LSTAB 3.36 L

Film capacity of built-in replenish-ment tanks

80 rolls (135 film, 24 exposures)

Power backup Backup-battery in case of power failure for the film transport.

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��%�% 3��?��

Chemical process RA-4 NP

Paper loading syst5em Daylight cassette for 175m rollsautomatic paper loading

Paper transport system Single sheet transport

Processing time (dry to dry) 4 minutes 30 seconds

Processing speed 635mm / minute



Evaporation compensation Automatic, from integrated water tank

Capacity of working tanks DEV 5.49 L(racks installed) BL 5.59 L

STAB 1 4.47 LSTAB 2 4.38 LSTAB 3 4.38 L

Capacity of replenishment and recov-ery tanks (RA-4)

ML+ 320 to 740 DEV 3.40 LBL 4.40 LSTAB 7.40 L

ML+ 120 and 240 DEV 13.5 LBL 13.5 LSTAB 13.5 L

Capacity of replenishment and recov-ery tanks (PRIME)

ML+ 320 to 740 DEV 4.50 LBL 3.00 LSTAB 10.0 L

Print capacity of built-in replenish-ment tanks

ML+ 320 to 740 1700 prints (3.5” x 5”)

ML+ 220 and 240 DEV (print size 3.5” x 5”) 6800 prints

ML+ 120 and 140 BL (print size 3.5” x 5”) 5200 printsSTAB (print size 3.5” x 5”) 3100 prints

Power backup Backup-battery in case of power failure for the paper transport.

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��' �&��(�)��

The shipping kit is included with every delivered machine. There is a separate shipping kit for each part:

� one for the printer part

� one for the wet part

It contains all necessary consumables and other helpful items

��'�� -��

C��D >��&��(��&��(��?��&��G

-�� 4�� J��!Exposure lamp 24V / 250W 11.61.46 5Fuse 5A (5 x 20mm) 20.94.12 10Fuse 2A (5 x 20mm) 11.21.21 10Hex key 1.5mm 13.55.65 1Hex key 2.5mm 20.90.45 1Testfilm 135 film (Kodak Gold 100-6) 34.91.33 1Memory card 11.62.70 1

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��'� 3��

-�� 4�� J��!Splice tape 00GSM2300 1Washing bottle 00GSM7555 1Graduated cylinder, 100ml 0021-101-03 4Manual film puller 0021-906-84 1Hose clamp SNP14 0026-480-07 5Twincheck labels 0028-493-03 1Fuse 1.25A (5 x 20mm) 0028-758-11 5Fuse 2A (5 x 20mm) 0028-758-13 5Fuse 10A (5 x 20mm) 0028-751-27 5Fuse 1A (6.3 x 32mm) 0028-759-75 5Fuse 25A (6.3 x 32mm) 0028-755-42 5Fuse 2A (6.3 x 32mm) 0028-759-78 5Fuse 2.5A (6.3 x 32mm) 0028-759-79 5Fuse 4A (6.3 x 32mm) 0028-759-81 5Fuse 8A (6.3 x 32mm) 0028-759-85 5Replenishment filter 0029-100-23 1Manual tape dispenser 0029-230-09 15 lt. container tank 0029-302-11 1Extension hose 0029-302-12 1Tube 14 x 19 0034-411-06 1Film loading cassette 14221-155-0 2Tools 14991-009-2 1Hook for cylinder 15160-127-0 4Splash shield 15410-180-0 1Developer rack tray 15605-421-1 1126 film box 15615-075-0 2110 film box 15615-076-0 2120 film box 15615-088-0 2135 film adapter 16245-449-1 2Seeger 16315-009-0 10Seeger 16315-017-1 10Seeger 16315-019-1 10Seeger 16315-020-0 10Air filter 16445-137-1 1Chemical filter 16445-139-0 22Air filter 16445-517-0 1Film loading caps 0025-514-02 2Film leader 16555-211-0 10Rack tray 16605-051-1 1Dripping tray 16605-057-2 1Film preparation station 18582-112-0 1O-ring kit 18988-460-0 4Print collector 16615-256-0 1Film loading 14211-036-0 1Paper panel 15425-087-4 1

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��* + ��

More details about the following options as well as other information concerning service aspects are found in chapter 14.

>��

Cleans the film with brushes and discharges any electrostatic with ionized air.

;��

This interface plus the corresponding software allows the control of quality via a modem.

-��$��

Allows either four (passport) or two (wallet) prints on the same 3.5” paper.

�B��&��

Provides larger replenishment tanks.

��

Allows certain statistics and calculation data to be printed.

2��(��&��

Prints an additional subject to the regular print.

H�� )��

Improving and upgrading the machine, such as

� 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

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�� 2

��

This chapter contains procedures for unpacking and installing a Master Lab+ therefore:

;��&��&��!��)��(��(��&��A��!��$��&��&��

The chapter is organized as follows:

2.2 Pre-Installation requirements

2.3 Unpacking the Master Lab+

2.4 Installation

2.5 Checking the system

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� -��.��

� �� >��saml02001a

Please note:

�� 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 elec-tronic rack to be drawn out for service purposes.

1226

0..500

780 745

100

Replen. Console(Optional)

600800

All measurements in Millimeter

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� � ;��&��(&�

�� A minimal room height of 2250mm (7.38ft.) is required to allow the film and/or paper dryer to be lifted.

saml02002a

� �# >��

The floor in the Master Lab+ working area must be capable of supporting at least 410kg/m2.

��

-��D

� �&��$��(&��$��&��')(�8 �%��9��(&��

� �&��(�$��(&��$��&��"/)(�8� �*��9��(&��

� �% ��

Observe the following:

� 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.

Repl.Console

(Optional)

2250

All measurements in Millimeter

Max. net weight of the Master Lab+ 355kg (7.82cwt.sh.)Max. operating weight (with chemistry) 407kg (9cwt.sh.)

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� �' ;��&��!

� Operate the machine at a room temperature between +15oC and +30oC.

� The maximum relative humidity (not condensing) is 75%.

� For the minimum permissible relative air humidity consult the specifications from the paper manufacturer (about 30%)

� �* +��(

It is advisable to install a room temperature cooling system. The Master Lab+ produces an average heat of 5800kJ (max. 7700kJ).

� �� B&��

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

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Exhaust tube

Ø 50mm

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� 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.

� �" ;��

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

� �, ��)��

�� 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 stan-dards and must be capable of carrying the maximum machine current (see tech-nical specification in chapter 1.4).

The customer has to ensure that the Mains socket has a good and reliable grounding connection.

�# 0��)��(��&��

�#�� 1&��)��(��&��(��(��

�� GRETAG IMAGING AG takes out a transport insurance when a machine is shipped. The customer is invoiced for the insurance and transport costs.

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��!��&��&��(��!��2;��+2��&�� $��)��&��!��G

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�#� ��

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.)

�#�# ��

C��D +��&��&��!��G

��

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)

� 1 spanner 7mm and 8mm� 1 spanner 10mm and 11mm� 1 spanner 16mm and 17mm� 1 screw driver 4mm (No. 2)� 1 ‘Phillips’ screw driver (No. 1)� 1 hex key 3mm� 1 hex key 4mm

�#�% 0��)��(��&��

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.

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' 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+.

�% Turn the four feet upward until the machine rests on the four wheels.

saml02006a

% Remove the cardboard packing.

saml02007a

� Lower the four feet until they rest on the pallet (use the spanner size 17mm from the tool kit).

saml02008a

�# Remove the four Z-shaped steel brackets (the counter nut is for additional security).

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�� 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.

saml02009a

�' Make a ramp by nailing the two planks provided to the pallet with two nails each.

1+0��4CG

�&��&�� !�&�� !G�1��!�(��&��&��$��&��

C� ��!��&��?�!��!��(��!��)G

1+0��4CG

C� ��&��&��&��$��$��&��&��G�I��$��(��&��G

-��&��$��$��!G

saml02010a

�* Push the machine down the ramp until it is off the pallet.

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�% ��

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.

�%�� >��)��8�� /�� %/9

If your machine does not have a film processor, skip this chapter and proceed with the next one.

# Rinse the replenishment tanks with warm water.

3+;C�C2G

3&�� !��$��)�$��&��&��?�$�� (�� (�((��G�

�� $��!��&��G

saml02011a

� Remove the replenishment tanks from the film processor.

saml02012a

Open the screw caps of the replenishment tanks.

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% Fill the replenishment tanks for the film processor with the corresponding chemicals. A color dot indicates which chemicals belongs into which replenishment tank:� Blue dot = developer� Red dot = bleach� Green dot = fixer� Yellow dot = stabilizer

' Close all screw caps so no chemicals are spilled when the tanks are moved.

1+0��4CG

3&��!��&��)�?��&��&��&��&��)��&G�4�&��$��$��?�$&��&��)��&��$��&��G

saml02013a

* Reinsert the full replenishment tanks.

� Open the screw caps.

saml02014a

" Pull the draw-off unit from the fill-ing unit.

saml02015a

, Insert it into the replenishment tanks.

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�/ Fill the working tanks of the film processor with the corresponding chemi-cals. A color dot indicates which chemicals belongs into which working tank:� Blue dot = developer� Red dot = bleach� Green dot = fixer� Yellow dot = stabilizer

�� Check the working tanks for leaks.

C��D ��)��?��&��)��!G��&��)��$��&��14�[email protected]��-��,/��0��&��&�� $��&��)�(�G

� Ensure that the filling unit of the overflow tanks of the film processor is pushed down properly.

�# Fill the top-off tank with water.

�%� >��(��&��)�

1+0��4CG

3&��!��&��$��)��(��)�?��&��&��&��&��)��&G�4�&��$��$��?�$&��&��)��&��&��$��&��G

3+;C�C2G

3&�� !��$��)�$��&��&��?�$�� (�� (�((��G�

�� $��!��&��G

saml02016a

� Remove the replenishment tanks from the paper processor

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# Rinse the replenishment tanks with warm water.

% Fill the replenishment tanks for the paper processor with the corresponding chemicals. A color dot indicates which chemicals belongs into which replen-ishment tank:� Blue dot = developer� Red dot = bleach / fix� Yellow dot = stabilizer

' Close all screw caps so no chemicals are spilled when the tanks are moved.

saml02017a

Open the screw caps of the replenishment tanks.

1+0��4CG

3&��!��&��)�?��&��&��&��&��)��&G�4�&��$��$��?�$&��&��)��&��&��$��&��G

saml02018a

* Reinsert the full replenishment tanks.

� Open the screw caps.

saml02019a

" Pull the draw-off unit from the fill-ing unit.

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�/ Fill the working tanks of the paper processor with the corresponding chem-icals. A color dot indicates which chemicals belongs into which working tank:� Blue dot = developer� Red dot = bleach� Yellow dot = stabilizer

�� Check the working tanks for leaks.

C��D ��)��?��&��)��!G��&��)��$��&��14�[email protected]��-��,/��0��&��&�� $��&��)�(�G

� 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.

�%�# ��&��(��

The mechanical configuration consists of installing and connecting equipments removed for transport.

saml02020a

, Insert it into the replenishment tanks.

1+0��4CG

3&��!��&��$��)��(��)�?��&��&��&��&��)��&G�4�&��$��$��?�$&��&��)��&��&��$��&��G

saml02021a

� Install the fix lens for Master Lab+ 320, 340, 120 and 140.

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�%�% H��(��

After the Master Lab+ is mechanically prepared, connect the power to the machine.

There are three possibilities of power connection:� single phase 230V with protective Ground (200 ... 240V)� three phase 230V with protective Ground (200 ... 240V)� three phase 380V with protective Ground (376 ... 415V)

�%�' ��

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.

saml02022a

Install the zoom lens for Master Lab+ 520, 740, 220 and 240.

saml02023a

# Install the film deck.

saml02024a

% Install the light shaft.

2

1

��-4;�+C�G

�&��(��?��&��&�� &��!��&��?�� #/H��(��&��G

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� 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 accord-ing UL-CSA)

�%�* -��(��&��

The power cable has to be prepared as shown before it is thread into the machine.

saml02025a

�%�� 1��(��&��

9mm

≥ 0.5DCable diameter D

Strain relief

yellow/green

min. 60mm (2.4")max. 90mm (3.5")

�+C2�;G

��)��&��&��(��C4��((��&��!��(��&��$��G

��&��)�&�� !��(��!��?��!�� )��!��G

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� Thread the cable into the machine and through the strain relief.

Tighten the strain relief.

The connections for the various types of mains supplies are shown in the next figure.

saml02027a

saml02026a

# Connect the incoming cable to the terminal block X3.

X3XZ

Linefilter

Phase 1

Ph 2/Neutral

Ground

L1

L2

L3

MP

1

2

3

4

-1- Black

-4- Black

Mains cable

-173-

-174-

-175-

-176-

-YG-

-YG- -YG3-

-1-

-2-

-3-

-4-

X 3

-3- Black

-2- BlackXZ

200 - 240V /1 Phase

Phase 1

Phase 2

Phase 3

Ground

L1

L2

L3

MP

1

2

3

4

-1- Black

-2- Black

-4- Black

-3- Black

Mains cable

-173-

-174-

-175-

-176-

-YG-

-YG- -YG3-

-1-

-2-

-3-

-4-

X 3

200 - 240V/3 Phase ∆

Phase 1

Phase 2

Phase 3

Neutral

Ground

L1

L2

L3

MP

1

2

3

4

-1- Black

-2- Black

-4- Black

-3- Black

Mains cable

-173-

-174-

-175-

-176-

-YG-

-YG- -YG3-

-1-

-2-

-3-

-4-

X 3

376 - 415V/3 Phase

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saml02029a

* Set the bridges (jumpers) on terminal block XT according to the incoming voltage.

� In case of three phase 230V disconnect wire # 172

saml02028a

% With three phase 230V or 380V disconnect the wire bridges (jumper) on the filter Z.

saml02030a

' With three phase 230V or 380V you have to connect the bridge (jumper) on terminal block X2 between terminal 2 and 3.

Z

L1' L2' L3'N'

L1 L2 N L3

-1-

-2-

-3-

-4-

-173-

-174-

-175-

-176-

-YG-

LOAD

LINE

X = Remove

200-240V/3phase376-415V/3phase

Z

L1' L2' L3'N'

L1 L2 N L3

-1-

-2-

-3-

-4-

-173-

-174-

-175-

-176-

-YG-

LOAD

LINE

200-240V 1 Phase

Transformer

XT

X2

1 2 3 4

172

171

104

107

200-240V/1Phase

106

106

1 2 3 4

171

104

107

172

200-240V/3 Phase

376-415V/3 Phase

106

106

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saml02031a

H��(��(�

saml02032a

" Check the connection on the auto-transformer for the right voltage. Change if necessary.

172

103

103

107

107

105

105

110

109

109

109

108

200-240V/1 Phase

172

103

103

107

107

105

105

110

109

109

109

108

200-240V/3 Phase ∆

172

103

103

107

107

105

105

110

109

109

109

108

376-415V/3 Phase

#103

240V

220V~#111

230V

220V

208V

200V

0V

0V

H��(� ��(��&�� (��

200V 14A 9.2A208V 14.2A 9.3A220V 14.5A 9.5A230V 14.8A 9.6A240V 15.2A 9.8A380V 5.2A400V 5.3A415V 5.4A

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�' 1&��)��(��&��!��

�'�� 1&��)��&��-��

� 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.

* 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.

saml01001a

% Switch ON the Master Lab+ with the main circuit breaker.

saml02033a

' Pull out the drawer.

ATS

POWER

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saml02034a

1 Pump cooling fan (blows into the machine)2 Wet part electronic cooling fan (blows into the machine)3 Printer part electronic fan (blows up into the machine)4 Exhaust fan (blows fume out of the machine)5 Lamp cooling fan (blows out of the lamp house)

�'� 1&��)��&��

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 E14��F. A softkey menu is displayed

Press the key below >-;41.

# Press the key below ��-��-.The actual temperatures in the various tanks are displayed.

' Press E14��F. A softkey menu is displayed.

* Press the key below >-;41.

1

2

3

45

saml02035a

% Check the replenishment rates with four graduated plastic cylinders supplied by placing the replenishment tubes into the cylinders.

100

90

80

70

60

50

100:1

in 20 °Cml

100

90

80

70

60

50

100:1

in 20 °Cml

100

90

80

70

60

50

100:1

in 20 °Cml

100

90

80

70

60

50

100:1

in 20 °Cml

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� Press the key below �+C;�-�.The nominal replenishment quantities of the various tanks are displayed.

" Press the key below ��.An amount – equal to 20 strokes – is pumped into the cylinders.If the quan-tity 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

After the operating temperatures have been reached (about 1 hour after switch-ing ON) check the temperatures with an accurate mercury or electronic ther-mometer. The procedure is as follows:

� Press E14��F. A softkey menu is displayed.

�# Press the key below >-;41.

�% Press the key below ��-��-.The actual temperatures in the various tanks are displayed.

saml02036a

, Remove the lid of the film processor.

saml02037a

�/ Lift the cover of the film dryer

�� Remove the light shield covering the tanks.

��-4;�+C�G

�&��&��B��&��A��&��)��&��(��&�

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If the actual value deviates more than the permissible tolerance from the nomi-nal value, a recalibration is necessary. Proceed as described in chapter 11.8.1

�'�# 1&��)��(��&��

Check that the temperatures in the paper processor tanks rise with the following procedure:

� Press E14��F. A softkey menu is displayed.

Press the key below --;41.

# Press the key below ��-��-.The actual temperatures of the various tanks are displayed.

saml02038a

�' Insert an accurate thermometer into the tank right by the tempera-ture sensor and compare the mea-sured value with the value dis-played.

saml02039a

�* When the temperature measure-ment 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.

vvvvv

vvvvvvvvvvvv

vvvvvvvvvvv

vvvvvvvvvvv

vvvvvv vvvvv

vvvvvvvvvvv

vvvvvvvvvvvvvv

vvvvvvvvvvvvvvv vvvv

vv

vvvvvvvvvvvv

vvvvvvvvvvvv

vvvvvvvvv

vvvvvv vvvvvv

vvvvvvvvvvv

vvvvvvvvvvvvv

vvvvvvvvv

vvvvvv vvvvvvv

vvvvvvvvvvvv

vvvvvvvvvvv

vvvvvvvvvv

vvvvv vvvvvvv

vvvvvvvvvvvv

vvvvvvvvvvv

vvvvvvvvvv

vvvvv

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' Press E14��F. A softkey menu is displayed.

* Press the key below --;41.

� Press the key below �+C;�-�.The nominal replenishment quantities of the various tanks are displayed.

" Press the key below ��.An amount – equal to 20 strokes – is pumped into the cylinders. If the quan-tity 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 switch-ing ON) check the temperatures with an accurate mercury or electronic ther-mometer. The procedure is as follows:

saml02041a

% Check the replenishment rates with three graduated plastic cylin-ders supplied by placing the replenishment tubes into the cylin-ders.

saml02042a

, Remove the lid of the paper pro-cessor.

saml02043a

�/ Lift the cover of the paper dryer. Make sure the cover locks on both sides.

100

90

80

70

60

50

40

30

20

10

100:1

in 20 °Cml

100

90

80

70

60

50

40

30

20

10

100:1

in 20 °Cml

100

90

80

70

60

50

40

30

20

10

100:1

in 20 °Cml

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�# Press E14��F. A softkey menu is displayed.

�% Press the key below --;41.

�' Now press the key below ��-��-.The actual temperatures of the various tanks are displayed.

If the actual value deviates more than the permissible tolerance from the nomi-nal value, a recalibration is necessary. Proceed as described in chapter 12.9.1.

saml02044a

�� Turn both fasteners on the cross-over 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.

��-4;�+C�G

�&��&��A��&��)G

saml02046a�* Insert an accurate thermometer

into the tank right by the tempera-ture sensor and compare the mea-sured value with the value dis-played.

saml02047a

�� When the temperature measure-ment is finished, lower the lower part of the dryer and lock it.

saml02046a

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�'�% 1��(��&��)�

� 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 E��F.

% Enter the password. (default is 3340) and confirm with E�C��;F.A softkey menu is displayed.

' Press the key below -;�C��;.

* Press the key below �+��;.

� Press the key below ��;�1�and change the code for the reference paper.

" Confirm with E�C��;F.

, Press any menu key to exit the present menu

saml02048a

�" 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.

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�/ Now, insert a film strip and place the first negative in the viewing window.

�� Press E14��F. A softkey menu is displayed.

� Press the key below -;�C��;.

�# Press the key below ��C�.

�% Press the key below ��K44�.

�' Press the key below ��+;�.

The negative is now transported into the exposure position, paper is cut and brought into the exposure position on the paper deck.

�� Confirm with E�C��;F.

�" Press any menu key to exit the present menu

�, Load a film strip with the key.

/ Position the negative in the viewing window with the arrow keys and .

� Press E�+�C�F.

Enter the password (default is 7890) and confirm with E�C��;F.

# Press the key below -;�C��;.

% Press the key below >��;+1:.

' Press the key below �C��.

saml02051a

�* 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.

3+;C�C2G

�� !��&��!��B��!��$��&��,��#,��5��(��&��)��&��$��!��B��!��G

Crown Gear

CW CCW

1 2 43 5 6 7

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* Press the key below +�6�L- to adjust the exposure position.

� Press the key below ��+;�.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 E�C��;F.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 key.

# Press E�+�C�F.

## Enter the password (default is 7890) and confirm with E�C��;F.

#% Press the key below -;�C��;.

#' Press the key below >��;+1:.

#* Press the key below �C��.

#� Press the key below +�6H��3.

#" 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 E�C��;F.

%/ Press any menu key to exit the present menu.

�'�' ��(��&��$�)�.��

� Press E��F and proceed as follows to set the 7-day timer.


# Press the key below �I��.

% Press the key below 3+:�0- and enter the on/off times.

C��D ��(��&��4C��4>>�� %D//��&��$�)�.��&��!G

<SET> SYSTEM WAKEUP

Monday Set any Time to

[24:00] [24:00] 24:00 for disable

ON OFF

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' Repeat this step for every day of the week.

* At the end press any menu key to exit the present menu.

�'�* ��(��

� Press E��F and proceed as follows to set the actual time and date.



% Press the key below �+�� and enter the correct date and time.

' Remount all removed side panels.

�'��

� Press E��F and proceed as follows to set the reference film.


# Press the key below -;�C��;.

% Press the key below �+��;

' Press the key below��Cuntil the aim values are reached (refer to the Operating Manual SETUP).

* Press any menu key to exit the present menu

�'�" �� (��&��&��

Press E14��F. A softkey menu is displayed.

<SET> SYSTEM DATTIM

Actual Date and Time

1999 6 17 13:25

Year Month Day Time

saml02052a

� Insert the memory card

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% Press the key below �+H�.

' Press the key below ��+;� to save the parameters.

* Remove the memory card as soon as the saving procedure is finished.

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�� 3

#�� &��!��

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 navi-gate through the menu system.

saml03001a

<ENTER>

<ENTER>

SOFTKEY

SOFTKEY

SOFTKEY

Standard

Display

Corresponding Menu Key<MAINT>

Menu

1. Level(1. line of Display)

2. Level

n. Level

Last Level

Screen # 1

MenuLast Level

Menu

Last Level

Menu

Last Level

Screen # 2

Screen # n

Last Screen

AnyMenu

Key

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#� ��&��-��

��(�� >��

��!��

� # % ' *

E�+�C�FEnter the maintenance menu (Pass-word)

PRINTER Select printer functionsPATRACK Select paper track

INIT Initialize paper trackADJUST Adjust exposure position

ADJUST Enter exposure position in (mm) and confirm with E�C��;F

ALL Overall initialization of paper trans-port

DISTR Reset of distributorTRANSP

ADVANCE Regular paper transportFETCH Move paper from cassette to paper

deckLEAVE

�� !��

Move paper from paper deck to pro-cessor

FEED Move paper from paper deck to feeder

TURN Turn feeder to processor / distribu-tor

DISTR Move paper from distributor to pro-cessor

CASSSENS Display paper end, splice detectorCODE Display magnet settings & cassette

codeEXTRACT Activates paper extractor-motor

(without a cassette only)FORW Extracting forward

BACKW Extracting backwardSTOP Stop extracting

KNIFE Move knife, display light barrierCUTLFT Move knife left

CUTRGHT Move knife rightPDECK Select paper deck

MOVE Move paper deck transport 100mm/cont.

FORW Move paper 100mm/cont. forwardBACKW Move paper 100mm/cont. backwardSTOP Stop

FANVACUUM Vacuum fan ON/OFF

EXITSENS Display light barriers feederFEEDER Turn feeder and display light barri-

ersTURNPRI Turn feeder into printer position and

display light barriersTURNPRO Turn feeder into processor position

and display light barriers.continued on next page

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��!��

� # % ' *

E�+�C�F Enter the maintenance menu (Pass-word)

PRINTER Select printer functionsPATRACK Select film track

EXITDISTR Start distributor, reset, display error

START Start transport in distributor, display error

RESET Reset distributorFITRACK

INIT Initialize film trackFDECK Press E�C��;F to init software

(after changing a film deck)ADJEXP Adjust exposure window with soft-

keysSTART Move the film to exposure position

<- Move film left, confirm with E�C��;F

-> Move film right, confirm with E�C��;F

ADJVIEW Adjust viewer window with soft keys<- Move film left, confirm with

E�C��;F-> Move film right, confirm with

E�C��;F

SENS Adjust sensorsA135 Move film, calibrate, display photo

sensors� PosDiode: density, absolute, off-

set� -DxData: density, absolute, off-

set� DxClock: density, absolute, off-

set� STC Data: density, absolute, off-

set(Fuji frame number)

STEPS Number of steps to move filmFORW Move film forward (number of steps)

BACKW Move film backward (number of steps)

CALIB Calibration of photo diodes

A110 Move film, display microswitch viewer and exposure

STEPS Number of steps to move filmFORW Move film forward (number of steps)


continued on next page

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��!��

� # % ' *


PRINTER Select printer functionsFITRACK Select film track

SENS Adjust sensorsUNI Move film, display light barrier

home-positionSTEPS Number of steps to move filmFORW Move film forward (number of steps)


ATAPS Display DX and MOF signalsSTEPS Number of steps to move filmFORW Move film forward (number of steps)


CALIB Dark calibration

CODE Display film deck code and mask code

MOVE Forward, backward, stop motor ON/OFF

FORW Move film continuously forwardBACKW Move film continuously backwardSTOP Stop film movementMOTOR Motor ON/OFF

ACTUAT Position LED, clamp, viewer lampCLAMP Activate negative maskPOSLED Position LED ON/OFFVIEWER Viewer lamp ON/OFF

EXPSYSFIXTIME Allows to copy prints with user

defined constant exposure times [ms] for tests. Scanner is OFF

BLUE Enter the time for blue in [ms]GREEN Enter the time for green in [ms]RED Enter the time for red in [ms]ATTEN Attenuator ON/OFFFIXTIME "#��!��

��$Set fixtime mode ON/OFF

LAMPSYSMODE Lamp voltage ON/OFFATTEN Swing attenuator

TURN Move attenuator in/outSENS Display state of temperature switchCODE Status light barrier and light shaft

codecontinued on next page

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��!��

� # % ' *


PRINTER Select printer functionsEXPSYS Select exposure system

FWHEELINIT Initialize filter wheelEXPOSE Exposure time 40ms for each color

START Start an exposure cycle of 40msCOLORS Turn dark > blue > green > red >

dark > white > dark display home sensor.

TURN Start the test cycleCONT Turn continues

START Start rotating the filter wheelSTOP Stop rotating the filter wheel

SHUTTER Swing shutter, display light barriersTURN Turn shutter in/out

TEMPCOR Temperature correctionYELLOW Density correction yellowMAGENTA Density correction magentaCYAN Density correction cyan

MEASYSSENS Display temperature in measuring

systemSCANLIN Measure and display one scan line

(12 diodes), gain, offset, absolute of blue, green, red.(Diode 1 ... 10 Scan diodesDiode 11 Reference diode)

START Scan one line of negativeGAIN Enter value for gain

See results with

T-CALIBAUTO Measure calib. strip automatically

(ADM)MAN Measure calib. strip manually

(D19C)AIM Enter aim values

OTHEROPTICS

CODE Read lens code (in home position only!)

ZOOMGETPOS

RELEASE De-energize zoom drive, move zoom by hand

GETPOS Get actual zoom position in stepsPOSITION Display actual position in steps.

continued on next page

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��(�� >��

��!��

� # % ' *


PRINTER Select printer functionsOTHER

ZOOMGOPOS

START Move zoom to specified positionPOSITION Enter position of zoom in [steps]

ELECTRSENS Status of DIP-Switch 1 - 7 on CPU

board, memory card, backup bat-tery, software version of CPU board.

SERIAL Status of connected options, paper transport, wet part

BACKPRIINIT Initialize the backprinterRIBBON Switch the ribbon motor ON/OFF

TEST_EX Expose a grey print

��(�� >��

��!��

� # % ' *


P.PROC Select paper processor functionsTEMP

CALTMPDEV Actual temperature in °C in the

developerBLEACH Actual temperature in °C in the

bleachfixSTAB Actual temperature in °C in the sta-

bilizerDRYER Actual temperature in °C in the dryer

STATUS Actual temperature in comparison to the set temperature for developer, bleachfix, stabilizer and dryer

HEATERDEV Heater of developer ON/OFFBLEACH Heater of bleachfix ON/OFFSTAB1 Heater of stabilizer 1 ON/OFFSTAB2 Heater of stabilizer 2 ON/OFFSTAB3 Heater of stabilizer 3 ON/OFFDRYER "#��!��

��$Heater of dryer ON/OFF

Continued on next page

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��!��

� # % ' *


P.PROC Select paper processor functionsTEMP

PROBES Condition of the temperature probes and heaters in developer, bleachfix, stabilizer and dryer

LIQUIDCALPUMP

DEV Actual pump rate for 20 strokes and per m2 for the developer

BLEACH Actual pump rate for 20 strokes and per m2 for the bleachfix

STAB Actual pump rate for 20 strokes and per m2 for the stabilizer

TEST Execute 20 pump strokesPUMPS Switch agitation and replenishment

pumpsDEV Switch developer agitation pump

ON/OFFBLEACH Switch bleachfix agitation pump ON/

OFFSTAB Switch stabilizer agitation pump ON/

OFFREPL Switch replenishment pumps ON/

OFFSENS Display level condition in the work-

ing tanks, the replenishment and recovery tanks (optional console only). Displays status of flow/vac-uum sensor.

AIR Switch fans ON/OFFDRYER Switch dryer fan ON/OFFEXHAUST Switch exhaust fan ON/OFFCOOLING Switch cooling fan ON/OFF

TRANSPPAPER

MOTOR Switch paper transport motor ON/OFF

SORTERMOVE Move sorter and shows position

LEFT Move sorter to the leftRIGHT Move sorter to the rightSTOP Stop sorter movement

STATUS Status of the sorterSENS Condition of light barriers, paper

width and presence of sorter kit.


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#� � ��&��

(Valid for machines with film processor only!)

��(�� >��

��!��

� # % ' *


P.PROC Select paper processorTRANSP Select transport

STATUS Status of the paper processorSENS Condition of the tacho light barrier

SYSTEM Select system functionsON/OFF

PROCESS Switch paper processor ON/OFFDRYER Switch dryer ON/OFF

DEVTIM Developer time in secondsSWITCH

BUZZER Switch buzzer ON/OFF24VBAT Switch 24V ON/OFFACPOW Switch AC-Power OFFDCPOW Switch DC-Power ON/OFF

STATUS Display the various status of the paper processor

SENS Displays status of various sensors of the system

��(�� >��

��!��

� # % ' *


F.PROC Select film processor functionsTEMP

CALTMPDEV Actual temperature in °C in the

developerBLEACH Actual temperature in °C in the

bleachFIX Actual temperature in °C in the fixerSTAB Actual temperature in °C in the sta-

bilizerDRYER Actual temperature in °C in the dryer

STATUS Actual temperature in comparison to the set temperature for developer, bleach, fixer, stabilizer and dryer


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��!��

� # % ' *


F.PROC Select film processor functionsTEMP

HEATERDEV Heater of developer ON/OFFBLEACH Heater of bleach ON/OFFFIX1 Heater of fixer 1 ON/OFFFIX2 Heater of fixer 2 ON/OFFSTAB1 Heater of stabilizer 1 ON/OFFSTAB2 Heater of stabilizer 2 ON/OFFDRYER Heater of dryer ON/OFF

PROBES Condition of the temperature probes and heaters in developer, bleach, fixer, stabilizer and dryer

LIQUIDCALPUMP

DEV Actual pump rate for 20 strokes and per m2 for the developer

BLEACH Actual pump rate for 20 strokes and per m2 for the bleach

FIX Actual pump rate for 20 strokes and per m2 for the fixer

STAB Actual pump rate for 20 strokes and per m2 for the stabilizer

TEST Execute 20 pump strokesPUMPS

DEV Switch developer agitation pump ON/OFF

BLEACH Switch bleach agitation pump ON/OFF

FIX Switch fixer agitation pump ON/OFFSTAB Switch stabilizer agitation pump ON/

OFFREPL Switch replenishment pumps ON/

OFFSENS Displays level condition in the work-

ing tanks, the replenishment and recovery tanks (optional console only). Displays status of flow sen-sors.

AIR Switch fans ON/OFFDRYER Switch dryer fan ON/OFFAIRBLEA Switch air blower bleach ON/OFF

TRANSP Select film transportFILM

MOTOR Switch film transport motor ON/OFF


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��!��

� # % ' *


F.PROC Select film processor functionsTRANSP Select film transport

LOADLOCK Switch film loadingCUT Activate the knife when a film load-

ing cassette is inserted.STATUS Status of the film processor and its

various modules.SENS Display the tacho light barrier and

the film detecting sensor.

SYSTEMON/OFF

PROCESS Switch film processor ON/OFFDRYER Switch dryer ON/OFF

DEVTIM Developer time in seconds

SWITCHBUZZER Switch buzzer ON/OFF24VBAT Switch 24V ON/OFFACPOW Switch AC-Power OFFDCPOW Switch DC-Power ON/OFF

STATUS Display the various status of the film processor

SENS Displays status of various sensors of the system

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OTHER Select various other partsSYSTEM Select various system parts

LANGDEFAULT Load the default language (English)MEMCARD Load language from the language

card

PASSWDPASSWD Enter new password

SOFT Display software version of printer part, wet part, paper transport and keyboard, LCD etc.

ADM Automatic DensitometerMOVE

REMHEAD Move the measuring head and indi-cate 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 ras-ter segment)

-> Move the head one step to the right (One step is NOT equal to one ras-ter segment)

%��'

<- Move the head to the left end posi-tion

-> Move the head to the right end posi-tion

HOME Move the head to the center position (marked with an arrow on the raster segment).

TRANSP Transport the stripTYPE 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 backwardSTROUT Transport the strip out of the ADM

ACTUATESTRACC Enable / disable the function ‘Strip

access’LAMP Lamp ON/OFF


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OTHER Select various other partsADM Automatic Densitometer

TESTDARKMEA Dark measurement

REM Remission DensitometerTRANS Transmission Densitometer

BRIMEA Bright measurementREM Remission Densitometer

TRANS Transmission DensitometerWHIMEA White measurementMIPOS Move head to center positionRESET Selftest of the ADM, reset all stored

commands in the ADMSENS Information about:

� Transmission of the sensor for the raster segment

� Transmission of the sensor for the strip detector

� Sensor for the filter wheel (in the measuring head)

CALIB Calibration of the ADM. Providing information about:� Measured and target values for

white� Measured and target values for

dark� Distance between the reference

marks.� Max. number of measurements

between reference marks for re-mission densitometer

� Max. number of measurements between reference marks for transmission densitometer

MEASFILM Measurement of a film strip

START Start the measuring process."#��!��$

FORW Next measuring positionBACKW Previous measuring position

DIST Measuring position (mm)PAPER Measurement of a paper strip

START Start the measurementHEAD<-> Offset of the head from the center

position (mm)"#��!��$

FORW Next measuring positionBACKW Previous measuring position

DIST Measuring position (mm)

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#� �% ��B��

The following maintenance menu is only valid for software version 3.30

��(�� >��

��!��

� # % ' *


OTHER Select various other functionsINDEX Select index functions for optical

IndexprinterMOVE

IDXUNIT Activate the index unitHOME Set index unit to home position

WORK-POS

Set index unit to work position

LOGO Movement of the logo turretNEXT Move to the next logo positionHOME Move to logo home position

ZOOM Move to index zoom magnificationSTART Move to index zoom positionHOME Move to index zoom home position

POSITION Enter number of steps for zoom movement

TRANSLSTART Move to index translation positionHOME Move to translation home position

POSITION Enter number of steps for translator movement

MIRRORSFDECK Turn film deck mirrorLOGO Turn logo mirror

EXPOSEFRAMENR

EXPOSER Expose frame number for specified time

TIME Set exposure time for frame numberFORMAT

EXP_C Expose format indicator ‘C’ for spec-ified time

EXP_P Expose format indicator ‘P’ for spec-ified time

TIME Set exposure time for format indica-tor

TEXTEXPOSE Expose text for specified time

TIME Set exposure time for textLOGO

EXPOSE Expose logo for specified timeTIME Set exposure time for logo


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#� �' ��1��A��
The following maintenance menu is only valid as of software version 5.xx

��(�� >��

��!��

� # % ' *

E�+�C�F Entering the maintenance menu (Password)

OTHER Select various other functionsINDEX Select index functions

CALIBLEFT Move paper to the leftRIGHT Move paper to the rightUP Move zoom translation upDOWN Move zoom translation downCALTYP Selection of frame min./max. or logo

FMTWHLINT With E�C��;F, the format wheel

id initializedADJUST

NEXT-1+1

FMTWHLADJUST

CHECKMIRNEUTRAL

H-FMTP-FMTC-FMT

FRAMENRYES/NO Confirmation for saving the data of

the format wheel setting.EXPOSE

EXPOSE Expose frame number for specified time

TIME Set exposure time for frame number

��(�� >��

��!��

� # % ' *


OTHER These menu items are described in detail in the Service Manual Cus-tomizer Master Lab+ P/N 98.29.02

SYSTEMADMCCDLCDINDEX

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#� �* ��(��

#� �� &��+��-�0��

A set of maintenance functions are provided on the ALMLPLUS board to check the pumps and sensors.

��(�� >��

��!��

� # % ' *


DEBUGINFO For software development only!P.PROC For software development only!F.PROC For software development only!APS FID (Test string) For software devel-

opment only!DEBUG

TEST STRING For software development only!TEST STRING For software development only!TEST STRING For software development only!

saml04007a

� Make sure that the automatic top-off system is ON. The green light must be ON

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 step-ping-up switch SW1 as given in the following tables:

ATS

green

lamp

SW1

0

4

8

C

0

4

8

C

0

4

8

C

SW2 SW3

MAIN LED

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��()&* +��,��-.&

saml13019a

-��3� +��

0 Maintenance OFF1 Pump and valve film developer (EV1)2 Pump and valve film bleach (EV2)3 Pump and valve film fixer 1 (EV3)4 Pump and valve film fixer 2 (EV4)5 Pump and valve film stabilizer 1 (EV5)6 Pump and valve film stabilizer 2 (EV6)7 Pump and valve paper developer (EV7)8 Pump and valve paper bleachfix (EV8)9 Pump and valve paper stabilizer 1 (EV9)A Pump and valve paper stabilizer 2 (EV10)B Pump and valve paper stabilizer 3 (EV11)C Tank empty lamp (red lamp)D BuzzerE Checking switch SW2 as given in the next tableF Checking switch SW3 as given in the next table

EV1

EV2

EV3

EV4

EV5

EV6

EV7

EV8

EV9

EV10

EV11

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 stabilizer 1


Electro valve paper developer

Electro valve paper bleach

Electro valve paper stabilizer 1



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

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

0

4

8

C

0

4

8

C

0

4

8

C

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-��3�

-��3

+��

-��3�

-��3#

+��

E

0 All LED’s OFF

F

0 All LED’s OFF1 EV1 1 EV12 EV2 2 EV23 EV3 3 EV34 EV4 4 EV45 EV5 5 EV56 EV6 6 EV67 EV7 7 EV78 EV8 8 EV89 EV7 9 EV7A EV6 A EV6B EV5 B EV5C EV4 C EV4D EV3 D EV3E EV2 E EV2F EV1 F EV1

Position of SW2 Position of SW3

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-�� 4

-�� &��&�� &��=��!��(��=��!��+��!��&��.��&��4��(��?��$��&�� !��&��

�&��.��&�)��$��(��&��&��(!�8��(��(��&��9�

%��

For the standard preventive maintenance which should be done every half year the following material is required:

-�� J�!�

-��

11.54.43 Filter mat 1

3��

16445-139-0 Chemical filter 1116445-137-0 Filter mat 116445-145-0 Filter mat 115525-159-0 Squeegee roller 4

��

0029-100-22 Filter for replenishment pump 70021-658-51 Flap valve for replenishment pump 70021-658-56 Bellow 3/4” for bleach replenishment pump 10021-658-53 Bellow 1” for replenishment pump 50021-658-62 Bellow 1.5” for stabilizer pump 10026-729-44 Drain tap 1

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%� 2��-��

� Save all data on the memory card.

Check the +5Vdc supply according to instructions in chapter 5.4.4

# Shut down the machine.

% 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.

-�� J�!�

+�B��!��

20.66.98 Lens cleaning tissues14.20.88 Lens cleaning liquid35.37.28 TRI-FLOW teflonbased lubricant18540-061-0 Pure silicon oil

Vacuum cleanerBrushAlcohol

3+;C�C2G

+�$�!��$��&��&��&��(G

C��?��5��&��&��3��&��&��B��&�� &��8��)��$��&��&��&��!��9��&��!��$��&� ��(��$�'/H��&�$� ��?�$&�� (�� &��)��.��(��G

��-4;�+C�G

��=��(��&��.��(��7��&�� A��&��.&�� .��.��(��G

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%�# -��

%�#�� 4��!��

� 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.

C��D ;��&��&��)��&��&��(��&��(&��D

� �;��D �� 1��D �� D �� 1��D ��

% 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.

saml04001a 1 Lamp2 IR filter (coated side up)3 Correction filter (coated side up)4 Test filter5 Filter wheel (blue/green/red color

filters, coated side up)6 Filter wheel motor7 Fixed light cone8 Exchangeable light shaft9 Film deck10 Shutter11* Lens turret12* Turret lock13* Lens code reader14* Zoom lens motor15* Zoom lens16 Paper17 Paper deck

* = ML+ 220 / 240 / 520 / 740 only!

9

8

7

2

5

6

11

10

12

14

15

13

16

17

1

3

4

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*�� Clean the conveyer rollers and the reader unit with alcohol.

*� Check the tension of the toothed belt (see chapter 9.6.4)

� 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.

, >�� /�� %/��' /��%/��!GUnlock 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 menuE�+�C�F�.�>��;+1:�.��L-�I��.��+�-�I��.�+��C

�' Press the key below��0;C�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 menuE�+�C�F�.�>��;+1:�.��L-�I��.�>3@��.�14�4;�

�� >�� /�� %/��' /��%/��!GCheck the movement of the shutter, at least 20 times with the menuE�+�C�F�.�>��;+1:�.��L-�I��.��@0��;

�" Press the key below��0;C

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%�#� ��(��!��saml04002a

1 Lamp 2 Lamp house3 Test filter 4 Filter wheel5 Light shaft 6 Film7 Photo diode 8 Measuring board (MESY)9 Measuring box 10 Measuring filter11 Measuring lens 12 Optical box13 Deviation mirror 14 Film deck15 Lower diffuser 16 Upper diffuser17 Correction filter 18 IR-filter

� Clean the test filter in the lamp house

Clean the measuring filter of the measuring box with lens cleaner.

# Use a brush to dust the inside and outside of the optical box

saml04003a 1 Measuring lens2 Deflection mirror3 Fibre optic4 Magnets

1

17

2

3

4

16

15

5

6

14

131 2 11

10

9

7

8

18

1

2

3

4

4

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% 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!).

%�#�# -��&saml04004a

��/)& +��

1 Paper cassette 2 Light trap3 Paper extractor front panel 4 PAMID board5 Paper extractor motor 6 Knife motor7 Paper deck transport motor 8 Paper deck9 Feeder pivot drive motor 10 Feeder11 Paper distributor (ML+ X40 only!) 12 Drive shaft of paper processor13 Paper distributor carriage motor 14 Paper distributor motor

7

6

5

2

1

9

3

4

8

11

10

12

13

14

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saml04005a

��/)0 1��

1 Paper cassette 2 Paper extractor and knife unit3 Detection of knife position 4 Vacuum fan5 Paper deck 6 Detection of feeder position7 Feeder 8 Paper width detector9 Paper detector of feeder 10 Feeder pivot drive motor11 Paper cassette code detection 12 Paper present detector13 Paper splice sensor 14 Paper deck drive stepper motor15 Knife drive DC motor 16 Paper extractor stepper motor17 Paper distributor 18 Paper transport stepper motor19 Distributor carriage stepper motor 20 Detection of carriage position21 Paper path sensors

The paper path needs the following maintenance:

� Shut down the machine with the main switch.

Dust the paper cassette and the paper path from the paper inlet to the paper distributor.

1

23

4

5

6

7

89

10

6

12 13

14 15 163

17

18

19

21

20

11

11

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% 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:� Fasteners of the light trap.� Tension and pressure springs of the paper inlet and the knife unit.� Rollers of the feeder and the paper distributor.

* 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.

saml04006a

# Check the fasteners (+) of all paper cassettes for correct func-tion. Replace defective fasteners

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A

A

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�� Check the play between the driving mechanism of the paper deck and the feeder.

� 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:E�+�C�F�.�-;�C��;�.�4�@�;�.��M�L-

�' Check the prints for the following criteria:� how has the print been cut, it must be a clean cut.� that no edges are damaged.� that no pressure marks are on the prints� 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).

%�% 3��

%�%�� 2��

It is advisable to do the following maintenance at least every half year. It is fur-ther 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 inspec-tion of various parts. Cleaning is only covered to some extent as this is a duty which has to be done much more frequently.

3+;C�C2G

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C�(��(��&�� )��(��!��!��&��$��?��(��!��(&�G

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%�%� >��saml04009a

1 Exhaust fan 2 Dryer3 Temperature sensor dryer 4 Dryer heating5 Dryer fan 6 Squeegee roller7 Speedometer of transport motor 8 Transport motor9 Stabilizer 2 10 Stabilizer 111 Fixer 2 12 Fixer 113 Bleach 14 Developer15 Transport safety switch 16 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)

1

3

2

4

6

5

7

8

9

15

16

1314 12 11 10

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" 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

�� Clean the film outlet station and the dryer housing with a brush and a vac-uum cleaner.

saml04010a

1 Pulley 30T 2 Pulley 15T3 Toothed belt 4 Friction bearing5 Ball bearing 6 Worm gears

� Check the condition of the worm gears on the main drive shaft. Use TRI-FLOW to lubricate the worm gears, the ball bearings and the friction bear-ings.If a worm gear or a bearing has to be replaced, refer to chapter 11

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23

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�% 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 (fur-ring)

�� Check chemical tanks, pumps and hoses for possible leaks.

�" Open all filter housings in the replenishment tubes.

�, Clean the filters under running water.

C��D 7��&��4.��(�G

/ Remove the suction tube of the automatic top-off tank.

� Switch ON the machine with the main switch.

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.

C��D �1��&��)��(�$��&��$��&��!G

saml04011a

�# Check the belt tension of the main drive and adjust if necessary.

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5 N

5mm

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saml04011a

� Remove the film loading station.

1+0��4CG

7��$��&�� &��(��&��(�)��G3&�� (��&�� ?��&��$��!��!��!��(��G

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.

#� 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 lubri-cate with very little TRI-FLOW to prevent films from getting dirty.

� � � � � � � � � � � � �

� � � � � � �

� � � � � � � �

M805

A

Sensor board

A

A A

AA

AA

AA

A A

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#' 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:E�+�C�F�.�-�-;41�.�+�;�.��L@+0��

%* Switch the exhaust fan OFF and ON again and check the air flow of the fan.

%� Check the transport speed by inserting an ��! leader card into the Mas-ter 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:E�+�C�F�.�>�-;41�.��I��.��H��

'� Close all covers of the film processor and the dryer.

saml04014a

#% Check the contact resistance of both micro switches with an Ohm-meter. Activate the switches sev-eral times by hand. The resistance must be below 1Ohm

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%�%�# -��saml12001a

1 Dryer 2 Temperature sensor of dryer3 Dryer heating 1 (230V / 450W) 4 Dryer fan 15 Dryer heating 2 (230V / 450W) 6 Dryer fan 27 Speedometer of transport motor 8 Transport motor9 Stabilizer tank 3 10 Stabilizer tank 211 Stabilizer tank 1 12 Bleachfix tank13 Developer tank 14 Transport switch15 Print collector 16 Water tank (auto top-off system)

saml04015a

1 Sorter transport motor 2 Large print detection (5” and up)3 Sensor, sorter right 4 Sensor, sorter left5 Sensor, sorter end

1

2

3

4

5

6

7

8

9 10 11 12 13

14

15

16

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� 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)

� 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.

�/ Clean the paper outlet station and the dryer housing with a brush and a vac-uum cleaner.

saml04016a

1 Pulley 18T 2 Pulley 15T3 Toothed belt 4 Friction bearing5 Ball bearing 6 Worm gears

�� Check the condition of the worm gears on the main drive shaft. Use TRI-FLOW to lubricate the worm gears, the ball bearings and the friction bear-ings.If a worm gear or a bearing has to be replaced, refer to chapter 12

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23

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�# Remove the cover of the tank heaters and temperature/level sensors.

�% Clean the frame located underneath by removing all chemical residues (fur-ring)

�' Check chemical tanks, pumps and hoses for possible leaks.

�* Open all filter housings in the replenishment tubes.

�� Clean the filters under running water.

C��D 7��&��4.��(�G

�" Remove the suction tube of the automatic top-off tank.

�, Switch ON the machine with the main switch.

/ 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.

C��D �1��&��)��(�$��&��$��&��!G

' Switch ON the machine.

* Insert a test negative into the film deck.

saml04017a

� Check the belt tension of the main drive and adjust if necessary.

1+0��4CG

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�&��.��!��&��)��$��&�$��&��&��!�$��G

5 N

5mm

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� 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:E�+�C�F�.�-�-;41�.��I��.��H��

#" Close all covers of the film processor and the dryer.

#, Lubricate the guide rails of the sorter with vasoline.

%�%�% 1��(��

� 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)

saml04018a

%/ Check the belt tension. Adjust if necessary.

2.5 N

8mm

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-�$��! 5

'�� 4 �� $��

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 -4wer ��tributor (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:� the lamp power supply, produces a stable 20Vdc for the exposure lamp� the 34V regulator supplying the stepper motor drivers of the paper path

and the filter wheel� 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.

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saml05001a

'� -�$��!�$��

'� �� 3��(

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 trans-former.

For the setup of the transformer to the different voltages refer to chapter 2.4.4.

'� � 7��)��

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.

'� �# >��&��$��!

The power supply board and the battery charger board contain fuses.

Batterylow

Batterycharger

Powerfail

Printerpower

on / off

DC / DC5V

Printer

Wetsection

BLOW

+24V

+24V

+5V

GND

GND

PF

+45V

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4�� saml05002a

Power supply board

Battery charger board

>��N

H��O+P

�!��

1) T = surge resisting fuse (slow blow)F = quick acting fuse (fast blow)

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F1 25 T 6.3 x 32 0028-755-42 19.5Vac of the main transformerF2 25 T 6.3 x 32 0028-755-42 19.5Vac of the main transformerF3 25 T 6.3 x 32 0028-755-42 32Vac of the main transformerF4 25 T 6.3 x 32 0028-755-42 32Vac of the main transformer

F5 10 T 5 x 20 13.58.28

24VdcAnalog section of the MCBSorter MotorTransport motor paper processorTransport motor film processorKnife solenoidFilm loading cassette locking solenoid

>��N

H��O+P

�!��


��.��

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F1 10 T 5 x 20 13.58.2824VdcBackup battery

+

-

F1

F5

F3

F2

F1

F4

Battery Charger Board

Power Supply

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C�$� ��saml05003a

>��N

H��O+P

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F1 25 T 6.3 x 32 0028-755-42 19.5Vac of the main transformerF2 25 T 6.3 x 32 0028-755-42 19.5Vac of the main transformerF3 25 T 6.3 x 32 0028-755-42 32Vac of the main transformerF4 25 T 6.3 x 32 0028-755-42 32Vac of the main transformer

F5 10 T 5 x 20 13.58.28

24VdcAnalog section of the MCBSorter MotorTransport motor paper processorTransport motor film processorKnife solenoidFilm loading cassette locking solenoid

F6 10 T 5 x 20 13.58.2824VdcBackup battery

F6

F5

F3F2F1

F4

Power Supply

-

+

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'�# -�$��!��

'�#�� $��!

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.

'�#� ��$��!

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.

'�#�# #%H��(��

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 theregulator to recover.

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'�#�% >��&��$��!

;��)�$��&��-4��saml05004a

PODIS

Electronics power supply

>��N

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F1 5 T 5 x 20 13.54.62

+24VdcAttenuator solenoidZoom drive stepper motorShutter motorKnife motorFeeder motorFilm deck stepper motorViewing window lamp (f-deck)Pressure mask solenoid (f-deck)Distributor stepper motorDistributor clutches

>��N

H��O+P

�!��


��.��

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F1 2 F 5 x 20 11.21.095VdcCPUCBO / CBO2

RET +OUT

Lamp Power Supply

IN

Electronics Power Supply PowerDistributor

PODIS

F1

F1

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;��)�$��&��$�-4��saml05005a

PODIS

Electronics power supply

>��N

H��O+P

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��.��

-C -��

F1 6.3 T 5 x 20 11.21.24

+24VdcAttenuator solenoidZoom drive stepper motorShutter motorKnife motorFeeder motorFilm deck stepper motorViewing window lamp (f-deck)Pressure mask solenoid (f-deck)Distributor stepper motorDistributor clutches

F4 6.3 T 5 x 20 11.21.24

+34Vdc Stepper motor filter wheelStepper motor extractorStepper motor paper deck

F5 6.3 T 5 x 20 11.21.24+42VdcExposure lamp power supplyVacuum fan paper deck.

>��N

H��O+P

�!��


��.��

-C -��

F1 2 F 5 x 20 11.21.095VdcCPUCBO / CBO2

RET +OUT

Lamp Power Supply

IN

Electronics Power Supply

PODISF1

PowerDistributor

F1

F5

F4

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>��saml05006a

>��N

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F1 1 F 6.3 x 32 13.59.35 Heater developer, paperF2 1 F 6.3 x 32 13.59.35 Heater bleach, paperF3 1 F 6.3 x 32 13.59.35 Heater stabilizer 1, paperF4 1 F 6.3 x 32 13.59.35 Heater stabilizer 2, paperF5 1 F 6.3 x 32 13.59.35 Heater stabilizer 3, paperF6 2.5 F 6.3 x 32 0028-759-79 Heater dryer 1, paperF7 2.5 F 6.3 x 32 0028-759-79 Heater dryer 2, paperF8 2 F 6.3 x 32 14.04.34 Heater developer, film2)

2) These fuses are not used in machines without film processor and may be used as spares.

F9 1 F 6.3 x 32 13.59.35 Heater bleach, film2)

F10 1 F 6.3 x 32 13.59.35 Heater fixer 1, film2)

F11 1 F 6.3 x 32 13.59.35 Heater fixer 2, film2)

F12 1 F 6.3 x 32 13.59.35 Heater stabilizer 1, film2)

F13 1 F 6.3 x 32 13.59.35 Heater stabilizer 2, film2)

F14 4 F 6.3 x 32 0028-759-81 Heater dryer, film2)

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14

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'�#�' ��&��$��!

The LED’s indicate the following when li up:

4�� C�$� ��saml05007a saml05008a

4�� C�$� ��

D1Board receives +24VdcFuse F1 is good

D2+24VdcFuse F1 is good

D2 Board receives +42Vdc D4 Board receives +24VdcD4 Regulator produces +34Vdc D6 Regulator produces +34Vdc

D8+42VdcFuse F5 is good

D10 Board receives +42Vdc

D1

D2

D4

D2 D4 D6 D8 D10

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'�% �� (

'�%�� 3��$��!

There are no adjustments necessary.

To access the power supply:

'�%� 1&��)��(��&��)��

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.

C��D ��&��&��!��(��A��!��!G

% Connect a load of 2A .. 5A (e.g. spare exposure lamp) to each battery.

saml01001a

� Switch OFF the Master Lab+ with the main switch and disconnect the power cable.

Loosen the cap screw on the drawer.

saml05009a

# Pull the drawer out.1 Power supply2 Batteries3 Transformer

ATS

POWER

123

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' Measure the voltage of the battery:� if the voltage stays >11.5V for more than 20 seconds, the batter is ok.� if the voltage drops below 11V during the 20 seconds, the battery has

to be replaced.

* Reconnect the cables to the batteries.

� Switch ON the Master Lab+.

'�%�# -��$��!

To access the power supply:

1+0��4C

7��$��&��&��(�� !�&��G��=��&��$��&�!��(��?�!��!��!��G

1+0��4CG

��!�&��=��&��$��&��&��$��)��7��$��&��!��&��!��!��$��&��&��(��&��&�� &�!�&� ��

saml05010a

� Remove the cover over the elec-tronic rack.

saml05011a

Turn both screws holding the elec-tronic board 90o counterclockwise and tilt the board down.

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'�%�% ��$��!

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

�+C2�;G

7�� !��?��&��&�� (�� (��G

saml05012

# Turn the four screws of the protec-tive cover 90o counterclockwise and remove the protective cover.

% Remove the transparent protec-tive plate.

CBO

U15

Filte

rwheel

U14

Film

deck

U7

Paperdeck

U8

Paperextra

ctor

U9

Zoom

+5V +40VGND

J412

J407J410

+24V+45V

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saml05014a

'�%�' ��!��&��B��

The supply voltage for the 250W exposure lamp must be set to 20.0V+/-0.1V.

saml05015a

% 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.

+24V

GND

+5V

+34V

42V

F2

F3

F1

CBO2


F1

R21

3+;C�C2G

3&��!��$��)��&��B��?��$��&��&��&��!�� !�&��G

��=��&��&��&��?�!��!��!��(��G

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# Switch on the lamp with the menuE�+�C�F�

% Enter the password (default is 7890) and confirm with E�C��;F.

' Move further down the menu through:-;�C��;�.��+�-�I��.��4��.�4C

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 menuE1@�1:F�.�-;�C��;�.��L-4��and proceed as described in the Operating Manual.

saml05016a

� Open the lamp house cover and manually activate the lamp house cover switch

Connect a voltmeter to the termi-nal block in the lamp house.

1+0��4CG

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saml05017a

* Turn the potentiometer R13 on the lamp power supply until the volt-age is 20.0V+/-0.1V

R13R18

RET +OUT

Lamp Power Supply

IN


F1

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Sch. ELT. ALIM. M_L (circuit diagram) 17319.014.2 1 to 4

Alimentatore Master Lab (layout drawing) 14074.243.2 1

Overview Fig. 1 1

Overview ATEX 14074.208.0 1

Schematic ATEX 15074.0119.0 1

Layout ATEX 15074.0119.0 1

Overview Power control 14074.208.0 1

Schematics Power control SE0133.SCH 1

Layout Power control C.S. B226 1

Schematics Batery charger ATEX 15074.0120.0 1

Layout battery charger ATEX 15074.0120.0 1

Schematics battery charger Power control 1

Layout battery charger Power control C.S. B227 1

�� $��(�N -�(��&��

PBA Power Distributor PODIS (new) 34.79.13 ES 1

PBA Power Distributor PODIS (new) 34.79.13 AZ 1

PBA Power Distributor PODIS (old) 34.79.13 AZ 2

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Measuring

System

Densitometer

D188/D19C

Memory

Card

Keyboard

Lineprinter

Pricing

Modem

Aux. 1

Film Deck

Paper

Transport

Optical

System

Power Supply

Printer section

Power Supply

Wet section

Slave B

Wet section

A/D converter

Slave EDistributor

Date / Time

Aux. 2

Main

Processor

CPU 80186

Control

Board

Slave CPaper deck

ADMslave

Slave DFilterwheel

Frame #

MOF

Indexprintslave

80186

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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

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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 volt-age needs to reach the allowable minimum value of 4.75V

The reset signal may also be triggered by actuating the input signals HARD-WARE RESET, SOFTWARE RESET or BREAK.

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

9 x RS232 8 Bit Bus

36

IN

32

OUT

20

IN

Serial

Communication

Interface

Processor type AMD 80186Clock rate 8MHzSingle bus cycle 125nsMemory cycle time 4 cycles for even word/byte access

8 cycles for odd word accessAddress range 1024 kilobytes

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saml06003a

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The code memory stores the machine program (software). The maximum stor-age 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 run-ning at 8MHz.

*� �' ��!

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 run-ning at 8MHz.

*� �* 7��)��!

This functional unit maintains the supply voltage to the data memory thus pre-serving the memory contents on shutdown of the regular power supply. Buffer-ing however is limited to the +VBAT voltage (nominal value = 5V). Upon shut-down of the mains supply the battery maintains the supply voltage.

saml06004a

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Reset

Logic

CPU 80186

UART

GPO Port

Offboard

Slave C

Slave D

Supply Voltage

£ 4.75V

Reset jumper

Keyboard

(F-Clear)

Software Reset

(GPO 0)

+5V

Lithium Battery

+VBat

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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.

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.

*� ��

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 cre-ates the transfer rates for the serial interface channels. The serial interface acts as a parallel / serial converter.

A ‘BREAK’ on channel A (E>F�E1��+;F) actuates a reset, while a ‘BREAK’ on channel I may trigger an NMI (selectable via J2).

��2)&* 60��3��7��

The interface configuration is as follows:

��2)0* ��

-��

1 - 2 The BREAK signal on the interface I is ineffective2 - 3 The BREAK signal on the interface I triggers a non maskable interrupt (NMI)

A Keyboard 19200 bps RS232 mode (+12V, -12V)B Wet part 19200 bps special mode (isolated by opto-isolator)C Paper transport 19200 bps special mode (0, +5V, inverted signals)E Densitometer 1200 bps RS232 mode (+5V TTL) for external communicationF Line printer 9600 bps RS232 mode (+12V, -12V) for ext. communicationG Modem 2400 bps RS232 mode (+12V, -12V) for ext. communicationH Aux. 1 19200 bps RS232 mode (+12V, -12V) for ext. communicationI Aux., CRT 9600 bps RS232 mode (+12V, -12V) for ext. communicationK Backprinter 1200 bps special mode (0, +5V, inverted signals)

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The data format is as follows:

� 8 data bits per character

� 1 stop bit

� even parity

*� �" -��

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.

�+�1 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

*� �, +��

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 volt-ages generated on the CPU board.

saml06005a

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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 inter-nally. 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.

CPUA/D

ConverterS/H

prog.

GainMUX

1 Uref (on board)

8

12 12

12 integrators

Control

1 1 1

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The bus interface is used to integrate a memory card into the system by con-necting it to the microprocessor bus.

The maximum addressable storing capacity is 32 Kilobytes.

C��D 0��$�� #/��"�)��!��!��0��$�� //��# �)��!��!��

*� �� 2��

The general purpose input port provides 8 inputs. These inputs are:� DIP switches (2 - 6)� RAM/ROM select of external memory card� Check of external memory card (low = connected)� Battery check (high = battery discharged)

*� �� 2��

The general purpose output port provides 8 outputs used for general system functions on the board.

*� ��# 1��)

The clock is not implemented because the clock of the wet part is used as sys-tem clock.

*� ��% -�$��

Voltage +5V +12V -12VPower consumption (measured values) 1.6A 80mA 80mA

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The LED 18 on the CPU displays three conditions recognizable by the blinking rhythm illustrated below.

saml06007a

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Battery

D 18

D 7

D 5

D 6

LED When OND5 Board receives -12Vdc powerD6 Board receives +12Vdc powerD7 Board receives + 5Vdc power

Reset of the CPU

RAM defect

EPROM defect

CPU okapprox. 1Hz

approx. 1Hz

8s 6s3s

3s

3s

on

on

off

on

off

off

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SW1 OFF Shows run-time error ON For R&D purposes onlySW2 OFF without shutter/distributor ON with shutter/distributorSW3 OFF with wet part ON without wet partSW4 OFF with lens turret ON without lens turretSW5 OFF with film processor ON without film processorSW6 OFF CPU test off ON CPU test onSW7 OFF unused ON ---

6�� ( 4��

J2 1 - 2 BREAK I (NMI) disabled 2 - 3 NMI enabled

1��! 1��!

J6 2 - 3 6 x 128 kilobyte 1 - 2 2 x 128 kilobyteJ7 2 - 3, 4 - 5 (U15, U18) 2 - 3, 4 - 5 (U15, U18)J8 2 - 3, 4 - 5 U16, U19 X , X 2 x 256 kilobyteJ9 X U17, U20 1 - 2 (U17, U20)J28 2 - 3 Battery on 1 - 2 Battery offJ30 open No reset of CPU 1 - 2 Reset of CPU

��-��$��&��"

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SW1 OFF unused ON ---SW2 OFF unused ON ---SW3 OFF with wet part ON without wet partSW4 OFF with lens turret ON without lens turretSW5 OFF with film processor ON without film processorSW6 OFF CPU test off ON CPU test onSW7 OFF unused ON ---

6�� ( 4��

J2 1 - 2 BREAK I (NMI) disabled 2 - 3 NMI enabled

1��! 1��!

J6 2 - 3 6 x 128 kilobyte 1 - 2 2 x 128 kilobyteJ7 2 - 3, 4 - 5 (U15, U18) 2 - 3, 4 - 5 (U15, U18)J8 2 - 3, 4 - 5 U16, U19 X , X 2 x 256 kilobyteJ9 X U17, U20 1 - 2 (U17, U20)J28 2 - 3 Battery on 1 - 2 Battery offJ30 open No reset of CPU 1 - 2 Reset of CPU

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saml06025a

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S178

1 7

J7

J8

J9

1

1

1

J17

J18

J16

J11

J1

J25

J27

J24

J26

1

8

J13

J14

A / D converter

Battery

J28

J30

J61

1

1

J2

1

U21 RAMU14 RAM

DC-DCconverter

+

-

1 16

1732 1732

1 16

-�� (��

1 +12V (input)2 +5V (Input)3 Code (Input)4 Ground (Input)5 Ground (input)6 -12V (input)7 Ground (output to CBO)8 +5V (output to CBO)

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The control board contains the stepper motor drivers and the control for the sole-noids 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:

� paper deck� zoom drive� paper extractor

saml06008a

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Slave C also controls the slave E, located in the distributor with its own micro-controller 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.

J403 J416

J417

U15

Filterwheel

U14

Film

deck

U7

Paperdeck

U8

Paperextractor

U9

Zoom

U11

U4U13

U6

Slave DFilterwheel

Slave CPapertransp.

J411

D20Testconnector

forinternaltests

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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 sole-noids.

The print counter is now connected directly to J411 and no longer via an addi-tional circuit board.

saml06009a

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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).

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.

D11

D20

J417

Filterwheel Film deck

Extractor

Paper deck

Zoom S2

D9S4

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Magazinemotor

Deckmotor

Zoommotor

Vacuumfan

Printcounter

Cassettepresent

Cassettecode0...15

LEDObj.ON/OFF

OB1

OB2

OB3

OB4

OB5

Objectivechanged

GSD

200

GSD

200S

GSD

200

&

>=1

45V

PWM

3524

>=1

clock

Iset

direction

Zoom

Home

DC

Adr.

Data

CPU

8031

SLAVEC

Int0

Int1

Mem

PIO

PORT

8255

PortA

PortB

PortC

DC

DC

L6508

12

34

L298

Int0

Int1

&

>=1

>=1 HW

Reset

+45V

+40V

+24V

Pwr.Gnd

+5V

Log.Gnd

Knifemotor

Feedermotor

Paper

width

Feeder

end

Feeder

Print

Kniferight

Knifeleft

FeederPrinterpos.

FeederProcessorpos.

VacuumfanON/OFF

Printcounter

SplicePaperend

Hallswitches

Distributor

SLAVEE

Paperwidth

Start

Distr.active

Busy

Error

Reset

Distr.connected

Reset

SLAVEC

HW

Reset

RS232

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174 saml06011a

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Printcounter

Vacuumfan

Panoramafeeder

(Magnet)

Feeder

Board

Paper

width

Feeder

end

Hallswitches

Knife

right

Knife

left

Feeder

Printerpos.

Feeder

Proc.pos.

Knifemotor

Feedermotor

Zoom

home

Paper

distributor

Paperwidth

Start

Distr.active

Busy

Error

Reset

Distr.conn.

HW

Reste

ToCPU

Objchanged

OB1

OB2

OB3

OB4

OB5

Cassettepresent

Cassettecode

Paperwidth

Splice

+42V

+34V

+24V

+24V

Control Control Control

CPU 80C32

EPROM

8255

TxD

RxD

ResetfromCPU

GND

PwrGND

Extractor

Paperdeck

Zoom

Lens-Sensor

Board

OB5 OB4 OB3 OB2 OB1

Objchanged

SensMLdigit.

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saml06012a

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>��174

The CBO contains no fuses!

Backprinter

Shuttermotor

Shutteropen

Shutterclosed

Shutterboard

Film cleaner

Battery

Reset

Reset

ADDRADDR

VBatt

DATADATA

CPU

80C188DATA

EPROM

SRAM

ADDR

DIP-Switch

DATA

LED array

MOF

UART

To CPU80C32

RxD

TxD

MLCPU

ADMUART

Index

82510

Serialto Host

Serial 4(Reserve)

Serial 3(Reserve)

MainCPU

+24V

Negativeviewer

Negativeclamp

Film deckmotor

Film deck

Film notch pos. 2Film notch pos. 1

Film deck code 1Film deck code 2

Film deck code 3Film deck code 4

Control

Home pos.Filterwheel

Light shaftcode 1

Light shaftcode 2

Lightattenuator

Filterwheel

Control

CPU

80C31EPROM

Reset

ToCPU

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F1

F2F3

>��H��O+P

�!��


��O��P

-C -��

F1 6.3 T 5 x 20 11.21.24 +34Vdc

Stepper motor paper deckStepper motor extractorStepper motor filter wheel

F2 6.3 T 5 x 20 11.21.24 +24Vdc

Knife motorFeeder motorPanorama feeder motorLight attenuator solenoidShutter motorStepper motor film deckNegative clampNegative viewer lampStepper motor zoomMirror motor (Customizer)

Format wheel motor (optical APS)

F3 6.3 T 5 x 20 11.21.24 +42Vdc

Vacuum fan

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*�*�' ��&��174��&��174

174 174 saml06014a saml06015a

D20 When ON indicates zoom in home position

D20 When ON indicates zoom in home position

D9/1 Not usedD9/2 Failure RAM-Battery

Continuously ON when failureD9/3 Failure RAM

Continuously ON when failureD9/4 Paper transport

Shortly ON during communica-tionADMShortly ON during communica-tion

D9/6 Index-SlaveShortly ON during communica-tion

D9/7 CBO-CPUShortly ON during communica-tion

D9/8 MOFShortly ON during communica-tion

D9/9 Not usedD9/10 Not used

D 20

D 20

D 9

D 11

1

-12V

+42V

+5V

+12V

+24V

+34V

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The keyboard is the man-machine interface. It communicates with the main pro-cessor via a serial interface. The microprocessor in the keyboard receives the commands for the LCD display and the LED’s. When a key is activated a corre-sponding key code is sent to the main processor.

saml06016a

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The keyboard is based on a matrix of 7 columns by 6 rows, with the keys situ-ated 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.

*�� )�!�

The keys E4CF, E4>>F and E��;F including their LED’s are connected directly to the wet part and NO electrical connection with the printer part is made.

*��# ��)�!��

A reset can be triggered on the main processor with the special key combination E>F�E1��+;F.

POWER

ON OFF

TIMER

F

MENU

COMM CHECK

SET DISP

MAINT STAT 1 2 3 .

-

7 8 9

4 5 6

0

DATA CORRECTIONS

FILM FORMAT PAPER

CLEAR

ENTER

OPERATION

MAN AUTO ORDER STOP

FIX

��-4;�+C�G

�&��$��&��4C��4>>�$��&��&��)�!��G

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��2)&2 3��4��4��

Control-Bus

Data-Bus

Latch

RS232

Buffer

Buzzer

Key-Matrix

LCD

4x40Characters

Key-Matrix

7x6

(41Keys)

1x6

(Menu

Keys)

RXD

TXD

CTS

RTS

PowerControl

Contrast

Maskprogrammed Microprocessor

+1

-1

MCB

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*��' �1��!

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):

saml06018a

��2)&: ��

The following combinations have to be watched:

� standard European languages and Russian (Cyrillic) P/N 37.05.69

� Japanese P/N 34.55.31

Displaycontrolle

r

��-4;�+C�G

��!��!��&� ��&��(&��!��-;4�G

1��-;4��

O0 P�-;4��O-CP

HD44780A00 1.02 34.59.07HD44780A02 1.03 37.06.48

��(��(��

1) Language abbreviations according DIN 2335 and ISO 639

�� -C �-;4��-C

ja 34.55.31 34.59.07en, de, fr and so on 37.05.69 34.59.07ru 37.05.69 37.06.48

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*��* ��=�

The LED’s 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 LED’s.

*��

The serial interface allows the connection of external devices to the Master Lab+

saml06019a

��2)&; ��

Such devices are:

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:� 8 data bits per character� 1 stop bit� even parity.

Densitometer

Modem

Line printer

Aux. 1

Aux. 2

� Densitometer 1200 Baud (TTL-level)

� Modem 2400 Baud

� Line printer (for software version below 5.0)

9600 Baud

� Aux. 1 9600 Baud

� Aux. 2 19200 Baud

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*�" ��!��

*�"�� 4 �� $

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 %��' position.

saml06020a

��2)&= ?��,��

The memory card stores the machine specific data (based on software version 3.16), i.e.:

� all film memories� all paper memories� all format memories� master memory� exposure memory� adjustment value of film position for several film decks� setup values of the wet part� statistics (NOD / MAD)� quality (chemistry) reference and corrections only, no daily data� ADM calibration� backprinter text string� index calibration values

For further information on handling the memory card, please consult the ‘Oper-ating Manual’ supplied with every machine.

3+;C�C2G

�� &��!��&��&��(��&��$��&��!�� $��.��!��&��G��&��!��G

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*�"� ;��(��&��!��

When restoring data from the memory card there are some special behaviors of the software to be known:

;��(��&��

� When you restore a ��(�� film channel, the DX-table is C4� restored from the memory card!

� When you restore all film channels, the DX-table is also read from the mem-ory card.

;��(��

� When you restore �� data (using the menu E14��F�.��I��.�;�.��4;��.�-;�C��;�.�+��) the NOD and MAD data are C4� read from the memory card.

� If you want these data as well, you have to restore them separately with the menu E14��F�.��I��.�;��4;��.�-;�C��;�.�4�@�;�.�C4��+�.

*�, +�5��

*�,�� +�5��&��1-0

There is no adjustment required on the Printer CPU.

*�,� ;��(��&��1-0

saml01001a

� If not already done, make a backup of all machine data on a memory card.

Switch off the machine.

saml05010a

# Remove the cover of the electron-ics

% Disconnect all the cables from the CPU.

' Remove all screws holding the CPU and remove the PBA.

ATS

POWER

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* 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.

*�,�# ;��(��&��)��!��&��1-0

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

* Set the jumper again to ON.

� Switch on the machine

" Restore the previously written backup with the machine data from the mem-ory card to the printer as described in chapter 6.8.2

*�,�% 1��(��&��;+�=�

Before upgrading software or after replacing the backup battery it is necessary to bring the RAM’s 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 RAM’s.

saml06021a % Desolder the battery

' Solder the new battery.

C��D 3��&��&��!G

1+0��4CG

��!�&��=��&��$��&��&��$��)��7��$��&��!��&��!��!��$��&��&��(��&��&�� &�!�&� ��

ON/OFF

+ -

+

J28Battery

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A RAM clear kit V1.00 (P/N 37.63.25) is available to bring the RAM’s into a defined status. This kit contains a description about the procedure and 4 EPROMS:

� RAM clearer Version 1.00 CPU U15 P/N 37.63.26� RAM clearer Version 1.00 CPU U17 P/N 37.63.27� RAM clearer Version 1.00 CPU U18 P/N 37.63.28� RAM clearer Version 1.00 CPU U20 P/N 37.63.29

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 EPROM’s U15 to U20.

C��D 0��!��&��&��-;4�=��)��!��(��&��!��$��1��)��G

' Insert the four EPROM’s delivered in the kit.

* Ensure that the jumper J28 for the battery on the CPU board is set to ON.

� Switch ON the machine.

, 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

*�,�' +�5��(��&��174��174

There are no adjustment, neither on the CBO nor on the CBO2.

*�,�* ;��(��&��174��174

� First switch OFF the machine at the keyboard followed by the main switch

saml06026a" Watch indicator D18 on the CPU

board. It has to blink at a fre-quency of 1Hz for about 17 sec-onds indicating the boot status.

Start

EndMemory will be

cleared and tested Blinking indicates a properly cleaned memory

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Open the cover of the electronics as described in chapter 6.9.2

� Reassemble in reverse order

*�,�� 1��5��&��1�

*�,�" ;��(��&��)��!��&��!��

saml05011a # Turn both screws holding the elec-tronic 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 contain-ing software from the old board and insert them at the same places on the new board.

saml06022a Above the E4>>F key – in the upper right corner – is a recessed potentiom-eter.

� Take a screw driver #1 and adjust the contrast.

POWER

ON OFF

TIMER

Contrastpotmeter

3+;C�C2G

C� �� &��!��&��!��$��!��&��G�I��!��;��&��!��$�!��$��&��&��!��((��&��&��&��&��&��$��&��G

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saml06023a

� Place your finger on the hook and remove the battery cover.

Take out the lithium battery.

1+0��4CG

��!�&��=��&��$��&��&��$��)��7��$��&��!��&��!��!��$��&��&��(��&��&�� &�!�&� ��

saml06024a

# Confirm the polarity as shown and insert the new battery.

% Insert the battery cover.

' Remove the memory card from the machine.

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*��/ ��&��

�� $��(�N -�(��&��

Master Lab+ Overview 34.58.52 ES 1 to 10

Functional units on CPU board 34.58.52 BS 1

PBA Main Processor CPU (old type of CPU) 34.74.24 AZ 1

PBA Main Processor CPU 34.59.83 AZ 1

PBA Main Processor CPU 34.59.83 AZ 2

PBA Control Board CBO 34.59.85 AZ 1

PBA Control Board 2 CBO2 36.45.20 AZ 1

PBA Control Board 2 (CPU 80C188) 36.45.20 BS 1



PBA Control Board 2 (reduced layout drawing) 36.45.20 BS 4

PBA Counter CBO 36.08.82 ES 1

PBA Counter CBO 34.08.82 AZ 1

PBA Keyboard 1 34.75.61 AZ 1

PBA Keyboard 2 34.78.25 AZ 1

Memory card reader cpl. 34.79.15 ES 1

Memory card reader cpl. 34.79.15 AZ 1

Memory card reader cpl. 34.79.15 AZ 2

PBA Serial Interface SERIN 34.55.44 ES 1

PBA Serial Interface SERIN (old) 34.55.44 AZ 1 only

Gruppo Connectori Accesori (new) 14074.227.1 1

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4��!�� 7

�� 4 �� $��

The optical system of the Master Lab+ includes the lamp house, the light shaft, the measuring optics and the printing optics.

saml07001a

��:)& #��

Exposure lamp 24V/250W

IR cut-off Filter

Band-pass filter

Filterwheel

Filter motor

Light cone

Light shaft110, Disc, 126135, APS, 120

Film deck

Lens turret

Lens code reader

Zoom lens motor

Zoom lens

Print

Paper deck

Lock mechanism

LAMPHOUSE

Light attenuator/Testfilter

110 autom.135 autom.APS autom.Universal

Shutter (in x40 andIndex only)

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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:

� 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 scan-ner. 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 doesn’t affect the light path used for measuring.

�� &��

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 Lab’s this fan is connected in par-allel 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

��:)0 ?��,��

Coated area

Black dot

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�� >��$&��

The filter wheel is an aluminum disk divided into six sections. These sections are used for:

� three diachroic color filter sections (blue, green and red)� two opaque sections and� a fully transparent section

saml07003a

��:)( ��,��

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:

� with the CBO: a GSD-200, controlled by a microprocessor� 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 fol-lowing commands:

� accelerate to 10 revolutions per second � rotate at a constant speed (counterclockwise only) during scanning

cycle� brake and stop at the home position� reset, initialize and stop at the home position

The slave processor is reset either by the hardware during start-up or by a com-mand from the CPU. In either event, the slave processor locates the home posi-tion and waits for further commands

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.

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��# 7��)��(��(saml07004a

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:� Reset: min. 34ms to max. 1s� 60o turn: 39.2ms� Cont -> Home: min. 150ms to max. 270ms� 1 turn: 97.4ms, i.e. 10.27 revolutions per second� Min. time interval between two consecutive commands

for a 60° turn 40.0ms� Max. exposure time per color:60s� Clock rate of slave:11.529MHz.

��% ��(&��?��

The light attenuator is a rectangular perforated aluminum plate to provide a pre-cise 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:

� light path position to reduce the amount of light or� 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.

SM-D Continuous

J1/P13

SM-D Load

J1/P14

SM-D Direction

J1/P15

Slave-D Busy

J1/P44

Reset\ Slave-D

J1/P16

Meas. pos. Filterwheel

J1/P38

Home pos. Filterwheel

J1/P40

8031

Logic

SM

Filterwheel

Fork type light barrier

L 2972x L 6203

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��' ��(&��&��

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:

� one for 110 film and DISC� one for 135 and 126 film� 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:

��* �&��

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 dur-ing 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.

��

4��!��&��&� ��

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.

�1� �1 ��(&��&��

0 0 No light shaft1 0 Light shaft for 110 film and DISC0 1 Light shaft for 135 and 126 film1 1 Light shaft for 120 film

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The position of the unlock button is monitored by a light barrier. Pressing the but-ton 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

��:)/ 6 ��6/&(��+5

��" ��

A label with the lens code is glued to the lens barrel. The label is divided into five sections.

saml07006a

��:)8 ��

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.

Zo

J413

1

810

Jumper P/N 14.16.71

OB 1

OB 2

OB 3

OB 4

OB 5

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saml07007a

��:)2 ��!��

The following table gives an overview of the codes used for the various lenses.

��:)&* ��

Code 2

used for Zoom ACode 3

used for Zoom B

Code 20

used for Fix-lens F = 90

47� 47 47# 47% 47' �� ;��)�

0 0 0 0 0 0 no lens1 0 0 0 0 1 Large format zoom0 1 0 0 0 2 Zoom A1 1 0 0 0 3 Zoom B0 0 1 0 0 4 Wide range zoom II1 0 1 0 0 5 Index tubus0 1 1 0 0 6 Wide range zoom III1 1 1 0 0 7 CRT optics (ML Digital only!)0 0 0 1 0 8 Fix lens F = 721 0 0 1 0 9 Passport 4-UP’s (135 film)0 1 0 1 0 10 Wallet 2-UP’s1 1 0 1 0 11 Fix lens F = 1240 0 1 1 0 12 Passport 4-UP’s (120 film)1 0 1 1 0 13 Fix lens F = 1570 1 1 1 0 14 Fix lens F = 1231 1 1 1 0 15 Fix lens F = 1350 0 0 0 1 16 Fix lens F = 1501 0 0 0 1 17 Fix lens F = 1450 1 0 0 1 18 Fix lens F = 1871 1 0 0 1 19 Fix lens F = 50.50 0 1 0 1 20 Fix lens F = 901 0 1 0 1 21 Fix lens F = 1210 1 1 0 1 22 Fix lens F = 1201 1 1 0 1 23 Fix lens F = 1710 0 0 1 1 24 Fix lens F = 1621 0 0 1 1 25 Fix lens F = 1400 1 0 1 1 26 Fix lens F = 1081 1 0 1 1 27 not yet in use!0 0 1 1 1 28 Fix lens F = 1721 0 1 1 1 29 Fix lens F = 1670 1 1 1 1 30 Fix lens F = 1271 1 1 1 1 31 not yet in use!

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��, 1��(�&

Use the following formula to calculate the required focal length for a particular magnification:

Example:

The dioptric, an optical correction to compensate for the difference between the target and the actual focal length is calculated with the following formula

��/ K��

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 num-ber 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.

where: f = focal length in mmA = distance from film to paper deck in mm

(800mm for Master Lab+)m = magnification (print length / negative length)

Print size 8” x 12”Negative size 60mm x 70mmMagnification m = 305mm / 69mm = 4.42Focal length f = 800mm x (4.42 / 5.422) = 120.37As read from the table f = 120, a fix-lens with code 22

f Am

m 1+( ) 2- - - - - - - - - - - - - - - - - - - - -×=

B1

f t e ta r g- - - - - - - - - - - - - 1

f a c t u a l- - - - - - - - - - - - - -–

1 0 0 0×=

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�� ;��5��

�� ;��(��&��B��

� Open the lamp house cover

Replace the lamp.

# Close the lamp house cover

% Switch ON the machine.

' Recalibrate the system by performing a printer test (see Operating Manual).

�� +�5��(��&�� (�

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).

�� # +�5��(��$&��

� Switch OFF the machine.

Open the lamp house cover.

��-4;�+C�G

7��&��(��(��&��B��?��)��&��-��$��&��4>>G

3+;C�C2G

�&��&��!�� !�&��G��=��&��&��&��G��&��$��!��!��!��(��G

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� the lamp house cover.

" Switch ON the machine.

�� % +�5��(��&��

saml07008a # 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.

tension:1 kg

saml07009a

� Remove the light shaft.

saml07010a

Remove the film deck.

saml07011a

# Remove all lenses.

2

1

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, 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.

saml07012a

% Remove the table by loosening the screws (+,�7,�1,�� and �).

saml07013a

' Remove the shutter by loosening the screws (>, 2 and @).

* Disconnect the cable.

saml07014a

� From the top, loosen screw (�) in the turret shaft.

saml07015a

" Unhook the tension spring (1) from the light barrier mounting bracket.

Shieldingplate

A

B

C

D

E

Disconnect

cable

F

G

H

I

1

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�% 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.

C��D ��!��A�� (��(��&��$��(��5��.��G

saml07014a

�/ Tighten screw (�) in the turret shaft.

saml07016a

�� Adjust the latching mechanism by loosening both screws (2) on the zoom drive, below the brass cylin-der.

� Hookup the tension spring (1).

�# Pullout the unlock button and fas-ten both screws (2) on the brass cylinder.

saml07017a

�� Loosen the three screws of the zoom drive.

�" Move the plate until the crown gear of the zoom has a distance of ~0.2mm.

I

1

2

~ 0.2mm

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�� ' ��(

Five infrared reflective light barriers mounted on the PBA LESE are reading the code information of the lens.

C��D ��&��$��&��?��5��6%�#��$��"��/��&��174��174 ��

To adjust the sensitivity of these sensors proceed as follows:

To verify correct adjustment, insert various lenses and check for correct reading.

Select the menu:E�+�C�F�.�-;�C��;�.�4�@�;�.�4-��1��.�14��

The screen displays the detected color and the resulting lens code.

C��D �&��$��(��!��=��&�$��!G��&��!�&��$��G�7��G

saml07018a

� On the PBA LESE connect a volt-meter between GND and the test point LS1 to LS5 (depending on the sensor to be tested or adjusted).

saml07019a

Cover all sensors with the black pattern of the label

# Adjust the voltage of each sensor to 300mV.

saml07020a

% Cover all sensors with the white pattern of the label.

' Check the voltage of each sensor. It should be 3.5V or more.

MAINT PRINTER OTHER OPTICS CODE

Lightbar. 0: Black Lightbar. 2: Black

Lightbar. 1: White Lightbar. 3: Black

Lenscode: 02 Lighrbar. 4: Black

POT.

METERS

TEST-

POINTS

GND

LS5

LS4

LS3

LS2

LS1

J 803

SENSORS

OB1

OB2

OB3

OB4

OB5

Code label

BLACK: logic 0 = ≤ 0.4V

Code label

WHITE: logic 1 = ≥ 3.5V

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�� * K��

-��(��&��5��

� Remove the front cover.

There are two ways to adjust the focus:� with grain finder if available or else� without grain finder, by means of a printed focus ring.

+�5��(�$��&�(��

% Select the menu:E14��F�.�-;�C��;�.��C��.��>41�

C��D �&��(��&��$��&��&��G

��-4;�+C�G

�� &��&��&��A��.��.��A��&��!��G

�4C=��&��(��&��$��(��. ��.��A��&��!��G�4�&��$��&��A��&��$��

��G

saml07021a

Loosen the three set screws (L) on the head ring (Ring 1) to allow the zoom to be turned for focusing.

Lens turret

Ring 1

X X X

saml07022a

# Insert the focus test film(P/N 34.91.51) in the film deck.

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* Place a piece of white photo paper onto the paper deck.

� Place the grain finder onto the paper.

" Press the key below ��+;�. 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.

�� Remove the photo paper from the paper deck.

� Readjust the home position of the zoom as described in chapter 7.2.7

+�5��(�$��&��(��

saml07023a

' Turn the crown gear of the zoom clockwise to the mechanical end-stop (highest magnification).

saml07021a

�/ Tighten the three set screws (X) without altering the position of the zoom.

Crown Gear

CW

Lens turret

Ring 1

X X X

saml07023a � Turn the crown gear of the zoom clockwise to the mechanical end-stop (highest magnification).

saml07024a Prepare a piece of adhesive paper tape with 7 marks at about every 2.5cm (1”) and number them from 1 to 7.

Crown Gear

CW

1 2 3 4 5 6 7

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' Select the menu:E14��F�.�-;�C��;�.��C��.��>41

* 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 ��+;��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.

saml07025a

# Stick this prepared paper tape carefully to Ring 2 so that the mark 4 is positioned exactly below the screw hole of Ring 1.

C��D ��=��&��&��$��&��A��G

saml05022a

% Insert the focus test film(P/N 34.91.51) in the film deck.

1 2 3 4 5 6 7Ring 1

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�' Readjust the home position of the zoom as described in chapter 7.2.7.

�� (��&��&��

saml07021a

�% Tighten the three set screws on the zoom.

Lens turret

Ring 1

X X X

saml07026a

� Loosen the set screw in ring 2.

Turn the crown gear of the zoom counterclockwise to the mechani-cal end stop and hold it in this position.

saml07027a

# Slowly turn ring 2 counterclock-wise until the LED D20 on the CBO/CBO2 lights up

Crown Gear

Ring 2

Set screw

CCW

J403

J416

J417

U15Filterwheel

U14Filmdeck

U7Paper deck

U8Paper extractor

U9Zoom

U11

U4

U13

U6

SlaveD

Filte

rwheel

SlaveC

Papertra

nsp.

J411

Test connectorfor internal tests

D20

D11

D20

J417

Filterwheel Film deck

Extractor

Paper deck

Zoom S2

D9S4

CBO

CBO2

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� Check the correct adjustments with the menuE�+�C�F�.�-;�C��;�.�4�@�;�.�4-��1��.�14��

C��D �&�� &�$��!��=��&�$��!G��&��!�&��$��G�7��G

�� " >��(��B��.��

Adjust the focus:� with grain finder as described in chapter �'-867,1*�:,7+�*5$,1�),1'(5� without grain finder as described in chapter �'-867,1*�:,7+287�*5$,1�

),1'(5

# Tighten the counter-ring or the set screw on the lens barrel (depending on the lens)

saml07028a

% Now turn ring 2 additionally in counterclockwise direction� 4 teeth with zoom A and B� 3 teeth with a wide range

zoom

saml07026a

' Ensure that ring 2 sits properly on the crown gear.

* Tighten the set screw in ring 2.

MAINT PRINTER OTHER OPTICS CODE

Lightbar. 0: Black Lightbar. 2: Black

Lightbar. 1: White Lightbar. 3: Black

Lenscode: 02 Lighrbar. 4: Black

Ring 2

CCW

Crown Gear

Ring 2

Set screw

CCW

saml07029a

� Loosen the counter-ring or the set screw on the lens barrel (depend-ing on the lens).

Lens Barrel

Counter-Ring

Lens

Set screw

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�� , +�5��(��&��B��

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)

�� / +��

The Master Lab+ is capable to work with two kinds of Densitometers:� Densitometer D188 / D19C� automatic Densitometer ADM

Information about installation, setup, operation and maintenance are given in separate manuals, listed below:

� 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)

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��# ��&��

�� $��(�N -�(��&��

PBA Shutter Connector SHUT 34.55.63 ES 1

PBA Shutter Connector SHUT 34.55.63 AZ 1

PBA Lens Sensor LESE 34.78.91 ES 1

PBA Lens Sensor LESE 34.78.91 AZ 1

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��(��!�� 8

"�� 4 �� $��

The measuring system is below the film deck. It encompasses mainly three parts:

� the optic box� the measuring box� 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 ana-log-to-digital interface as connection between the analog signals of the measur-ing 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).

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saml08001a

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"�� 4��B

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 per-manently attached.

Detail A

Lamp

Prefilter

Lamp house

Filter Wheelupper Diffusor

lower Diffusor

Light shaft

Film

Film

deck

Optic Box

Measuring

Filter

Measuring

Box

Photo-

diode

MESY

Silver

coatingMirror

Detail B

Light attenuator/Testfilter

Antireflectionangle

MESY

thread

Triplet

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saml08002a

��;)0 ��!��

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).

C��D �&��$��(��&��(&��&��&��(��G

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

��;)( #��!�"��,��$

Optic box 110

Optic box 120

Optic box 135

Fiber optic

Mirror

Triplet

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"�� (��B�$��&��(��8��9

Scanning pattern for all film formats:

"��# >��(��L.1��

The sensor assembly for film positioning and DX-Code detection is described in detail in chapter 9.4

"��% ��(

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

Film decksScanning grid

Optic box & light shaft

Format

Diodes y PPL1)

1) PPl = Pixels per line

Diodes x LPP2)

2) LPP = Lines per picture

Width (mm)

Length (mm)

Automatic types

135 autoPanorama 4 12 48 135 12 36Full frame 8 12 96 135 24 36Half frame 8 6 48 135 24 18

110 auto 10 12 120 110 12.9 17.0Classic 10 12 120 135 15.6 22.3

APS HTV 10 12 120 135 15.6 27.4Panorama 8 12 96 135 9.6 27.4

Universal typeDisc 6 8 48 110 8.25 10.6110 10 12 120 110 12.9 17.0126 10 10 100 135 28.1 28.8135 8 12 96 135 24 36135HF3)

3) HF = Half frame

8 6 48 135 24 18135HF Q4)

4) HF Q = Half frame across

10 12 120 110 18 24120 (4.5 x 6) 10 8 80 120 56 41.5120 (4.5x6Q)5)

5) Q = across

8 10 80 120 41.5 56120 (6 x 6) 10 10 100 120 56 56120 (6 x 7) 10 12 120 120 56 72

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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 caus-ing an interrupt on the main processor. The main processor now sequentially reads the values stored in the integrators and converts them to digital data.

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

��;)/ 1��,��

J14/P40

Control board

Homepos

Filterwheel

GLSHome-pos.

J4/P9

8031

U13

106SlaveD

IN14J40/P38

IN14

J1/P38

IN16IN16J1/P40

pos.Meas.

> 1

U82

Integrators

Reset, Start

1

2

23 TMR01U1

> 1 U82

uP 80186

44INT1

8

910

3

5

6

1 U107

12

10

63

EPLD

U49CPU-Board

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saml08005a

��;)8 3��4��

saml08006a

��;)2 +��91��

The following timing diagram of a scanning cycle shows two full turns of the filter wheel, respectively 1 line of 11 diodes.

U/I-Con.

J25

11x

Reserve

3x

Scanarray

Tempe-rature

C

Temp.-

Sensor

Photo-

diode

FIDE

DX and

Pos-

Diodes

Buffer

*1

Amp. N.C.

Buffer

Amp

*1

J24

I/U-Conv.

I/U-Conv.

Photo-

diode

Scan-

diodes

MESY

11x

Buffer

Amp

*1

J24

CPU

25 : 1

Integrator

Logic

MultiplexerTo ADC

Processor

Data exchange channel selection

System clock from CPU

INT1 to CPU,

Read measuring

values

Start of measuring

SlaveD, Filter wheel

Control

logic

Reset, Start

ratures, U , Reserved Inputs

DX and Pos.-Diodes, Tempe-

ref

U

Photo-

Diodes

1-12 - dte

Mux

-20 dBDek

D - D0 10

logic

A A A A PCS21 2 3 4

Control

RD

AD GND

WR

AD +5V

DC

DC

+ 5V

- 15V

- 10V

AGND

+ 15V

2 - 20 7 -1

D - D12 14

CS, CE, R/C

S/H

Mode

D - D0 11D

D State AD15

A

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saml08007a

��;): ��

"��' ��(��8��I9

The measuring board contains 11 photodiodes forming a linear array. Each pho-todiode 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)

"� ;��(��&��(��!��

3.85ms

0 = Sample or Reset

1 = Hold or Sample

ca.250nsec

ca.30usec

gain U67, U68/P11

Status ADC resp.S/H

1 = Convert

resp. Hold

0 = Read resp.

Sample

Integrator gate, e.g.

Integrator hold, e.g.

Select channel resp.

U58/P6

U58/P11

1 = Hold

0 = Reset

Average time

3.85ms 3.85ms

Measuring position

of filter wheel

Light intensity, e.g.

Filter wheel home signal

illumination measuring

29.75ms

37.85ms

45.95ms

53.05ms

BD2

5.32msec

97.2msec

102.6msec

13.56ms

21.65ms

G

Home

Start Scanning

BD1

R WD2

Home

G R

saml07009a

� Remove the light shaft.

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� After replacement, reassemble in reverse order.

saml07010a

Remove the film deck.

saml08008a

# Loosen screws 8+9 and 879.

saml08009a

% On the CPU, disconnect the cable from connector J24.

saml08010a

' Remove the cable clamp and pull the cable through the cable pas-sage.

* Pull out the measuring box includ-ing the cable.

2

1

A

B

J8J9

1

J1J25J27J24J26

18

A / D converter

Battery J28J30 J6

11

1

DC-DCconverter

+-

disconnect J24

DistributorCable clamp

Cable

Paperdeck

Cable passage

Scanner box

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"�# 1&��)��(��&��(��!��

� Ensure that the automatic 135 film deck and the 135 light shaft is installed. If not, install them.

Initialize the system

# Select the menu:E�+�C�F�.�-;�C��;�.��+��I��.��1+C��C

% Make sure the gain is set to 1 then press the key just below ��+;� with-out a film in the film deck.

' To check the other diodes press the key just below C�L�.

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:

"�#�� #'��

Conditions:� automatic 135 film deck inserted� No film in the film deck� Gain set to 1.

"�#� � /��

Conditions:� Universal 120 film deck inserted� No film in the film deck� Gain set to 1.

<MAINT> PRINTER MEASSYS SCANLIN

Press <START>, to scan one line of Neg..

Read results on next screen [ 1]

START GAIN

<MAINT> PRINTER MEASSYS SCANLIN

Blue Green Red Gain 0

A/D-Raw 1500 1500 1500 Diode 1

Offset 820 820 820 NEXT

�!�� , ��/ ��8��(&�� 9

72; 72; 72; ;27

A/D-Raw (1000 to 2000) not used 1500 not used 1100Offset +/- 100 not used 800 not used 800A/D-Raw - Offset not used ~700 not used ~300ALARM -> A/D-Raw - Offset < 43 < 16

A/D-Raw < 4095

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saml08011a

��;); 1��

"�% ��<�=

In older Master Lab’s the following calibration procedure is used when the cus-tomer 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 trans-mission 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.

"�%��

� Calibration strip P/N 36.17.68 (a strip similar to the control strip for the film processor).

�!�� , ��/ ��8��(&�� 9

72; 72; 72; ;27

A/D-Raw (1000 to 2000) 1500 1500 1500 1100Offset +/- 100 800 800 800 800A/D-Raw - Offset ~700 ~700 ~700 ~300ALARM -> A/D-Raw - Offset < 43 < 16

A/D-Raw < 4095

Optic box Measuring box

Diodes

11

1

2

3

4

5

6

7

8

9

10

fiberoptics (lightvalue)

120film

135film

Light value

��-4;�+C�G

�&��$��(��$��J.��J;. ��!G��$��&��+��G

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� The aim values (label with values should be on every calibration strip).

"�%� -��

� Select the menuE�+�C�F�.�-;�C��;�.��+�I��.��.1+��7�.�+0�4

Insert the calibration strip into the film deck.

# Position the first measuring field in the viewing window.

% Start the measuring cycle wit E�C��;F.

' Select the menu:E�+�C�F�.�-;�C��;�.��+�I��.��.1+��7.

* Press the key just below the word +��.

� Enter the provided aim values in the following sequence:

�� 1. Screen: Y (B)

�� 2. Screen: Dmax (R/G/B)

��# 3. Screen: LD (R/G/B)

��% 4. Screen: press E�C��;F to save data.

" In case the following event message appears, proceed as advised in the event message.

Code: M19

Text: Scanner wrong calibrated

Cause: There are no reasonable values from the calibration strip avail-able (measured values or aim values)

Remedy: Repeat the calibration procedure for the scanner.

<MAINT> PRINTER MEASYS T_CALIB AUTO

Insert Film and

press <ENTER> to start

<MAINT> PRINTER MEASYS T_CALIB AIM

Y (B)

[0.00]

RED GREEN BLUE

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"�' ��(��&��

"�'�� ;��

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 den-sity 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.

"�'� -��

� 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:E�+�C�F�.�-;�C��;�.��+�I��.��C�

# Write down the actual displayed temperature from the measuring box.For example:

% Perform a Printer Test in the evening and measure it with a densitometer.

C��D ��=��&��H+��&�� G

' Select the menu:E�+�C�F�.�-;�C��;�.��+�I��.��C�.

* Write down the actual displayed temperature from the measuring box.For example:

� Calculate the difference.

I��$ ��(�� 1!��

Morning 0.80 0.80 0.80 20oCEveningDifference

I��$ ��(�� 1!��

Morning 0.80 0.80 0.80 20oCEvening 0.95 0.87 0.74 31oCDifference

I��$ ��(�� 1!��

Morning 0.80 0.80 0.80 20oCEvening 0.95 0.87 0.74 30oCDifference +0.15 +0.07 -0.06 10oC

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" To calculate the temperature compensation values use the formula:

Regarding the values in our example: e.g. for Yellow = (0.95 - 0.80) x (-10) / 10oC = -0.15

, Select the menuE�+�C�F�.�-;�C��;�.��L-�I��.��-14;

�/ 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

C��D 0��&��!��(�� !G4��!� ��&��(��./� /��/� /��G

"�* ��&��

V a l u eC o l o r 1 0–( )×∆T e m p e r a t u r e∆

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --=

�� $��(�N -�(��&��

PBA Measuring System MESY 34.75.70 ES 1

PBA Measuring System MESY 34.75.70 AZ 1

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>��& 9

,�� 4 �� $��

The film path mechanism basically encompasses of four different film decks:

� Automatic film deck 135

� Automatic film deck APSThis film deck is not covered in this manual. Please refer to:Service Manual Addendum APS P/N 98.27.42 for optical IndexprinterService Manual Customizer P/N 98.29.02 for digital Indexprinter

� Automatic film deck 110

� Universal film deck

Each film deck includes at least the following assemblies and positions:

� Drive

� Positioning diodes

� Viewing position

� Scanning position

� Exposure position

,��

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.

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,�� -��(��

These diodes are used to determine the frame position and to detect the DX-Code information.

,��# H��$��(��

The viewing position provides an illuminated viewing window. Once a frame is positioned the viewing window, the operator may check the negative visually.

,��% ��(��

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 cal-culate the exposure times of every color for each single negative.

,��' �B��

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.

,� >��)��(

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

��=)& �1��,��4��&(8��

J609

J603

J604

1

1

0

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saml09004a

��=)0 �1�&(890�,��4��&(8� <�)��

saml09001a

��=)( �1��,��4�� 4

saml09002a

��=)/ �1��,��4��&&>��

1

FDECKCODE

J15

1 0

Normal

FUJI

J614

J613

J612 1

0

0

J614

J613

J612 1

0

1

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,�# 7��)��(��)�

,�#�� +��#'��)saml09005a

J601A

J602

J605

J25

J409

J655

CBO

FIVI 135

FIPOTFIPOR

CPU

FIDE 135

J608

J607

J606J 609

J 603

J 604

BC 2

A/D - Interface

5 LED's6 Photo-diodes

TransmitterReceiver

Steppermotor

2 Viewinglamps

Pressure solenoid

- Power supply- Steppermotor- Digital signals

Analog signals:- Positioning diodes- DX-diodes

Coding (3)

Amplifiers forphotodiodes

Power sourcefor LED's

1 0

MSB BC 3

LSB BC 1

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,�#� +��#'��)��>�5��saml09008a

J2

J1

J9

J25

J409

J8

CBO

FIVI 135

FIPOTFIPOR

CPU

FIDE 135/2

J4

J5

J14

J 15

A/D - Interface

6 LED's7 Photo-diodes

TransmitterReceiver

Steppermotor

2 Viewinglamps

Pressure solenoid


Analog signals:- Positioning diodes- DX-diodes

Amplifiers forphotodiodes

Power sourcefor LED's

1 0

Normal 135

Fuji code

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,�#�# +��/��)saml09006a

J601B

J409

CBO

FIVI 110

FIDE 110/U

J624

J620

J621J 612

J 613

J 614

BC 2

Steppermotor

1 Viewinglamp

Pressure solenoid


Coding (5)

J618

J616

Positioning switch

Positioning switch

1 0

LSB BC 1

MSB BC 3

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,�#�% 0�� )saml09007a

J601B

J409

CBO

FIVI UNI

FIDE 110/U

J625

J621J 612

J 613

J 614

BC 2

Steppermotor

5 Viewing lamps1 Hall sensor


Coding (1)

J615 Lightbarrier

home position

MSB BC 3

LSB BC 1

1 0

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,�% �&��)�

,�%�� #'��)

The automatic 135 film deck uses sensors to position the film. The film deck han-dles 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

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The positioning diodes measure the density of the film. They provide the infor-mation 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 LED’s 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.

saml09010a

��=)2 1@)��

Transportroller

Viewingposition

DX/Positioningdiodes

Measuringposition

Exposure

station

Transportroller

Transportroller

Film-transport

SM

Film-transport

SM

LED's

Film

Diaphragm

Photodiodes

Power source

Amplifier

DATA track (DX-Code)

CLOCK track (DX-Code)

Front view

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,�%� ��/��)

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 110-films 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

��=): 1��&&>��4

,�' �&�� )

,�'�� 2��

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 step-per 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 han-dle different film formats. The home position of the sledge (= viewing position) is controlled by a light barrier.

saml09014a

��=); ?��,�� 4

Transportroller

Viewingposition

Measuringposition

Exposure

station

Transportroller

Transportroller

Film-transport

Microswitch

viewingposition

Microswitch

exposure

position

SM

6 x 6

Flap

InsertFilmmask

Sledge

Filmtransport

SM

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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 cor-responding optical box and the correct light shaft. For the transport to the expo-sure position the film is fixed with a flap.

saml09015a

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The following table shows the different codes for the various inserts:

6 x 6

1 (LSB)248(MSB) 16

Top view

C��*��7

" % �

��7��

>��A�4��B��(&��&��

0 01) 0 0 0 0 no insert ---

1 0 0 0 0 1120 (4.5 x 6Q)

120 (4.5 x 6Q+)120

2 0 0 0 12) 0 110 1103 0 0 0 1 1 126 1264 0 0 1 0 0 135 FF (24 x 36) 1355 0 0 1 0 1 135 HF (18 x 24) 1356 0 0 1 1 0 120 (4.5 x 6) 1207 0 0 1 1 1 120 (6 x 6) 1208 0 1 0 0 0 reserved ---9 0 1 0 0 1 reserved ---10 0 1 0 1 0 120 (6 x 7.2) 12011 0 1 0 1 1 reserved ---12 0 1 1 0 0 reserved ---13 0 1 1 0 1 reserved ---14 0 1 1 1 0 Disc 11015 0 1 1 1 1 reserved ---

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,�* 1&��)��5��#'��/��)�

C��D �&��$��(��5��&��#'��)��/��)��&��(��&��)��

,�*�� 1&��)��(��(��&��L.1��

To check the positioning and the DX-Code diodes of the 135 film deck proceed as follows:

� Select the menu:E�+�C�F�.�-;�C��;�.�>��;+1:�.��C��.�+�#'

Without a film inserted in the film deck press the key just below 1+��7. 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!

C��*��7

" % �

��7��

>��A�4��B��(&��&��

16 1 0 0 0 0

Cropping masks13.8 x 19.8 (110) 110

18.8 x 24.8 (135HF) 13524.8 x 36.8 (135FF) 135

42.6 x 56.8 (120 / 45 x 60) 12017 1 0 0 0 1 135 HF (18 x 24Q) 13518 1 0 0 1 0 reserved ---

19 1 0 0 1 1 reserved ---20 1 0 1 0 0 reserved ---21 1 0 1 0 1 reserved ---22 1 0 1 1 0 reserved ---23 1 0 1 1 1 reserved ---24 1 1 0 0 0 reserved ---25 1 1 0 0 1 reserved ---26 1 1 0 1 0 reserved ---27 1 1 0 1 1 reserved ---28 1 1 1 0 0 reserved ---29 1 1 1 0 1 reserved ---30 1 1 1 1 0 reserved ---31 1 1 1 1 1 reserved ---

1) 0 = no magnet inserted

2) 1 = magnet inserted

<MAINT> PRINTER FITRACK SENS A135

Pos.Diode Density A/D-Raw Offset

[ 1] 0.00 2132 816

STEPS FORW BACKW CALIB

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,�*� +�5��(��B�� $��(��

Production tolerances are compensated with this adjustment. Because the viewing and the exposure position are in correlation we have to adjust in the fol-lowing sequence:

� 1st = Exposure position

� 2nd = Viewing position

� 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 view-ing window. If necessary adjust the position with the or the keys.

# Select the menu:E�+�C�F�.�-;�C��;�.�>��;+1:�.��C��.�+�6�L-

% Open the front cover to get access to the paper deck.

' Press the key just below the word ��+;�.

* 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 E. or .F until no borders of unexposed mask are left at either side.

+�.;�$ 4��Positioning diodes

min. 1100 to max. 3500 725 to 925DX-Code dataDX-Code clock

��-4;�+C�G

��!�� &��5��(��&��G

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)

<MAINT> PRINTER FITRACK INIT ADJEXP

Press <START> to move Film to Exposure-

position -7

START <- ->

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" Confirm with E�C��;F.

, Now position a frame with enough contrast in the viewing window.

C��D ��=��&��&��&�� $��(�$��$�$��&��&��(�)�!�G

�/ Select the menu:E�+�C�F�.�-;�C��;�.�>��;+1:�.��C��.�+�6H��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 E�C��;F.

,�*�# +�5��(��&��

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.

� Remount the plastic cover of the film deck.

<MAINT> PRINTER FITRACK INIT ADJVIEW

Adjust viewer position and press ENTER

-3

<- ->

saml09012a

Loosen the set screw of the lever.

# Turn the shaft to push the pres-sure 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 mea-sure approx. 0.6mm. If necessary adjust by turning the lever.

* Tighten the set screw again.

~ 0.6 mm

Set screw

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� Remove the plastic cover of the film deck.

saml09013a

Loosen both screws 8+9.

# 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.

,�� +�5��&�� )

,�� +�5��(�&��

# Select the menu:E�+�C�F�.�-;�C��;�.�>��;+1:�.��C��.�0C�

SM3.5 .. 4.5N(350 .. 450gr)

A

A

saml09016a

� Remove the cover on the upper side of the sledge.

Loosen both screws of the flag.

<MAINT> PRINTER FITRACK SENS UNI

Error stat. of film Home: YES

[ 1] Magnet: NO

STEPS FORW BACKW

6 x 6

Homesensorflag

1mm

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% Depending on the sledge position press either the key just below the word >4;3 or 7+1:3 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’.

C��D �&��!��!��&��(��!��(��&��&��)�!��(��G

,�� +�5��(��&��B��

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!

� Load a film strip

Select the menu:E�+�C�F�.�-;�C��;�.�>��;+1:�.��C��.�+�6�L-

# Open the front cover to get access to the paper deck.

% Press the key just below the word ��+;�.

' 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 E. or .F until no borders of unexposed mask are left at either side.

� Confirm with E�C��;F.

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)

<MAINT> PRINTER FITRACK INIT ADJEXP

Press <START> to move Film to Exposure-

position -7

START <- ->

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,�" ��&��

�� $��(�N -�(��&��

PBA Film Deck 135, FIDE 135 34.75.68 ES 1

PBA Film Deck 135, FIDE 135 34.75.68 AZ 1

PBA Film Pos. Sens. Trans., FIPOT 34.75.35 ES 1

PBA Film Pos. Sens. Trans., FIPOT 34.75.35 AZ 1

PBA Film Pos. Sens. Rec.,. FIPOR 34.75.37 ES 1

PBA Film Pos. Sens. Rec., FIPOR 34.75.37 AZ 1

PBA Film Viewing 135, FIVI 135 34.75.33 ES 1

PBA Film Viewing 135, FIVI 135 34.75.33 AZ 1

PBA Film Deck 110/UNI, FIDE 110/U 34.76.00 ES 1

PBA Film Deck 110/UNI, FIDE 110/U 34.76.00 AZ 1

PBA Film Viewing UNI, FIVI UNI 34.76.12 ES 1

PBA Film Viewing UNI, FIVI UNI 34.76.12 AZ 1

PBA Film Viewing 110, FIVI 110 34.76.92 ES 1

PBA Film Viewing 110, FIVI 110 34.76.92 AZ 1

PBA Filmdeck 135/2 37.08.95 ES 1 to 3

PBA Filmdeck 135/2 37.08.95 AZ 1

PBA Film Pos. Sens. Trans., FIPOT 37.08.98 ES 1

PBA Film Pos. Sens. Trans., FIPOT 37.08.98 AZ 1

PBA Film Pos. Sens. Rec.,. FIPOR 37.09.00 ES 1

PBA Film Pos. Sens. Rec., FIPOR 37.09.00 AZ 1

PBA Filmdeck, FIDT 37.01.35 ES 1

PBA Filmdeck, FIDT 37.01.35 AZ 1

PBA Filmdeck rec., FIDR 37.01.37 ES 1

PBA Filmdeck rec., FIDR 37.01.37 AZ 1

PBA Viewer lamp, VLB 37.01.98 ES 1

PBA Viewer lamp, VLB 37.01.98 AZ 1

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-��& 10

�/�� 4 �� $��

The paper transport system includes all movements of the paper from the paper cassette into the Paper processor.

This transport system includes:� the paper cassette� the paper extractor� the knife assembly� the paper deck� the feeder or panorama feeder� the conveyer (ML X’20) or the distributor (ML X’40)

The paper is extracted from the paper cassette and cut according to the speci-fied 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 distri-bution 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.

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saml10001a

��&>)& +��,��

1 Paper cassette (metal version) 2 Light trap (Adapter)3 Locking mechanism 4 Sensor board (PAMID)5 Extractor stepper motor 6 Knife with DC motor7 Paper deck stepper motor 8 Paper deck9 Feeder DC motor 10 Feeder or panorama feeder11 Distributor or conveyer 12 Main drive from PP (1cm / sec)13 Conveyer stepper motor 14 Distributor stepper motor (SM2)

�/�� -��

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.

Paper extractor unit

1

234

5

7

89

10

11

6

12

13

14

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There are different types of paper cassettes in use:� metal cassettes used so far for paper width 3.5” to 5”� older type plastic cassettes used for paper width 3.5” to 6”� new type plastic cassettes used for paper width 3.5” to 8.25”� metal cassettes used for paper width 7” to 8.25”

�/�� -��B��

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 accord-ing 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 (-+per �agazine ��en-tification). 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 dis-played. The remaining piece of paper must be removed manually from the paper deck.

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.

�/��# :��

A rolling knife is used to cut the paper. Both end stops - front and rear - are mon-itored by light barriers. The knife is driven by a DC motor. The cutting time is lim-ited by a time-out. If the knife does not reach the opposite end stop within 1.5 seconds, a knife error is displayed.

saml10002a

saml10003a

saml10004a

Metal type cassettePlastic type cassette

(old)Plastic type cassette

(new)

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�/��% 7��)��

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.

�/��' -��)

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.

�/��* >��-��

After the exposure the paper is moved to the feeder. The feeder has two posi-tions 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 (pan-orama).

saml10023a

Feeder

Sensor

'Panorama print'

Sensor

Print present

Sensor

Print > 4"

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�/�� 8��L%/��!G9

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:

� 1 track for ML X20� 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 distrib-uted 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

Distributor

Cover

Transport belt

SM 1

SM 2

Electromagneticclutch, left

Free wheeling

Main-transport

1 cm/sec.

Light barrierleft

Light barrierright

Homesensor

Distributor

Conveyer

Electromagneticclutch, right

Transport belts

Transport belt

Free wheeling

Free wheeling

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Two reflective light barriers are mounted on top of the distributor. If the respec-tive light barrier does not detect a print after a couple of steps, an error is dis-played. 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.

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.

DISTRIBUTOR ACTIVE: This line is used to inform the slave C that the distributor motion is in progress.

BUSY: This line remains active until the previous print has left the distributor.

ERROR: 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.

RESET: Following an error, a pulse on this line triggers a hardware reset of the distributor slave.

PAPER WIDTH: This line is used to inform the distributor if the paper width is 4” or smaller / 4” or larger.

DISTRIBUTOR CON-NECTED:

This line transmits the information if a distributor is connected or not.

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saml10006a

��&>)0 1��

Paperinto

Feeder

Feederto

Printerpos.

01

59

10

1112

13

141516

1819

20

78

21

17

624

2526

29

303132

333435

3637

4041

2223

2728

3839

42

4344

Paperinto

Dist.

Distribute

Righttrack

Lefttrack

Feederto

PPpos.

Paperadvance

SM1

SM1

SM2

1cm/sec.

1cm/sec.

1cm/sec.

1cm/sec.

Clutchright

Clutchleft

SENSORS:

SENSORS: Feeder->

printpresent

Distributorhome

MOTORS:

---

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�/��" ��(��(��&

The following timing diagrams show the interaction of the various systems dur-ing normal operation and show the reason for variations in production speed.

saml10007a

��&>)( ��(0>�9�80>��

Timing

01

23

45

910

111213

141516

181920

78

21

17

Filterwheelrotate

TransportFilm

ExtractPaper

CutPaper

Paperto

ExpoPos

Paperinto

Feeder

Feederto

Printerpos

6

9x13

PaperinFeeder

Calculate

Neg.Data

24

.....

2223

44

Vacuum

fan

on

NegativClamp

1Man

Expose

Paper(Atten.)

Masterlab

320/520

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saml10008a

��&>)/ ��(0>�9�80>��

Timing

01

23

45

910

111213

141516

181920

78

21

17

FilterWheelrotate

TransportFilm

ExtractPaper

CutPaper

Paperto

ExpoPos

Paperinto

Feeder

Feederto

Printerpos

6

9x13

PaperinFeeder

Calculate

Neg.Data

1Auto

242526

29

30313233

343536

37

4041

2223

2728

3839

42

4344

Vacuum

fan

on

Negative

Clamp

Expose

Paper(Atten.)

Masterlab320/520

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saml10009a

��&>)8 ��:/>��

Timing

01

23

45

910

111213

141516

181920

78

21

17

FilterWheelrotate

TransportFilm

ExtractPaper

CutPaper

Paperto

ExpoPos

Paperinto

Feeder

Feederto

Printerpos

6

9x13

Calculate

Neg.Data

242526

29

30313233343536

37

4041

2223

2728

3839

42

4344

Paperinto

Dist.

Shutterclosed

Distribute

TrackA

TrackB

3Man

Expose

Paper(Atten.)

Negative

Clamp

Vacuum

fan

on

Masterlab

740

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saml10010a

��&>)2 ��:/>��

Timing

FilterWheelrotate

TransportFilm

ExtractPaper

CutPaper

Paperto

ExpoPos

Paperinto

Feeder

Feederto

Printerpos.

9x13

Calculate

Neg.Data

Shutterclosed

1Auto

Expose

Paper(Atten.)

Negative

Clamp

Masterlab

740

01

23

45

910

1112

13

141516

181920

78

21

17

6242526

29

303132

3334353637

4041

2223

2728

3839

42

4344

Paperinto

Dist.

Distribute

TrackA

TrackB

Vacuum

fan

on

Feederto

PPpos.

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�/� �� $saml10048a

DC

= Hall sensor

= Reflective lightbarrier

= Fork type lightbarrier

= DC - Motor

= Stepper motorSM

DC

DC

DC

Lens/Zoom

Distributor

Feeder

Paper deck

Knife assembly

Paper cassette

Vacuum fan

Sensor board "PAMID"

Paper extractor

SM

SM

SM

SM

SM

- Lens code reading group

- Left track- Right track- Distributor carriagehome position

- Print present- Print > 4 inch- Print still in feeder- PP position- Printer position

- Knife right position- Knife left position

- Hall sensors (4x)- Papersplice- Paperend

= Solenoid

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�/�# ;��?��5��&��)�

�/�#�� (��

The detailed procedure is described in the ‘Operating Manual’.

C��D ��(��)��G

saml10011a

Metal type cassette

saml10012a

Plastic type cassette (old and new)

� 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.

saml10013a

Metal type cassette

saml10014a


Pull out the paper. It should pro-trude from the exit approximately 4cm (~1.5”)

ca. 4 cm

(~1.5 inches)

ca. 4 cm

(~1.5 inches)

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Three different sizes of light traps (adapters) are available for the various paper cassettes.

# Ensure the correct size is mounted.

% When inserting the cassette into the machine, make sure that the lever is in the unlock position (turned clockwise).

saml10015a

A Smallest type for metal type paper cassettes 3.5”, 4” and 5”

B) Medium type for old plastic type cassettes 3.5” to 6”.

C) Large type for metal type cas-settes 6” 7” and 8”

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.

6"

7"

9"

A

B

C

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�/�#� 1��(��&��

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

Coding is done according to the following table:

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.

-��!

1�� -��!�8��!��9

1 2 4 80 Reserved for test strip cassette1 X 3.5” MT2 X 3.5” GL3 X X 4.0” MT4 X 4.0” GL5 X X 5.0” MT6 X X 5.0” GL7 X X X 8.0” MT8 X 8.0” GL9 X X Paper 9

10 X X Paper 1011 X X X Paper 1112 X X Paper 1213 X X X Paper 1314 X X X Paper 1415 X X X X Paper 15

1248

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saml10019a

Metal type paper cassette

saml10020a


� >��!��!GFirst insert the washer (delivered with the cassette) into each hole a magnet is going to be placed.

Insert the magnets with the color dot upwards.

saml10021a

# Cover the holes with the black self-adhesive labels supplied with the cassette.

saml10022a

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 corre-sponding with the paper width onto the label to the cassette in the position ‘Paperwidth’.

Color dot

Washer

Color dot

Black self-adhesive

label

Paperwitdh

Paperchannel

4"

Pape

rchan

nel

Pape

rwidth

Paperchannel Paperwidth

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* The code of a docked paper cassette is checked with the menu:E�+�C�F�.�-;�C��;�.�-+�;+1:�.�1+��.�14��

�/�#�# +�5��(��&��$��&�

All paper cassettes are available as factory assembled units with the following part numbers:

It is possible to convert an existing plastic type paper cassette (old or new ver-sion) to an other paper width with the help of the particular parts. For certain con-version are conkits available containing all necessary parts.

MAINT PRINTER PATRACK CASS CODE

Magnet 0: Yes Magnet 2: No

Magnet 1: No Magnet 3: No

Cassette code : 1

��-4;�+C�G

4��!��!��$��&�$��&��&��&��&��G

Type of paper cassettes Partnumber RemarksMetal type paper cassette3.5” cassette 34.45.76 replaced by 37.61.884” cassette 34.45.77 replaced by 37.61.895” cassette 34.45.78 replaced by 37.61.906” cassette 34.22.80 replaced by 37.61.917” cassette 34.48.77 replaced by 37.64.848” cassette 34.45.79 replaced by 37.64.858.25” cassette 34.86.65 replaced by 37.64.86Plastic type paper cassette (old version)3.5” cassette 36.24.78 replaced by 37.61.884” cassette 36.24.79 replaced by 37.61.895” cassette 36.24.80 replaced by 37.61.906” cassette 36.24.81 replaced by 37.61.91

plastic type paper cassette (new version)3.5” cassette T2 37.61.884” cassette T2 37.61.895” cassette T2 37.61.906” Cassette T2 37.61.917” cassette T2 37.64.848” cassette T2 37.64.858.25” cassette T2 37.64.86

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There are four such kits available:

For conversion proceed as follows:

Part numberConversion to 3.5” 36.39.32Conversion to 4” 36.39.33Conversion to 5” 36.39.34Conversion to 6” 36.39.35

saml04006a

� Open both clips.

saml10026a

Open the paper cassette.

A

A

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� 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”.

saml10027a

# 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 ( )

C��D 7��&��(��8#9��&��$��&��8%9��&�!��G

saml10030a

* Mount the new roller (�) and spac-ers ( ) to the guiding plates. Don’t forget the washer (%) and the springs (#).

C��D >��*Q��.��8'9�&��G

'A'

12

24

2

3

3

12

24 5

2

3

3

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, 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.

�/�#�% 1&��)��(��&��&��B��

The maintenance menu allows you to check the status of the sensors in the extractor.

� Select the menu:E�+�C�F�.�-;�C��;�.�-+�;+1:�.�1+��.��C�4;�

�/�#�' ;�� (��&��B��

� Remove the paper cassette.

Remove the front panel and the panel of the electronics.

# If installed, remove the backprinter from the paper deck.

saml10028a

" Fix both screws (+).

'A'

MAINT PRINTER PATRACK CASS SENSORS

Paperend No

Splice No

Loading mechanism: closed

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� Reinstall in reverse order.

" Adjust the paper position in the Y-axis if necessary as described in chapter 10.3.11

�/�#�* 1&��)��(��&��)��

The sensors and the function of the knife can be checked with the maintenance menu.

� Select the menuE�+�C�F�.�-;�C��;�.�-+�;+1:�.�1+��.�:C�>�

�/�#�� ;��(��&��$��)��

� Remove the extractor as described in chapter 10.3.5

* Reinstall the extractor.

saml10031a

% Remove screws (A) and (B).

' Carefully pull out the complete assembly.

* Disconnect the cables.

paperdeck

distributor

B

A

electronic

rack

MAINT PRINTER PATRACK CASS KNIFE

Knife left No

Knife right Yes

CUTLFT CUTRGHT

saml10032a Remove screw (+) and (7).

# Exchange the lower knife blade.

% Adjust the distances (L) and (I) to a parallelism of +/_0.2mm.

' Tighten both screws (+) and (7).

Knife blade

X Y

A B

SM

PAMID

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� Adjust the paper position in the Y-axis if necessary as described in chapter 10.3.11

�/�#�" ;��(��&��(�)��

� Remove the extractor as described in chapter 10.3.5

� Reassemble in reverse order.

" Reinstall the extractor

, Adjust the paper position in the Y-axis if necessary as described in chapter 10.3.11

saml10033a

Loosen screw (A) in the support of the sliding bar.

# Push or pull the sliding bar towards the stepper motor of the paper extractor.

saml10034a

% Push the axis in the rolling knife support towards the sliding bar.

saml10035a

' Pull down the axis with the knife on it.

saml10036a

* Replace the complete circular blade.

A

Pull

Push

Down

Old

New

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�/�#�, ;�� (��&��)

C��D C��5��&��)��(��&��$��&��G

�/�#��/ +�5��(��&��&��

��-4;�+C�G

C� �� &��&��$�G

saml10037a

� Loosen screw (+, 7, 1 and �)

Unplug the cables and remove the paper deck.

SMA

B

C

DSealed

Sealed

Sealed

Sealed

saml10038a � 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 roll-ers 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).

SM

A

B

C

X

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�/�#�� +�5��(��&��$��8I.�B��9�

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

� Initialize the machine.

Insert a paper cassette and lock it. Leave it locked during the whole adjust-ment procedure.

# Select the menu:E�+�C�F�.�-;�C��;�.��L-�I��.�>3@��.�14�4;�

% Press the key below �0;C until white light is on the paper deck.

' Activate the negative mask solenoid with the menu:E�+�C�F�.�-;�C��;�.�>��;+1:�.�+1�0+��.

* Press the key below 1�+�- to activate the solenoid.

� Now, position a print on the paper deck with the menu:E�+�C�F�.�-;�C��;�.�-+�;+1:�.��;+C�-�.�>��1@.

" 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.

SMPaper

b

b'

Y (sidewise)(sidewise)

Light-up area

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�/�#�� +�5��(��&��(��8L.�B��9

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.

saml10042a

, Remove both screws (+) and (7) of the extractor.

saml10041a

�/ 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.

paperdeck

electronic

rack

B

A

A/B

topview

4 mm

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saml10040a

� Initialize the machine.

Insert a paper cassette and lock it. Leave it locked during the whole adjust-ment procedure.

# Select the menu:E�+�C�F�.�-;�C��;�.��L-�I��.�>3@��.�14�4;�

% Press the key below �0;C until white light is on the paper deck.

' Activate the negative mask solenoid with the menu:E�+�C�F�.�-;�C��;�.�>��;+1:�.�+1�0+��.

* Press the key below 1�+�- to activate the solenoid.

� Now, position a print on the paper deck with the menu:E�+�C�F�.�-;�C��;�.�-+�;+1:�.��;+C�-�.�>��1@.

" 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 menuE�+�C��.�-;�C��;�.�-+�;+1:�.��C��.�+�60��.

�/ Press the key below +�60�� and enter the amount of millimeters the position should be adjustedThe adjustable range is +/- 10mm.

MAINT PRINTER PATRACK INIT ADJUST

Paper position [mm]

[-0.0]

ADJUST

Positive numbers --> the print moves forwardNegative numbers --> the print moves backward

SM

X (longitudinal)

a a'

Paper

Light-up area

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�� Confirm with E�C��;F.

� Check the overspill again

�# Repeat the adjustment procedure until the overspill is correct.

�/�#��# 1&��(��(��&��!��

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:E��F�.��I��.�4-��4C�.�-+�;+1:.

C��D �&��E��F��!��$��G

Press the key below the word specifying the kind of feeder you want.

# Initiate the paper track with the menu:E�+�C�F�.�-;�C��;�.�-+�;+1:�.��C��.�+��.

% Confirm with E�C��;F.

�/�#��% +�5��(��&��&��

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.

SET SYSTEM OPTION PATRACK

Kind of Paper_Track

STD 2-TRACK 2-TRACK-12”

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).

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saml10043a

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

�/�#��' 1&��)��(��&��

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:E�+�C�F�.�-;�C��;�.�-+�;+1:�.��L��.��C�

C��D �&��&��-+>� ��.��!��G

Left

Middle

GND

Right

Photopaper mask

Light barrier

PAFE

MAINT PRINTER PATRACK EXIT SENS

Print at feeder end: No

Print width > 4 Inch: No

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To check the sensors monitoring the end positions of the feeder enter the menu:E�+�C�F�.�-;�C��;�.�-+�;+1:�.��L��.�>��;

# To check the sensor press the key below �0;C-;4 and the feeder turn to the processor position and the sensors change their state.

% Press now the key below �0;C-;� and the feeder returns to the stan-dard position.

�/�#��* ��!�� (��&��

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

�/�#�� ;�� (��&��

� Switch OFF the printer.

Remove the front panel.

MAINT PRINTER PATRACK EXIT FEEDER

Feeder in Printerposition: Yes

Feeder in Processorposition: No

TURNPRI TURMPRO

saml10044a

Loosen screw (+) but don’t remove it fully.

# Lift up the lever mounted to the motor drive shaft.

% Turn the feeder.

Printerposition

A

PPposition

Feeder

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* Reassemble in reverse order.

�/�#��" 1&��)��(��&��

-�$��!

� 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

��&>): 3��4��1�-�

1&��)��(��&��(&��

� 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.

saml10047a

# Remove the knurled screws (+) and (7) of the distributor cover.

% Remove the nuts (�) till (>) of the distributor itself.

' Disconnect the cables.

C��D ��)��&��&��&��=��$�G

Paper deck

DistributorElectronic

rackC

F E

D

BA

Distributorcover

Cover plate

Adr.

DataMem.

CPU8031

+ 24V

Pwr.Gnd

+ 5V

Log.Gnd

Paper Width > 4"

Start Distributor

Distr. Active

Distr. Busy

Distr. Error

Reset Distr.

Distr. connected

LB End Track left

LB End Track right

LB CarriageHome Position

Conveyor Motor

Distributor Motor

Clutch right

Clutch left

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��&��&��)�

� Check the mechanical operation of all moving parts. Pay particular atten-tion 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

C��D C� �� (��&��$&��&��$��$&��(��G

saml10045a

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.

light barrier

3 +/- 0.3mm

Free wheel

Sleeve shaft

Captive nut

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�/�% ��&��

�� $��(�N -�(��&��

PBA Backprinter 1 36.04.38 ES 1

PBA Backprinter 1 36.04.38 AZ 1

PBA Backprinter 2 36.04.58 ES 1

PBA Backprinter 2 36.04.58 AZ 1 only

PBA Distributor, DIST 34.24.05 ES 1

PBA Distributor, DIST 34.24.05 AZ 1

PBA Papermag. Ident., PAMID 34.75.21 ES 1

PBA Papermag. Ident., PAMID 34.75.21 AZ 1

PBA Pap. sens. Feeder, PAFE 34.78.85 ES 1

PBA Pap. sens. Feeder, PAFE 34.78.85 AZ 1

PBA Pap. sens. Feeder 2, PAFE2 36.43.01 ES 1

PBA Pap. sens. Feeder 2, PAFE2 36.43.01 AZ 1

Lichtschranke FEEDER 2 kpl. 36.43.22 AZ 1

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>�� 11

�� 4 �� $��

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:

� Tank 1 = Developer� Tank 2 = Bleach� Tank 3 + 4 = Fixer� 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.

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saml04009a

1 Exhaust fan 2 Dryer3 Temperature sensor dryer 4 Dryer heating 220V / 700W5 Dryer fan 6 Squeegee roller7 Speedometer of transport motor 8 Transport motor9 Stabilizer 2 10 Stabilizer 111 Fixer 2 12 Fixer 113 Bleach 14 Developer15 Transport safety switch 16 Film collecting bin

��

1

3

2

4

6

5

7

8

9

15

16

1314 12 11 10

Transport system with short leader (leader card)Film loading unit with cassette for one trackTransport speed 478mm / min.Selectable temperature range 30.1 ... 50.0°C for the chemical liquids

40.1 ... 79.9°C for the dryerMeasurable temperature range 0.0 ... 102.3°CTemperature accuracy +/- 0.05°C in the range of 0 ... 50°C

+/- 0.10°C in the range of 50 ... 102.3°CSelectable transport speed 190 ... 200s developer timeSelectable replenishment rates developer 10 ... 100ml / m

bleach 1.0 ... 50ml / mfixer 10 ... 100ml / mstabilizer 10 ... 100ml / m

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Process specification for C-41 process:

�� @��(��!��

�� >��&��(��!��

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).

A�� 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.

C��D >�B��&��&��(��&��&��&�!�� &��&��&��.��!��&��&�&�(&��&��B��

The difference between the two heaters is visible at the lower end.

Each heating element has a built-in thermal-lag switch switching the power OFF at 50°C +/-5°C.

7��&��O��P

��OR1P

+��OR1P

;��O��#'��P��

1) Length of a 135-24 film is approx. 1.10m.

-��$O��P

��)� ��O�P

Developer 195 -1/+3 37.8 +/- 0.3 +/- 0.2 20.7 12 - 18.5 11.84Bleach 48 38 +/- 3.0 +/- 3.0 4.6 1.35 - 2 2.60Fixer 1 48 38 +/- 3.0 +/- 3.0 29.6 2 - 2.7 2.69Fixer 2 48 38 +/- 3.0 +/- 3.0 29.6 1.35 - 2 2.58Stabilizer 1 48 38 +/- 3.0 +/- 3.0 35.8 2.15 2.70Stabilizer 2 45 38 +/- 3.0 +/- 3.0 35.8 2.15 2.58Dryer 82 55 +/- 5.0 +/- 5.0 ---- ---- ----


Bottom of a heater made of titanium bottom of a heater made of stainless steel

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��

Each tank has a combined liquid level and temperature sensor.The temperature is not measured in every tank, only in:

� the developer� the bleach� the second fixer and� the last stabilizer.

saml11004a

saml11003a

1 Heating wire 360Ohm = 0.64A2 Sand3 Thermal-lag switch4 220V / 0.64A connection5 Ground connection

1

2

3

4 5

Heater / sensorsupport

Float

Circlip

Temperaturesensor

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The processor board MCB compares the measured values of the temperature sensors with the preset values and calculates the required heating.

The resistance of the temperature sensors is:� at 20°C: 1.97kOhm� at 35°C: 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 acti-vated. 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.

�� # ��!��

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 85°C.

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.

�� % @��(��(��

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.

saml11005a

1 Fan2 Heater3 Temperature sensor4 Dryer cover5 Exhaust fan

1

2

3

4

5

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The dryer is switched on after the temperatures in the different chemistry tanks are at the setup values.

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 phaseDefinition: (actual temperature) = (setup temperature) - (warm up trigger value)

2 Keep temperature phaseDefinition:(actual temperature = (setup temperature - Thermostat trigger value)

3 Cool down phaseDefinition:(actual temperature > (setup temperature)

The different triggers are defined as follows:

The heating power for each tank in the different phases is as follows:

��# ;��&��!��

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.

1&��!$��((��

�&��((��

��((��

Developer (setup) - 0.2°C (setup) - 0.1°C (setup) +/- 0.2°CBleach (setup) - 2.9°C (setup) - 1.5°C (setup) +/- 3.0°CFixer (setup) - 2.9°C (setup) - 1.5°C (setup) +/- 3.0°CStabilizer (setup) - 2.9°C (setup) - 1.5°C (setup) +/- 3.0°CDryer ----- (setup) - 0.5°C (setup) +/- 5.0°C

1&��!��B��&��(�

��$��$��&��

)��&��

1��$��&��

Developer 300W 300W 75W 0WBleach 150W 75W 19W 0WFixer 1 150W 75W 10W 0WFixer 2 150W 75W 75W 0WStabilizer 1 150W 75W 10W 0WStabilizer 2 150W 75W 75W 0WDryer 700W 0W 700W 0W

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saml11006a

��&&)& +��1 Replenishment pump assembly 2 Chemical filters (four)3 Film replenishment tanks 4 Film processing tanks5 Vacuum sensor 6 Microswitch

Each pump has a different flow rate per stroke and the tubes have different col-ors for clear identification. For the C-41 process the following is valid:

��#�� >��$��

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 Lab’s up to serial number 100749 the flow is checked in the stabilizer chemistry with a float.

F3

F4GND

230V~L1Phase

230V~L2Phase

L17: Developer, Bleach, Fixer andStabilizer replenishment pumps

220Vac

to heater

+5V

Input

IndicatorLED

Fuseresistor

Fuseresistor

Fuse F3: 4A fast blow (L2)Fuse F4: 4A fast blow (L1)

Drive circuit

M802

1

5

2

3

4

Dev.

Bleach

Fixer

Stabilizer

6

��) >��$��)� ��

Developer 2.45ml blueBleach 0.55ml redFixer 3.50ml greenStabilizer 4.25ml yellow

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In Master Lab+ from serial number 100750 the flow is checked in the developer chemistry with a vacuum sensor.

��#� ;��&��(��

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.

2 The pumps make 20 strokes in the commands:� maual replenishment and� test cycle.

3 During start-up, when the machine is switched ON by the keyboard E4CF 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.

��% ;��!��

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.

�� The bleach aeration pump adds air (oxygen) to the bleach chemistry to support the oxidation.

-�� The developer has an additional spray pump.

saml11007a 1 Bleach aeration pump2 Bleach recirculation pump3 Fixer 1 recirculation pump4 Fixer 2 recirculation pump5 Developer spray pump6 Developer recirculation pump7 Stabilizer 2 recirculation pump8 Stabilizer 1 recirculation pump

1

2 3 4

5 6 7 8

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The developer spray pump sprays chemistry directly to the film surface accord-ing to specifications of the film and chemistry manufacturer.

saml11009a

1 Recirculation pumps 2 Bleach aeration pump

The developer spray pump is working like the dryer fan:� during a work cycle the pump is ON� without a work cycle the pump is OFF

��%�� ;��(��

The pumps are enabled at the following conditions:

1 In the standby mode all pumps are OFF

2 In the warm up mode all pumps are ON.

3 In the normal mode are two conditions to be observed:� During a work cycle the pumps are ON� Without a work cycle the pumps are continousely switched ON for 10s

and switched OFF for 90s.

4 In the shutdown mode all pumps are OFF if any work cycle is finished.

saml11008a 1 Developer tank spray bar assem-bly

2 Recirculation and spray bar pump

3 Recirculation pump4 Chemical filter5 Developer overflow tank

1

2 3

5

4

F3

F4

230V~L1Phase

230V~L2Phase

L11: Bleach air pumpL12: Developer pumpL13: Bleach pumpL14: Fixer pumpL15: Stabilizer pump

220Vac

to heater

+5V

Input

IndicatorLED

Fuseresistor

Fuseresistor


Drive circuit

M802

GND

1

2

Dev. Bleach Fixer Stabilizer

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��' ��!��

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

1 Motor 2 Toothed belt3 Main shaft 4 Friction bearing5 Ball bearing 6 Worm gears for racks7 Worm gear for film loading station

��'�� -��

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.

4

67

1

234

566

saml11011a

1 Motor2 Light barrier on M806 board3 Slotted disk4 Toothed belt5 Main shaft

54

32

1

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7��)��(��saml13006a

��'� ��(�A��(

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

��* >��(��

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 bot-tom 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.

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 bar-riers 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 car-tridge. At the end of the film, the cartridge is pulled forward and touches a roll

MCBM803 (Paper)

or

M802 (Film)

M

slotted disk

light barrier

t = 0.8 ... 9.2ms

t = fix 10ms

24Vdc

0

t

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bar activating microswitch #1. This microswitch activates the knife solenoid and the film is cut.

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(61'7�&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 doesn’t hap-pen within two minutes, the knife tries it again for another 10 times. This proce-dure 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 Coupled rubber rollers2 Spring to eject loading cassette3 Knife4 Solenoid to release loading cassette5 Solenoid to activate the knife6 Manual film cutting lever7 Safety switch

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8 Microswitch #1, activates the knife9 Microswitch #2, cassette present, enables the knife solenoid10 PBA M805a board

��*�� "/'��

4 �� $

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.

The M805 board reads the film size in the film loading station. The board con-tains 4 optical infrared sensors (OP1 = track 1 to OP4 = track 4).

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.

saml11015a

11 Roll bar, activates microswitch #1

89

10

11

4-� 4- 4-# 4-% ��X X X 120 film, 220 film

X X 135 film, 126 filmX 110 film

X Leader card

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saml13020a

��&&)0 �;>8��

4��

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.

C�$� ��

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 sec-ond board, the M805B.

�� ;��)�

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.

135 / 126

120 / 220

110

16mm26.5mm17mm17mm

Track1

Track2

Track3

Leader

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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 neg-atives on it. Therefore never open the film processor while a film is processed!

All racks in the tanks are locked with a metal bracket and with plastic locker that fixes the racks to the heater cover.

saml11017a

The dryer rack is screwed to the back wall

saml11016a

1 Main gear2 Squeegee roller3 Upper roller4 Guides5 Plastic clip to fix the cross under6 Lower roller7 Cross under

1

22

3

44

55

6

7

Metal bracket

Plastic locker

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��" ;��5��

��"�� @��(��!��

��!��$��&��(��&��&��

Each heater in the film processor and the dryer can be switched ON or OFF.

� Use the menu:E�+�C�F�.�>�-;41�.��-�.�@�+��;

H��$��(��&��

� Enter the menu:E14��F�.�>�-;41�.��-��-

The following display shows the temperatures

C��D �&��!��&��!�$&��&��!��)��&� ��&��G

1&��)��(��(��&��)��

� Display the temperatures as told before.

3+;C�C2G

�$��&�4>>��&��&�� &��(��&��&��!G

COMM F.PROC DISPTMP

[°C] DEV BLEACH FIX STAB DRYER

Nom : 37.8 38.0 38.0 38.0 55.0

Act : 37.5 37.8 37.6 38.0 36.4

3+;C�C2G

3&�� !��&� ��&��&��!��$��&�(�� (�((��

C�(��(��&�� )��(��!��!��&��$��?��(��!��(&�G

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Wait until the nominal and the actual values on the display don’t vary any more than 0.2°C.

C��D ��=��&��)��&��!��G��&��!�$&��&��.��!��)��&� ��&��G

saml02036a # Remove the lid of the film processor.

C��D �&��.��!�$&�� &�� &��.��(�� .��!��G

saml11018a

% Disable the safety stop by turning the screw 90° counterclockwise (service position).

' Press E�C��;F 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.

3+;C�C2G

3&�� !��&��)�?� ��!��!��&��&��G�4�&��$��!��.��&��&��!��&��)��&�!��!�� .��$��G

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C��D �&��&��B��&��A��&��)��&��(��&�

�� In a consecutive way enter the menus:E�+�C�F�.�>�-;41�.��-�.�1+��-�.��HE�+�C�F�.�>�-;41�.��-�.�1+��-�.�7��+1@E�+�C�F�.�>�-;41�.��-�.�1+��-�.�>�LE�+�C�F�.�>�-;41�.��-�.�1+��-�.��+7to compare the measured values for every bath with the corresponding value in the menu.

� Correct any difference of more than 0.2°C by correcting the corresponding value in brackets with the measured value

�# Confirm with E�C��;F.

�% 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 0.2°C.

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).

�/ Write the measured value on a piece of paper.

MAINT F.PROC TMP CALTMP DEV

Actual Temperature [°C]

[37.8]

saml02039a

�* When the temperature measure-ment is finished, place the light shield back over the tanks.

�� Lower the cover of the film dryer.vvvvv

vvvvvvvvvvvv

vvvvvvvvvvv

vvvvvvvvvvv

vvvvvv vvvvv

vvvvvvvvvvv

vvvvvvvvvvvvvv

vvvvvvvvvvvvvvv vvvv

vv

vvvvvvvvvvvv

vvvvvvvvvvvv

vvvvvvvvv

vvvvvv vvvvvv

vvvvvvvvvvv

vvvvvvvvvvvvv

vvvvvvvvv

vvvvvv vvvvvvv

vvvvvvvvvvvv

vvvvvvvvvvv

vvvvvvvvvv

vvvvv vvvvvvv

vvvvvvvvvvvv

vvvvvvvvvvv

vvvvvvvvvv

vvvvv

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1��(��&��!��

C��D ��&��!��!��&��.��&��+��!��!��&��?��$G

saml02040a

�" Remount the lid of the film processor.

saml02036a

� Remove the lid of the film processor.

saml11019a

Lift the cover of the film dryer

saml11020a

# Place the sensor of your electronic thermometer close to the built-in sensor and secure it.

saml11021a

% Close the dryer cover.

Wire clamp

Temperaturesensor

Dryer rack

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* Make sure, the chemistry bathes are at the right temperature and in the film processor is a work cycle in progress otherwise the heater doesn’t heat up correctly to its nominal value.

� Enter the menu:E�+�C�F�.�>�-;41�.��-�.�1+��-�.��;I�;�

" Correct any difference of more than +/-5oC by correcting the corresponding value in brackets with the measured value

, Confirm with E�C��;F.

�/ Repeat the measuring sequence until the value is within the tolerance.

1&��(��(��&��(

To change the nominal values of the temperatures:

� Enter the menu:E��F�.�>�-;41�.��-

C��D �&��E��F��$�� G

Change the value in brackets of the desired chemistry to the new value.

# Confirm with E�C��;F.

1&��)��(��

� Remove the side panel of the film processor

saml02040a

' Remount the lid of the film processor.

MAINT F.PROC TEMP CALTMP DRYER

Actual Temperature [oC]

[56.3]

SET F.PROC TEMP

Temperature [°C]

[37.8] [38.0] [38.0] [38.0] [55.0]

DEV BLEACH FIX STAB DRYER

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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 .

C��D 7�� !��&��!��&��)��&��$��!��&��&��!��&��&��)?��)��(��.��G

�/ Remount the sensor in the tank.

�� After the check, connect the sensor again.

� Close the cover of the cable duct.

�# Close the side panel of thefilm processor.

saml11022a

' 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) is1.97kOhm at 20°C2.10kOhm at 35°C

* 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.


Float

Circlip

Temperaturesensor

blue

green

red

white

black

1

2

3

4

5

bluegreen

red

white

t

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saml11023a

;��(��

Temperature

Level

M802 MCB

HeaterON/OFF->

<-Leveldata

saml02036a


saml02037a


# Remove the light shield covering the tanks.

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� Remove the chemistry filters

saml14006a

% Remove the side panel of the film processor

' Remove the cover of the cable duct.

* Unplug the connector of the tem-perature / level sensor to be replaced.

3+;C�C2G

3&�� !��&� ��&��&��!��$��&�(�� (�((��

C�(��(��&�� )��(��!��!��&��$��?��(��!��(&�G

saml11024a

" Remove both screws of the heater / sensor cover and lift it off.

Cable duct

Screws

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�� 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.

��"� ;��&��!��

��!��$��&��(��&��&��

The replenishment pumps can be switched ON or OFF manually.

� Enter the menuE�+�C�F�.�>�-;41�.��J0��.�-0�-��.�;�-�

saml11004a

, Remove the sensor by pushing it toward the racks.

C��D 7�� !��&��!��&��)��&��$��!��&��&��!��&��&��)?��)��(��G

�/ Insert the new temperature / level sensor as shown.


Float

Circlip

Temperaturesensor

��-4;�+C�G

��=��&��&��(?�!��$�� .��&��&��&��$��(��&��!G

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1&��)��(��&��&��

% Select the menu:E14��F�.�>�-;41�.��+C;�-�

' Press the key below the word ��.

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 mes-sage is displayed and the test is stopped.

3+;C�C2G

3&�� !��&� ��&��&��!��$��&�(�� (�((��

C�(��(��&�� )��(��!��!��&��$��?��(��!��(&�G

saml02036a

� Remove the lid over the film pro-cessor.

saml02035a Fix a graduated plastic cylinder to each tank having a repleishment tube.

# Lift the replenishment tubes, turn them and place them into the cyl-inders.

��-4;�+C�G

+�$�!��&��(��!��&��)�� .��(��B��(��&��&��!G

COMM F.PROC MANREPL

Nominal Quantity per Test Cycle [ml]

41.4 9.2 59.2 71.6

DEV BLEACH FIX STAB TEST

100

90

80

70

60

50

100:1

in 20 °Cml

100

90

80

70

60

50

100:1

in 20 °Cml

100

90

80

70

60

50

100:1

in 20 °Cml

100

90

80

70

60

50

100:1

in 20 °Cml

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* 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.

C��D 7�� !��&��&��&��(&��)G�4�&��.$��!��&��&��!��&��&��)?��)��(��G

1&��(��(��&��&��&��(��&��

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:E��F�.�>�-;41�.�;�-;+��

Change the value for the developer (value in the brackets) to the desired rate. The values for bleach, fixer and stabilizer will be calculated automati-cally after confirming.


1&��(��(��&��&��)��!

If the replenishment rate for a particular tank has to be changed, the pump vol-ume per stroke of that pump requires manual adjustment.


� Set the replenishment rate for the particular tank with the menu:E�+�C�F�.�>�-;41�.��J0��.�1+�-0�-

Always confirm with E�C��;F.

C��D >�� &��<1&��(��(��&��&��&��(��&��=G�7��$��?��

SET F.PROC REPRATE

Replenishment Rate [ml/m]

[20.7] 4.6 29.6 35.8

DEV BLEACH FIX STAB

MAINT F.PROC LIQUID CALPUMP

48.8 10.8 69.6 80.4 [ml]

21.7 [4.8] [31.0] [35.8] [ml/m]

DEV BLEACH FIX STAB TEST

The selectable range is for: bleach 1 ... 50ml/mfixer 10 ... 100ml/mstabilizer 10 ... 100ml/m

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��&��&��!��&��$��&��&��5��(��G

# 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.


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 mes-sage is displayed and the test is stopped.

* If the delivered quantity deviates from the %B20,1$/�C8$17,7<�3(5��(67��<&/(', adjust the pump again and repeat the calibration.

;��(��$��&��&��

C��D �&��$��&��&��#%��&��$��&��&��&��Q��$��

This procedure may be necessary if you have a defective bellow.

� Switch OFF the machine with the main switch.

Remove the upper side panel of the film processor.

saml11025a

% 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.

% OF STROKE

0

25

50

75

100

1

2

3

saml11047a

# Remove both screws (+) holding the film replenishment pump assembly

A A

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% Carefully pull the assembly toward you until you have good access to the bellows.

' Remove both elbow connectors of the bellow to be replaced.

* Remove both valves

C��D ��=��&��(��)��84.��(�9G

saml11026a

1)The displacer is mounted in the 3/4inch bellow only with the red valve assem-bly. All other valves have a black valve assembly

" 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.

�� Fasten the bellow with both screws (7) to the pump.

3+;C�C2G

7��$��&��&��&��&��.��$��3&��!��&��B��?��&��$��$��.�&��&��&��!��&�� &� ��(��(��&��&��G

saml11048a

� Remove both screws (7) fixing the bellow to the pump.

Valve assembly(red = bleach)(black = dev., fix., stab.)

O-ring

Elbow connector

Connector nut

Displacer

Valve body

Elbowconnector O-ring

Valve assembly(red = bleach)(black = dev., fix., stab.)

1)

B

B

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� Insert both valves with the gaskets.

C��D ��)��!��&��&��$�!G

�# Remount both elbows.

�% Reinstall the complete assembly.

�' Verify the proper function and adjsutment as described in chapter ��4��, Page 255

��"�# ��!��

��!��$��&��(��&��

The motor can manually be switched ON and OFF if no work cycle is in progress. Otherwise the command is ignored.

� Select the menuE�+�C�F�.�>�-;41�.��;+C�-�.�>��.��4�4;

1&��)��(��&��&��

The transport motor is located under the dryer and to get access, you must remove the dryer rack first.

saml02036a


saml11019a


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" Reassemble in reverse order.

;�� (��&��&��

� 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

saml11027a

# Remove the temperature sensor from the wire clamp.

% Loosen both fixing screws.

' Remove the dryer rack by moving it upward.

saml04011a

* 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 shaft2 = Toothed belt3 = Mounting screw4 = Motor

Fixing screws rack

Wire clamp

Temperature sensor

Dryer rack

5 N

5mm

1

2

3

4

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saml11030a

' 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).

, Pull out the main shaft from the front of the 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.

saml11031a

" Remove the safety clips of the 8 worm gears driving the racks.

1 2 1 3 1 5

4

Worm gear(front view)

Groove(1 of 3)

Safety clip

��-4;�+C�G

�&��$��(��&��!G��&��$��(��=��!��(��$��!��G

saml11032a' Make sure that on all worm gears

the grooves with the hole for the safety clip are aligned.

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� 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.

1&��(��(��&��

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.

C��D >�� !��&�� &�� .��G��&��&��&��&��!��1.%��G

For what ever reason it is necessary to change the speed do:

� Select the menu:E�+�C�F�.�>�-;41�.��I��.��H��

Press the key below the bracketed value and enter the new transport speed.


��"�% >��(��

;�� (��&��(��

� Remove the front panel and the cover of the printer electronics.

saml11031a

* Secure the worm gears with the safety clip.


Groove(1 of 3)

Safety clip

MAINT F.PROC SYSTEM DEVTIME

Developer time [s]

[195]

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Unplug the connectors of the film loading station for:� the knife solenoid� the cassette locking solenoid� the sensor board� the two micro-switches

' Remount in reverse order.

;��(��&��)��

� Remove the film loading station as already described.

saml11033a

# Remove both mounting screws at the top front of the film loading sta-tion.

% Remove the film loading station.

saml11034a

Remove the screws 8+9.

# Remove the knife support.

1+0��4CG

7�� !��$&��&��(��&��)��?�� !��&��G

I��!��!��(��G

A

� � � � � � � � � � � � �

� � � � � � �

� � � � � � � �

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" Reassemble in reverse order.

;��(��&��

� Remove the film loading station as described

saml11037a

Remove the twelve (12) screws marked (L) to open the film loading station and access the rollers.

# Reassemble in reverse order.

;��(��&��

C��D �&��"/'��"/'��!G

� Remove the film loading station as described.

saml11035a 1 Knife blade2 Circlip and bushing3 Knife pressure spring4 Knife support5 Knife solenoid6 Manual film cutting lever

% Carefully remove the circlips and the bushings (2).

' Remove the springs (3).

* Carefully remove the knife support assembly(4)

saml11036a

� When inserting the new knife sup-port assembly ensure that the blade is positioned right as shown!

2

C A U T I O N

S H A R P

B L A D E

1

3

4

5

6

Film transport

Knifeblade

XX X

XX X

X X

X X X

X

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saml13020b

The different film sizes are detected as follows:

saml11038a

Remove the four screws marked (I) to access the sensor board M805a.

# Proceed the same way on the lower side to access the M805b.

saml11039a These two boards in the film loading station read the film size in the loading station and detect the film length.

saml1140a There are four transmitters (M805a) and sensors (M805b) on the boardsOP1 = track 1 (transmissive sensor)OP2 = track 2 (transmissive sensor)OP3 = track 3 (transmissive sensor)OP4 = track 4 (reflective sensor)

OP4 detects the leader cardOP3 detects 110 filmOP2 + OP3 detects 126 and 135 filmOP1 + OP2 + OP3 detects 120 and 220 film

M805

Y Y

Sensorboard

Film

M805A

OP4

OP1 OP2 OP3

M805B

OP4

OP3110

OP2135 / 126

OP1120 / 220

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saml11041a

��"�' ;��)�

;��)��&��

M805A

M805B

M802

1+0��4CG

��=��$��&�4C��&��&��(��&��)��.�� &��&��.��)G

�&��.��!��&��)��$��&�$��&��&��!�$��G

saml02036a


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� Reinsert a rack in the reverse order.

��!��)

saml02037a



H�;I��-4;�+C�G

7�� !��$&��)��(��&��)��&��!��=��.��&��&��&��!�$��&��&��G�4�&��$��&��&��.��!��!��G

saml11017a

% Remove the three screws holding the metal bracket.

' Remove the metal bracket.

* Press the plastic locker and care-fully lift the rack out of the tank.

Metal bracket

Plastic locker

saml02036a


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� Reinsert in reverse order.

4��(��)

C��D �&��$��(��!�C4��.��&��3��B�&��(�� )��&�� !��)��(��&��&��(��$&��&��)�&��G

The following procedure is described at the example of the bleach rack.

� Before you disassemble the rack, clean it thoroughly with water.

saml02037a



saml11027a

% Take the temperature sensor out of the wire clamp.

' Remove both screws at the top of the rack.

* Lift out the rack.

Fixing screws rack

Wire clamp

Temperature sensor

Dryer rack

saml11042a

Remove both circlips on each axle of the gears.

# Remove the screw at the plastic locker.

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" 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

;��(��)

� 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.

saml11043a% 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.

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+��(��(��&��(��

C��D +��(��(��&��(��&�� !��)�&��$&��(��$&��&��&�� !��)��&��$��&��!��)G

# 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:� TRI-FLOW for racks in the tanks� pure silicon oil for the dryer rack

' Insert a leader card and manually transport it forward and backward by turning the main gear. Ensure the leader card doesn’t jam or catch any-where 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.

C��D �&��!�$&�� &�� &��(��<��+��>��-��=��.��!��G

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.

C��D �&��)��(�� .��(��&��)��&��$�!G��&��)��&��(��=��.��G

Satellite gear

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� Feed a leader card only through the film processor to check the film trans-port.

�# If the transport works ok, close all the covers removed.

saml11018a

�/ Disable the safety stop by turning the screw 90° counterclockwise (service position).

�� Press E�C��;F to clear the error. If a work cycle was in progress, the transport starts again.

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��, ��&��

�� $��(�N -�(��&��

Scheda M805A (circuit diagram) 17322.017.2 1

Scheda M805A (layout drawing) 15333.082.4 1

Scheda M805B (circuit diagram) 17322.018.0 1

Scheda M805B (layout drawing) 15333.083.1 1

Scheda M806 (circuit diagram) 17333.085.1 1

Scheda M806 (layout drawing) 15333.077.1 1

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-��+�� 12

� �� 4 �� $��

Following the exposure in the printer, the prints are fed to the paper processor. The paper processor has five tanks:

� the first tank is for the developer

� the second tank is for the bleachfix

� the remaining three tanks are for the stabilizer.

�� 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 tempera-ture. 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.

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saml12001a

1 Dryer 2 Temperature sensor of dryer3 Dryer heating 1 (230V / 450W) 4 Dryer fan 15 Dryer heating 2 (230V / 450W) 6 Dryer fan 27 Speedometer of transport motor 8 Transport motor9 Stabilizer tank 3 10 Stabilizer tank 211 Stabilizer tank 1 12 Bleachfix tank13 Developer tank 14 Transport switch15 Print collector 16 Water tank (auto top-off system)

� ��

1

2

3

4

5

6

7

8

9 10 11 12 13

14

15

16

Transport system single sheet with rollersMinimal format 9 x 9cm (3.5” x 3.5”)Maximal format 21 x 30.5cm (8.25” x 12”)Transport speed 635mm / min.

Selectable temperature range 30.1 ... 50.0oC for the chemistry40.1 ... 79.9oC for the dryer

Measurable temperature range 0.0 ... 102.3oCTemperature accuracy +/- 0.05oC in the range of 0 ... 50oC

+/- 0.10oC in the range of 50 ... 102.3oC

Selectable transport speed 40 ... 50s developer time

Selectable replenishment rates developer 70 ... 290ml / m2

bleachfix 100 ... 300ml / m2

stabilizer 100 ... 700ml / m2

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The following two tables give specific process data for two types of processes:� table 1 for RA-4 and� table 2 for Prime

Values for RA-4

Values for Prime

and the corresponding replenishment tanks are:

saml12002a

7��&��O��P

��Oo1P

+��Oo1P

;��O��2P

-��$�O��P

��)�O�P

Developer 45 -1/+3 35 +/-0.3 +/- 0.3 162 2.4 - 3.6 5.49Bleachfix 45 35 +/-3.0 +/- 3.0 214 2.4 - 3.6 5.59Stabilizer 1 35 35 +/-3.0 +/- 3.0 360 2.5 - 3.7 4.47Stabilizer 2 35 35 +/-3.0 +/- 3.0 360 2.5 - 3.7 4.38Stabilizer 3 35 35 +/-3.0 +/- 3.0 360 2.5 - 3.7 4.38Dryer 74 60 +/-5.0 +/- 5.0 --- --- ---

7��&��O��P

��Oo1P

+��Oo1P

;��O��2P

-��$�O��P

��)�O�P

Developer 45 -1/+3 38 +/-0.15 +/- 0.3 162 2.4 - 3.6 5.49Bleachfix 45 35 +/-3.0 +/- 3.0 108 2.4 - 3.6 5.59Stabilizer 1 35 35 +/-3.0 +/- 3.0 360 2.5 - 3.7 4.47Stabilizer 2 35 35 +/-3.0 +/- 3.0 360 2.5 - 3.7 4.38Stabilizer 3 35 35 +/-3.0 +/- 3.0 360 2.5 - 3.7 4.38Dryer 74 60 +/-5.0 +/- 5.0 --- --- ---

1&��! -��O��P ;+.%�O��P

Developer 4.5 3.4Bleachfix 3.0 4.4Stabilizer 10.0 7.4

200mm 122mm 90mm

110mm

110mm

250mm 80mm 120mm

RA-4

Prime

Stabilizer Bleach Developer

Stabilizer Bleach Developer

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� � @��(��!��

� � �� -��&��(��!��

A�� Each tank has a heating element made of stainless steel AISI. The heating ele-ment 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 50°C +/-5°C.

� � � ��

Each tank has a combined liquid level and temperature sensor, but the temper-atures are measured in three tanks only:

� the developer tank� the bleachfix tank and � the last stabilizer tank.

saml12004a

saml12003a

1 Heating wire 360kOhm2 Sand3 Thermal-lag switch

1

2

3

Ground

220VAC


Float

Circlip

Temperaturesensor

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The processor board MCB compares the measured values of the temperature sensors with the preset values and calculates the required heating.

The resistance of the temperature sensors is at:� 20°C = 1.97kOhm� 35°C = 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.

� � �# ��!��

The heater in the dryer section consists of two fans with directly mounted heat-ers. Each heater has a power of 450W at 220V. A built-in protective bimetal thermal switch cuts OFF the power if the temperature exceeds 85°C.

.

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.

� � �% @��(��(��

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.

saml12005a

1 Dryer cover2 Temperature sensor3 Heater 14 Fan 15 Heater 26 Fan 2

1

2

3

4

5

6

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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).

2 Keep temperature phase:Definition: (actual temperature) = (setup temperature) - (thermostat trigger value).

3 Cool down phase:Definition: (actual temperature) > (setup temperature)

The different triggers are defined as follows:

The heating power for each tank in the different phases is as follows;

� �# ;��&��!��

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 con-trolled 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 replenish-ment 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.

7��& 3�� &�� +��

Developer (setup) - 0.2oC (setup) - 0.15oC (setup) +/- 0.3oCBleachfix (setup) - 1.9oC (setup) - 1.0oC (setup) +/- 3.0oCStabilizer (setup) - 2.9oC (setup) - 1.5oC (setup) +/- 3.0oCDryer ---- (setup) - 0.5oC (setup) +/- 5.0oC

7��&��B��&��(�

��$��3��&��

:��&��

��$��&��

Developer 150W 112W 75W 0WBleachfix 150W 112W 84W 0WStabilizer 1 150W 84W 19W 0WStabilizer 2 150W 84W 19W 0WStabilizer 3 150W 84W 84W 0WDryer 1 450W 0W 450W 0WDryer 2 450W 0W 450W 0W

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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 devel-oper is monitored.

saml12006a

1 Replenishment pump assembly 2 Chemical filters (three)3 Paper replenishment tanks 4 Working tanks5 Vacuum sensors 6 Microswitch

� �#�� >��$��

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 Lab’s (up to serial number 100749) the level is checked in the stabi-lizer 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.

7��&>��$��)�

��RA-4 Prime

Developer 1.90ml 1.90ml blueBleachfix 2.55ml 1.28ml redstabilizer 4.25ml 4.25ml yellow

GND

230V~L1Phase

230V~L2Phase

L14: Developer, Bleach andStabilizer replenishment pumps


1

5

2

3

4

Dev.

Bleach

Stabilizer

6

F4

F3M803

Drive circuit 220Vac

to heater

+5V

Input

IndicatorLED

Fuseresistor

Fuseresistor

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The Master Lab 120, 140, 220 and 240 have no vacuum sensor. Every replen-ishment 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)

� �#� ;��&��(��

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 en-tered.

2 The pumps make 20 strokes in the commands:� manual replenishment and� test cycle.

3 During start-up, when the machine is switched ON by the keyboard E4CF 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 re-plenisher again.

� �% ;��!��

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.

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.

saml12007a

1 Stabilizer 3 recirculation pump2 Stabilizer 2 recirculation pump3 Stabilizer 1 recirculation pump4 Bleachfix recirculation pump5 Developer recirculation pump

1 2 3 4 5

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saml12009a

� �%�� ;��(��

The pumps are enabled at the following conditions:

1 In the standby mode all pumps are OFF.

2 In the warm-up mode all pumps are ON

3 In the normal mode are two conditions to be observed:� During a work cycle the pumps are ON.� Without a work cycle the pumps are continuously switched ON for 10s

and switched OFF for 90s

4 In the shutdown mode all pumps are OFF if any work cycle is finished.

saml12008a

1 Recirculation pumps2 Chemical filters3 Developer overflow tank

2

3

1

L9: Developer pumpL10: Bleach pumpL11: Stabilizer 1-2-3 pump

GND

DeveloperBleachfixStabilizer 1

230V~L1Phase

230V~L2Phase


F4

F3M803

220Vac

to heater

+5V

Input

IndicatorLED

Fuseresistor

Fuseresistor

Drive circuit

Stabilizer 2Stabilizer 3

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� �' +��.��!��

��)�� The automatic top-off system reduces the work load of the operator by automat-ically refilling the tanks with water to compensate for evaporated water. It there-fore reduces the risk of chemistry overconcentration. It also cleans the film squeegee rollers.

saml12010a

All the automatic top-off functions are controlled by the ALMLPLUS board.

saml13016a

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-

ATS

On/Off buttongreen lamp

red lamp

ALMLPLUS Board

Power supply 220VAC

MCBBoard

Tank sensor

Replenishmentconsol

J85

J84

J75

J89

J90

J87J86

J88

J76

J94

J93

SW1 SW2 SW3

0

4

8

C

0

4

8

C

0

4

8

C

ATS

Power supply 24VDC

PumpElectrovalves

Output(not used)

Input(not used)

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vates the pump and the electro valves for the quantities set with the rotary switches SW2 and SW3.

The replenishment console interface is a completely independent section on the board and acts as a level sensor interface.

� �'�� +��.��(��

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 nomi-nal quantity may be adjusted by switch SW2 from 20% to 320%.

2 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%.

3 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 sys-tem with the switch. If the alarm condition does not disappear after 5 min-utes, the Printer displays the message %�2:�/(9(/�$/$50’.

� �'� 3��!

Default values for each tank

��) �� &��.��&��8�3 ��//S9

� ��&��8�3#��//S9

Developer 117 57 23Bleachfix 117 27 12Stabilizer 1 82 40 17Stabilizer 2 82 37 17Stabilizer 3 90 45 25

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The water quantity is adjustable with selector SW2 and SW3

� �* ��!��

The transport system is driven by a 24Vdc motor with speed control and regu-lation 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 Motor 2 Toothed belt3 Main shaft 4 Friction bearing5 Ball bearing 6 Worm gears driving the racks7 Worm gear driving the distributor / conveyer

-��.��&��8�$��&��3 9

� ��&��8�$��&��3#9

0 20% 20%1 40% 40%2 60% 60%3 80% 80%4 100% 100%5 120% 120%6 140% 140%7 160% 160%8 180% 180%9 200% 200%A 220% 220%B 240% 240%C 260% 260%D 280% 280%E 300% 300%F 320% 320%

4

6 7

1

2 3 4

5 66

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� �*�� -��

-�� A slotted disk is mounted to the shaft of the motor. While turning, this disk inter-rupts 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 direc-tion of the difference

7��)��(��saml13006a

� �*� ��(�A��(

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

saml12012a

1 Motor2 Light barrier on M806 board3 Slotted disk4 Toothed belt5 Main shaft

54

3 2

1

MCBM803 (Paper)

or

M802 (Film)

M

slotted disk

light barrier

t = 0.8 ... 9.2ms

t = fix 10ms

24Vdc

0

t

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� �� ;��)�

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:

� a rack type for developer and bleachfix� a rack type for stabilizer 1 and 2� a rack type for stabilizer 3� a rack type for the dryer.

Every rack has several rollers driven by gears. The prints are transported between the rollers.

All racks in the tanks are locked with a metal bracket and two screws (+). The dryer rack is screwed to the rear wall.

saml12014a

The crossover assembly is mounted on top of the racks and fixed with two plas-tic screws.

saml12013a

1 Upper squeegee roller2 Lower squeegee roller3 Rollers (pressed against the

upper roller)4 Lower roller5 Crossunder

1

2

3

4

5

metal bracket Screws A

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saml12015a

� �" ��

-�� 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 posi-tions of the sorter arm are monitored by light barriers.

� �, ;��5��

� �,�� @��(��!��

��!��$��&��(��&��&��

Each heater in the paper processor and the dryer can be switched ON or OFF.

saml12016a

1 Switch for big prints2 Sorter arm3 Motor4 Pulley

saml12017a 5 SQ5 = Sorter in right position (home)

6 SQ6 = Sorter position for large prints (not in Master Lab+)

7 SQ7 = Sorter in final position8 SQ8 = Sorter in left position (order

separation)

1234

5 7 86

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� For the various heaters use the menu:E�+�C�F�.�-�-;41�.��-�.�@�+��;�.��HE�+�C�F�.�-�-;41�.��-�.�@�+��;�.�7��+1@E�+�C�F�.�-�-;41�.��-�.�@�+��;�.��+7�E�+�C�F�.�-�-;41�.��-�.�@�+��;�.��+7 E�+�C�F�.�-�-;41�.��-�.�@�+��;�.��+7#E�+�C�F�.�-�-;41�.��-�.�@�+��;�.��;I�;

C��D ��&��&��&��!��(��$��)��!��(��G

H��$��(��&��

� Enter the menu:E14��F�.�-�-;41�.��-��-

The following display shows the temperatures

C��D �&��!��&��!�$&��$��)��!��(��

1&��)��(��(��&��)��

� Display the temperatures as told before.

Wait until the nominal and the actual values on the display don’t vary more than 0.2°C.

3+;C�C2G

�$��&�4>>��&��&�� &��(��&��&��!G

COMM P.PROC DISPTMP

[°C] DEV. BLEACH STAB DRYER

Nom : 35.0 35.0 35.0 60.0

Act : 35.0 34.9 35.1 36.4

3+;C�C2G

3&�� !��&� ��&��&��!��$��&�(�� (�((��

C�(��(��&�� )��(��!��!��&��$��?��(��!��(&�G

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C��D ��=��&��)��&��!��?��&��!��&��!�$&��$��)��!��4�&��$��&��&��!��.&��%/o1

saml02042a # Remove the lid of the paper pro-cessor.

C��D 3&�� &��.�� &��!��&��(��5$163257$/$50,1�$3(5�52&(6625��.��&��!�

saml12018a

% Disable the safety stop by turning the screw in the dryer 90o counter-clockwise (service position).

' Press E�C��;F to clear the error. If a work cycle was in pro-cess, the transport starts again.

saml02043a

* Lift the cover of the paper dryer.

saml02044a

� Turn the two fasteners on the crossover and remove it.

saml02045a

" Unlock the lower part of the paper dryer and tip it up.

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C��D �&��&��A.��A��)�#��&��)�� G

� In a consecutive way enter the menus:E�+�C�F�.�-�-;41�.��-�.�1+��-�.��HE�+�C�F�.�-�-;41�.��-�.�1+��-�.�7��+1@E�+�C�F�.�-�-;41�.��-�.�1+��-�.��+7to compare the measured values for every bath with the corresponding val-ues in the menu.

�# Correct any difference of more than 0.2°C by correcting the corresponding value in brackets with the measured value.

�% Confirm with E�C��;F.

�' Wait a few minutes to allow the bath to adapt the temperature

�* Repeat the whole procedure again until the difference is less than 0.2°C between the measured and the displayed values.

3+;C�C2G

3&�� !��&��)�?� ��!��!��&��&��G�4�&��$��!��.��&��&��!��&��)��&�!��!�� .��$��G

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).

�� Write the measured value on a piece of paper.

MAINT P.PROC TEMP CALTMP DEV


[34.9]

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1��(��&��!��

C��D ��&��!��!��&��.��&��+��!��!��&��?��$G

� 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.

saml02047a

�� 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 proces-sor.

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% 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 +/-5°C select the menu:E�+�C�F�.�-�-;41�.��-�.�1+��-�.��;I�;

" Correct any difference of more than +/-5°C by correcting the corresponding value in brackets with the measured value.

, Confirm with E�C��;F.

�/ Repeat the measuring sequence until the value is within the tolerance.

1&��(��(��&��(��&��

To change the nominal value of the temperature proceed as follows:

� Select the menu:E��F�.�-�-;41�.��-

C��D �&��E��F��$�� G

Change the value in brackets of the desired chemistry to the new value.


1&��)��(��

� 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.

MAINT P.PROC TEMP CALTMP DRYER


[58.3]

SET P.PROC TEMP

Temperature [°C]

[35.0] [35.0] [35.0] [60.0]

DEV BLEACH STAB DRYER

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% Take the sensor out of the tank as described in chapter ‘Replacing the tem-perature / level sensor, page 294’.

C��D 7�� !��&��!��&��)��&��$��!��&��&��!��&��&��)?��)��(��.��G

�� Remount the sensor in the tank.

� After the check, connect the sensor again.

�# Close the cover of the cable duct.

�% Close the side panel of the paper processor.

saml12019a

' Connect an Ohm-Meter to pin 3 and pin 4 (red and white wire) to check the temperature sensor.

* Measure the resistance of the sen-sor (type Siemens KTY). It should readat 20°C: 1.97kOhmat 35°C: 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 posi-tion.

�/ The reed contact has to be open when the float is moved to the upper position.


Float

Circlip

Temperaturesensor

blue

green

red

white

black

1

2

3

4

5

bluegreen

red

white

t

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;��(��&��

� 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.

* Remove the chemistry filters.

Temperature

MCB

<- Heater ON/OFF

Level data ->

M803

Level

3+;C�C2G

3&�� !��&� ��&��&��!��$��&�(�� (�((��

C�(��(��&�� )��(��!��!��&��$��?��(��!��(&�G

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�� Reassemble in reverse order.

� �,� ;��&��!��

��!��$��&��(��&��&��

The replenishment pumps can be switched ON and OFF manually.

� Enter the menu:E�+�C�F�.�-�-;41�.��J0��.�-0�-��.�;�-�

saml12021a

� Remove both screws 8+9 of the heater / sensor cover

" Remove the cover 879.

saml12004a

, Remove the sensor by pushing it toward the racks.

C��D 7�� !��&��!��&��)��&��$��!��&��&��!��&��&��)?��)��(��G

�/ Insert the new sensor as shown.

Screws A B


Float

Circlip

Temperaturesensor

��-4;�+C�G

��=��&��&��(?�!��$�� .��&��&��&��$��(��&��!G

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1&��)��(��&��&��

� Remove the lid over the paper processor.

% Select the menuE14��F�.�-�-;41�.��+C;�-�


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 mes-sage 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.

3+;C�C2G

3&�� !��&� ��&��&��!��$��&�(�� (�((��

C�(��(��&�� )��(��!��!��&��$��?��(��!��(&�G

saml02041a

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.

��-4;�+C�G

+�$�!��&��(��!��&��)�� .��&��)��G

COMM P.PROC MANREPL

Nominal Quantity per Test Cycle [ml]

38.2 50.4 84.8

DEV BLEACH STAB TEST

100

90

80

70

60

50

40

30

20

10

100:1

in 20 °Cml

100

90

80

70

60

50

40

30

20

10

100:1

in 20 °Cml

100

90

80

70

60

50

40

30

20

10

100:1

in 20 °Cml

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C��D 7��&��&��)��&��(&��)G�4�&��$��!��&��&��!��&��&��)?��)��(��G

1&��(��(��&��&��(��&��(��&��

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:E��F�.�-�-;41�.�;�-;+��

Change the value for the developer (value in brackets) to the desired rate.The values for bleachfix and stabilizer are calculated automatically after confirming.


1&��(��(��&��&��(��)��!

If the replenishment rate for a particular tank has to be changed, the pump vol-ume per stroke of that pump requires manual adjustment.


� Set the replenishment rate for the particular tank with the menu:E�+�C�F�.�-�-;41�.��J0��.�1+�-0�-

Always confirm with E�C��;F.

C��D >�� &��<1&��(��(��&��&��&��(��&��=G�7��$��?��&��&��!��&��$��&��&��5��(��G

# Calculate the difference between the old and the new value in %.

SET P.PROC REPRATE

Replenishment Rate [ml/m2]

[162] 215 360

DEV BLEACH STAB

MAINT P.PROC LIQUID CALPUMP

38.2 50.4 84.8 [ml]

162 [215] [360] [ml/m2]

DEV BLEACH STAB TEST

The selectable range is: for bleachfix 100 ... 300ml/m2

for stabilizer 100 ... 700ml/m2

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Now, the calculated deviation has to be adjusted mechanically at the particular replenishment pump.


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 mes-sage is displayed and the test stops.

* If the delivered quantity deviates from the %B20,1$/�C8$17,7<�3(5��(67��<&/(', adjust the pump again and repeat the calibration.

;��(��$��&��&��

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.

% Carefully pull the assembly toward you until you have good access to the bellows.

saml11025a

% Adjust the screw to the desired replenisher rate.Turn the screw 8�9 cw to increase or ccw to decrease the rate.The stroke indicator 8 9 and the stroke scale 8#9 guide you in the right way.

% OF STROKE

0

25

50

75

100

1

2

3

saml12022a

# Remove both screws 8+9 holding the paper replenishment pump assembly.

A A

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' Remove both elbow connectors of the bellow to be replaced.

" 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.

�� Screw the new bellow clockwise to the old connecting rod.

� Fasten the bellow with both screws (7) to the pump.

3+;C�C2G

7��$��&��&��&��&��.��$��3&��!��&��B��&��$��$��&��&��&��!��&��G�� )��(��(��&G

saml12023a

* Remove both valves

C��D ��=��&��(��)��84.��(�9G

saml12024a

� Remove both screws (7) fixing the bellow to the pump.

B

B

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�% Remount both elbow connectors.

�' Reinstall the complete assembly.

�* Verify the proper function and adjustment as described in chapter 12.9.2

� �,�# ��!��

��!��$��&��(��&��

The motor can manually be switched ON or OFF if no work cycle is in progress. Otherwise the command is ignored.

� Select the menuE�+�C�F�.�-�-;41�.��;+C�-�.�-+-�;�.��4�4;

1&��)��(��5��(��&��&��

� Remove the lid of the paper processor.

saml12025a

�# Insert both valves together with the gaskets.

C��D ��)��!��&�$�G

saml12026a

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 (7).

A B

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The transport motor is located below the dryer.

;�� (��&��&��

� 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

1 Set screw M4 x 10 2 Pulley3 Bearing 4 Main shaft5 Worm gear 6 Worm gear driving the distributor/

conveyer.

' Loosen the set screw (item 1) of the pulley at the end of the shaft.

* Remove the pulley (item 2).

saml04017a

' The correct belt tension gives a displacement of less than 5mm with a force of 5N (500gr).

saml11029a

* If necessary, adjust the belt ten-sion by loosening the four screws (item 3) and moving the motor in the indicated direction.1 = Main shaft2 = Toothed belt3 = Mounting screw4 = Motor

5 N

5mm

1

2

3

4

1

2

3 54 3 3 6

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� Loosen the screws holding the three bearings (item 3) of the main shaft (item 4).

, Pull out the main shaft from the front of the Master Lab+

��(��(��(��&��&��

C��D 4��&��?��&��$��(��&��.��=��!��(��

� 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.

* 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.

1&��(��(��&��

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:

saml11031a

" Remove the safety clips of the six worm gears driving the racks.


Groove(1 of 3)

Safety clip

saml11031a

' Secure the worm gears with the safety clips.


Groove(1 of 3)

Safety clip

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� Select the menu:E�+�C�F�.�-�-;41�.��I��.��H��

Press the key below the value in brackets and enter the new transport speed.


C��D >�� &�� &��&��!��;+.%��G

� �,�% ;��)�

;��)��&��

MAINT P.PROC SYSTEM DEVTIM

Developer time [s]

[45]

1+0��4CG

��=��$��&�4C��&��&��(��&��)��.�� &��&��.��)G

�&��.��!��&��)��$��&�$��&��&��!�$��G

saml02042a

� Remove the lid of the paper pro-cessor.

saml02043a

Lift the cover of the dryer.

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� Carefully lift the rack out of the tank.

" Reinsert the rack in reverse order.

��!��)

saml02044a

# Turn both fasteners on the cross-over 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.

saml12014a

' Remove both screws (+) holding the metal bracket.

* Remove the metal bracket.

H�;I��-4;�+C�G

7�� !��$&��)��(��&��)��&��!��=��.��&��&��&��!�$��&��&��G�4�&��$��&��&��.��!��!��G

metal bracket Screws A

saml02042a

� Remove the lid of the paper pro-cessor.

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� Reinsert in reverse order.

4��(��)

C��D �&��$��(��!�C4��.��&��3��B�&��(�� )��&�� !��)��(��&��&��(��$&��&��)�&��G

The following procedure is described at the example of the stabilizer rack.

saml02043a

Lift the cover of the dryer.

saml02044a

# Turn both fasteners on the cross-over 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 (7).

A B

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� Before you disassemble the rack, clean it thoroughly with water.

% 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.

;��(��&��)

� Place all rollers into the correct position of one side wall.

% Reinsert the axle and secure the main gear with the circlip.

C��D �&��(��!��&��)��&��.��G

' Manually turn the main gear to check if all rollers turn smoothly in both directions. If necessary lubricate the bearings with:� TRI-FLOW for the racks in the tanks� pure silicon oil for the dryer rack.

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.

1

saml12030a

Mount the other side (#) of the rack.

# Remount the bracket (�).

C��D ��)��&��&��8%9��G

1

2

3

44

1 Bracket

2 Main gear

3 Side of the rack

4 Clips

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* Insert a print by manually turning the main gear and check for correct trans-port of the print.

� Carefully reinsert the rack in the tank.

" Secure the rack with the metal bracket.

, Remount the crossover and the dryer.

�/ Start the machine to check the paper transport.

C��D �&��!�$&�� &�� &��(��<��+��-��=��!��G

� �,�' ��

1&��)��(��&��

� Open the cover of the paper dryer.

Remove the cover under the sorter.

saml12018a

�� Disable the safety stop by turning the screw 90° counterclockwise (service position).

� Press E�C��;F to clear the error. If a work cycle was in progress, the transport starts again.

saml04018a

# The correct tension gives a dis-placement of less than 8mm under a force of 2.5N (250gr).

2.5 N

8mm

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�� $��(�N -�(��&��



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3��!�� 13

�#�� 4 �� $

The film and paper processor are controlled by the same CPU board. Each pro-cessor has its own driver board for pumps, heaters and so on. The film proces-sor 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

��&()& .��4��* The optional console RCB board is used to control an external replenish-

ment 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 con-sole.

Linefilter

Mainswitch

Powersupply

MCBWet section CPU

Printer

M803Paper

M802Film

SCSBSorter

Film SensorM805

Speed controlM806

Paper proc.

Speed controlM806

Film proc.

ConsoleRCB*

Top-off systemALMLPLUS

Battery

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saml13002a

��&()0 3��,�

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.

�#� �17��

�#� �� 4 �� $

The MCB board is a general purpose microcontroller board designed around the HD6303 microcontroller from Hitachi.

This board consists of � a 32kB EPROM� a 8kB RAM� a 16 channel analog / digital converter� a real time clock� a buzzer for acoustic alarm and� 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.

M802

M803 ALMLPLUS

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saml13003a

��&()( 3��4��3��

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.

�#� � >��

-��

1��!

The code memory – a EPROM – stores the machine program. The storage capacity is 32kBytes. This EPROM is plugged in socket U10.

CPU

A/Dconverter

Real timeclock

Datamemory

Codememory

Serialinterface

Timersinterface

Power andreset logic

Voltagereference

Input circuit

Backup supply

Printer

Processor type Hitachi HD63B03Y microcontroller, 8 bitClock rate 4.9152 MHzAddress range 64kBytes

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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.

7��)��!

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

��&()/ 3��

B��4��)�� The source of the backup voltage is a rechargeable battery. It is of the nickel-cadmium 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 %3��,' , immediately save your data on a memory card and replace the battery (see chapter 13.7.2).

��

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).

+��(��(��

This converter is used to make sensor data understandable for the microcontrol-ler. The analog data from the sensors in the film and paper processor are con-verted into digital data for the microcontroller.

+5V

3.6V

100mAh

Testpoint

+VBat

S + 5V

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saml13005a

��&()8 3��4��91��

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 con-verter is +5V.

��

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

��&()2 +��

-�$��(��

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.

Temperaturesensor(5)

Film processor F-Sensors

Temperaturesensor(4)

Paper processor P-Sensors

Ref.VoltageCircuitry

Low passfilter

Film

Low passfilter

Paper

A/DHD46508PA

MCUHD6303Y

Data bus

Address bus

Control bus

MCBM803 (Paper)

or

M802 (Film)

M

slotted disk

light barrier

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�#� �# ;��!��$��&��5��saml13007a

��&(): ��3*�< ��,��

;��!��$��&��

6��

MCB

0

Battery

+

Rotaryswitch

U2Microcontroller 1

J1

Buzzer

J2

Reset

button

Position 0: without sorterPosition 1: with sorter (also for single track machines)Position 2: 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

Jumper Default setting Option6� Closed Battery on Open Battery off

6 closed Serial interface in normal

modeOpen Serial interface in test

mode

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�#� �% ��saml13008a

��&(); ��3*��

��

��

MCB

0

Battery

+

Rotaryswitch

U2Microcontroller 1

J1

Buzzer

J2

GND

TP3

VBATT

TP2

+24V

L1L2

TP1

+5V

GND

Reset

button

Test point GND: GroundTest point 1: +5VTest point 2: +24VTest point 3: Battery voltage (nominal 3.6Vdc)

�� 3&��4C

�� Board receives +5Vdc� Board receives +24Vdc

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�#�# �"/ ��

C��D �&�� &��$��&��!G

�#�#�� 4 �� $

The M802 board drives all components of the film processor. It is controlled by the MCB board.

saml13009a

��&()= 3��4��;>0��

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:� bath and dryer heaters� dryer fan� agitation and aeration pumps� replenishment pumps� film cutting knife solenoid� film cassette locking solenoid� film transport motor

Received sensor data are:� replenishment pump microswitch and developer vacuum sensor� optical reader in the film loading station (M805) detecting the presence

of different film types� cassette present microswitch and film end microswitch in the film load-

ing station to activate the film cutting knife� tank level sensors checking low level in the tanks.

Heater drivers

220V ac

Motor drivers

220V ac

Solenoid drivers

24Vdc

Transport motor driver

24Vdc

Buffers / logic

Low pass filter

From/to

MCB

From

sensors

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�#�#� >��

��!

All signals coming from the MCB are passing a low pass filter and are buffered to reduce noise.

��

The solenoid drivers are power transistors switching 24Vdc. Each driver input has an indicator LED showing the status (see 13.3.4).

@�� 8 /H��9

The 220Vac heaters are switched on and off by triacs. These switching ele-ments are protected by two fuse resistors each. During an overload of a fuse resistor, it changes its resistive value to R =

saml13010a

��&()&> ��

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).

�� 8 /H��9

These drivers are exactly the same as the drivers for the heaters.

�� 8 %H9

The driver for the transport motor is a power FET.

3+;C�C2G

0��C4�� $��&��G�I��&��&�� G

∞

220V ac

to heater

+5V

Input

IndicatorLED

Fuseresistor

Fuseresistor

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��&()&& ��;>0

M802

F2 F1

F3

F4

>��H��O+P

�!��

1) F = quick acting fuse (fast blow)T = surge resisting fuse (slow blow)

��O��P

-�� -��

F1 8 F 6.3 x 32 0028-759-85 220Vac phaseF2 8 F 6.3 x 32 0028-759-85 220Vac neutral

Used for:Heater developer, filmHeater bleach, filmHeater fixer, filmHeater stabilizer, filmHeater dryer, film


Used for:Bleach aeration pump, filmDryer fan, filmReplenishment pump, filmSpray pump developer, filmRecirculation pump dev., filmRecirculation pump bleach, filmRecirculation pump fixer, filmRecirculation pump stabi., film

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�#�#�% ��&��"/ ��saml13012a

��&()&0 ��;>0

M802

L1

L5

L10

L15

L20

L23

�� 3&��4C

L1 Developer heater poweredL2 Bleach heater poweredL3 Fixer first heater poweredL4 Second fixer heater poweredL5 First stabilizer heater poweredL6 Second stabilizer heater poweredL7 Dryer heater poweredL8 Dryer fan poweredL9 not usedL10 not usedL11 Bleach aeration pump poweredL12 Developer recirculation and spray pump poweredL13 Bleach recirculation pump poweredL14 Fixer recirculation pump poweredL15 Stabilizer recirculation pump poweredL16 not usedL17 Developer, bleach, fixer and stabilizer multiple replenishment pump poweredL18 not usedL19 not usedL20 not usedL21 not usedL22 Film cutter solenoid poweredL23 Cassette locking solenoid powered

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�#�% �"/#��

This board is used for the paper processor. Therefore it is found in every machine.

�#�%�� 4 �� $

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

��&()&( 3��4��;>(��

It receives data from the sensors of the paper processor and sends these sig-nals 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:� bath and dryer heaters� agitation pumps� replenishment pumps� pump cooling fan� exhaust fan� printer part power (220Vac)� two way sorter motor� paper transport motor

Received sensor data are:� replenishment pump microswitch and developer vacuum sensor� tank level sensors checking low level in the tanks� lost liquid sensor� optical reader indicating the sorter position� microswitch indicating large format prints� sensor on the SCSB indicating prints coming out of the dryer.

Heater drivers

220V ac

Motor drivers

220V ac

Sorter drivers

24Vdc

Transport motor driver

24Vdc

Buf fers / logic

Supply printer part

220V ac

Low pass filter

From/to

MCBFrom

sensors

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�#�%� >��

��!

All signals coming from the MCB are passing a low pass filter and are buffered to reduce noise.

��

The sorter driver is capable to change the polarity of the 24Vdc to move the sorter in both directions

@�� 8 /H��9

The 220Vac heaters are switched on and off by triacs. These switching ele-ments are protected by two fuse resistors each. During an overload of a fuse resistor, it changes its resistive value to R =

saml13010a

��&()&/ ��


�� 8 /H��9

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.

3+;C�C2G

0��C4�� $��&��G�I��&��&�� G

∞

220V ac

to heater

+5V

Input

IndicatorLED

Fuseresistor

Fuseresistor

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This driver is the same as the driver for the exhaust fan. The fuse resistor R67 is 120Ohm / 1W.

�� 8 %H9

The driver for the transport motor is a power FET.

�#�%�# >��&��"/#��saml13014a

��&()&8 ��;>(

M803F1

F2 F4

F3

>��H��O+P

�!��


��O��P

-�� -��


Used for:Heater developer, paperHeater bleach, paperHeater stabilizer, paperHeater dryer, paper


Used for:Exhaust fanDryer fan, paperReplenishment pump, paperCooling fan pumpRecirculation pump dev., paperRecirculation pump bleach, paperRecirculation pump stabi., paperMain power for the printer part

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�#�%�% ��&��"/#��saml13015a

��&()&2 ��;>(

M803

L1

L5

L10

L15

L19

�� 3&��4C

L1 Developer heater poweredL2 Bleach heater poweredL3 First stabilizer heater poweredL4 Second stabilizer heater poweredL5 Third stabilizer heater poweredL6 First dryer heater poweredL7 Second dryer heater poweredL8 Dryer fan poweredL9 Developer recirculation pump poweredL10 Bleach recirculation pump poweredL11 Stabilizer recirculation pump poweredL12 not usedL13 not usedL14 Developer, bleach and stabilizer multiple replenishment pump poweredL15 Pump cooling fan poweredL16 Bath exhaust fan poweredL17 220Vac power line feeds printer partL18 Not usedL19 not used

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�#�' +��-�0��

�#�'�� 4 �� $

This board controls the automatic top-off system of the Master Lab+. This sys-tem 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

��&()&: ��,��

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.

�#�'� -��

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 =

ALMLPLUS Board

Power supply 220VAC

MCBBoard

Tank sensor

Replenishmentconsol

J85

J84

J75

J89

J90

J87J86

J88

J76

J94

J93

SW1 SW2 SW3

0

4

8

C

0

4

8

C

0

48

C

ATS

Power supply 24VDC

PumpElectrovalves

Output(not used)

Input(not used)

∞

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saml13017a

��&()&; ��


�#�'�# >��&��+��-�0��saml13018a

��&()&= ��+�5-

3+;C�C2G

0��C4�� $��&��G�I��&��&�� G

to pump

0V

+5V

Input

Fuseresistor

Fuseresistor

Fuse2A

220V ac

0

4

8

C

0

4

8

C

0

4

8

C

F1F2

>��H��O+P

�!��


��O��P

-�� -��

F1 1.25 F 5 x 20 +24VF2 2 F 5 x 20 Auto level pump (220Vac)

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�#�'�% ��&��+��-�0��saml13019a

��&()0> ��+�5-��

�#�* �1�7��

This board has to detect prints coming out of the dryer and to determine the cor-rect sorter position.

saml13023a

��&()0& �� -�-3

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.

EV1

EV2

EV3

EV4

EV5

EV6

EV7

EV8

EV9

EV10

EV11

ALAR

+24V

+5V

ACT

PUMP

MAIN

ON

TANK

BUZZ.

Electro valve film developer

Electro valve film bleach





Electro valve paper developer

Electro valve paper bleach




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

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

➩

0

4

8

C

0

4

8

C

0

4

8

C

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�#�� +��(��+�5��(��(��&��$��

�#�� &��17?��"/ ?��"/#?�;17��+��-�0��

% To close the drawer proceed in reverse order.

�#�� ;��(��&��!��&��17

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.

saml01001a

� Switch OFF the Master Lab+ with the main circuit breaker.

saml113021a

Loosen the cap socket screw in the drawer.

saml13002a

# Pull out the drawer and you have access to the MCB, M802, M803, RCB or ALMLPLUS

ATS

POWER

ATS

POWER

M802

M803 ALMLPLUS

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� Switch ON the machine

" Restore the previously written backup with the machine data from the mem-ory 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

�#��# �&��1�7��

To adjust or replace the board proceed as follows:

saml13027a

' Desolder the battery

* Solder the new battery.

C�� 3��&��&��!G

1+0��4CG

��!�&��=��&��$��&��&��$��)��7��$��&��!��&��!��!��$��&��&��(��&��&�� &�!�&� ��

Battery

saml02043a

� Lift the cover of the paper dryer. Make sure the cover locks on both sides.

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' To close the cover of the dryer, proceed in reverse order.

saml13024a

The SCSB board is located inside the cover of the dryer.

saml13025a# Measure the voltage across R2

respectively R4 without any paper present between the sensors.Use a digital voltmeter with a min-imal impedance of 1MOhm / Volt.

The voltage has to be higher than 35mV

saml13026a

% If the voltage is less, adjust the sensors mechanically until you have the highest voltage (35mV to 200mV)

R4R3R2R1

D1 D2Q1 Q2

R3

R2Q2

D2D1

Q1R4 R1

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�#�" ��&��

�� $��(�N -�(��&��

Overview schematics 17519.021.0 1 to 25

Schema a blocci MCB (block diagram MCB) 17433.004.0 1

Scheda MCB (circuit diagram MCB) 17319.013.3 1 to 5

Scheda MCB/N (layout drawing) 14074.207.1 1

Scheda MCB 4S (layout drawing) 15356.099.7 1





Scheda ALMLPLUS (circuit diagram) 17344.252.2 1 to 4

Scheda ALMLPLUS 4S (layout drawing) 15356.149.5 1

Scheda SCSB (circuit diagram) 17333.095.1 1

Scheda SCSB (layout drawing) 15335.004.2 1

Drawer, layout overview 14064.682.8 1

Drawer, internal wiring 18720.230.8 1

Wiring 220V 18720.231.9 1

Wiring 220V, pumps 17233.270.1 1

Wiring 230V, dryer 15399.283.5 1

Wiring 24V / 45V 15399.288.5 1

Fuseboard, schematics 17322.016.0 1

Fuseboard, layout 15311.016.0 1

Wiring signal level 15399.289.6 1

Wiring signal level, dryer 15399.274.7 1

Wiring signal level, replenishment console 15399.302.1 1

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4�� 14

�%�� 1��A��

The Customizer provides an attractive possibility of customizing products using existing conventional equipment. Complex prints are exposed onto regular pho-tographic paper in a short time.

For further details refer to:� Service Manual ‘Customizer Master Lab+’ P/N 98.29.02 and� Spare parts list ‘Customizer Master Lab+’ P/N 98.29.14 and� Operating Manual ‘Customizer Master Lab+’ P/N 98.29.15

�%� >��

�%� �� 2��

The film cleaner discharges any static electricity by means of ionized air and cleans the film with brushes.

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�%� � ��

� Switch OFF the machine first at the keyboard followed by the main switch.

' 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.

�/ Remount the aluminum plate behind the electronic unit.

�� Tilt up the electronic unit (CPU / CBO).

��-4;�+C�G

�&��$��(��&�� /H��.��!G

��/H��!��&� ��&��C4��&��-4��G��&��-4��&�!�$��G

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.

saml14033a

, Connect the cable to the corre-sponding terminal on the PODIS.Power

Distributor

PODIS

P/S

N

PE

Film Cleaner

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� Remount the side panel of the printer electronics.

�# Remount the black aluminum plate to the lamp house.

�% Insert the light shaft and the film deck.

�' Switch ON the machine again.

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�%�# ;��

�%�#�� 2��

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.

C��D >��!��&��$��&��&��E�+�C�F��=��$��!��$&��&�� &��(��&��?�� (��&��)��&��)�!��&��E�C��;F�)�!��)��&��(��.��!��G

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

MEMORYCARD

Setup Data

Quality Control

Production Statistics

Setup

Language

Quality Control

Production

Statistics

Setup Data

Spreadsheet or Database Program

Modem

Modem

PhoneLine

SETUP

MEMORYCARD

LAN-

GUAGE

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�%�#� ��

For detailed information about installation and use of the remote control inter-face 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.

��!��-1saml14002a

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.

�� saml14003a

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.

PCRS 232

Master Lab+

Modem e.g. COM 1

labeling: PC labeling

TXD

RXD

RTS

CTS

GND

DTR

2

3

4

5

7

20

2 TD

3 RD

4

5

7

20 DTR

GND

CTS

RTS

Master Lab+

PCRS 232

Master Lab+

e.g. COM 1

PC labeling

ModemModem

TXD

RXD

RTS

CTS

GND

+12V

DTR

Modem

labeling:Master Lab+

TD

RD

RTS

CTS

GND

DTR

DSR

ModemModem

TD

RD

RTS

CTS

DSR

GND

CD

DTR

RI

TD

RD

RTS

CTS

DSR

GND

CD

DTR

RI

2 222

3 3 3 3

4 4 4 4

5 5 5 5

6 67 7

7 7

8820

20

20 20

9

6

2222

Autoanswermode

RS 232

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�%�% ;��&��

�%�%�� 2��

C��D �&��&�� BB�� BB

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 Lab’s to manage the level sensors in the tanks of the console.

The dimensions of the console are:

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:

� 7 for replenishment and� 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:� An electronic board (called RCB), part of the kit for older Master Lab’s

to be installed in the electrical panel of the wet part� Function included in the ALMLPLUS board in Master Lab+

�%�%� ��

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.

Width: 78cm (30.7”)Height: 118cm (46.5”)Depth: 43cm (17”)

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% Remove the upper covers

' Remove the draw-off units

>�� -��saml14004a saml14005a



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* Remove the replenishment tanks from the machine.

� Close and remove the recovery tanks from the machine.

, Remove the overflow connection pipes at the working tanks.

�/ Disconnect the replenishment pipes at the filters coming from the draw-off unit.

>�� -��saml02011a saml02016a


saml14012a

" Remove the tank tray and support for the recovery tanks (4 screws)

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� Remount the new tank tray (with holes).

�# 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.

��-4;�+C�G

��&��!��&��)��!��&��$��)��!?��&��$��&��$��)��G

saml14013a

�� Remove the lower tank tray. Lift it on the opposite side of the lost liq-uid sensor and carefully pull it out while lifting the lost liquid sensor.

��-4;�+C�G

3&��(��&��)��&��&��(&��&��(&��)��=��)��&��G

4��=� ��saml14014a saml14015a

Lost liquid sensor

RCB Board

Cable duct

Cable duct

Cable duct

Cableduct

Cableduct

MCB Board

J75

J76

Cable duct

Cable duct

Cable duct

Cableduct

Cableduct

MCB Board

J76

ALMLPLUS board

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/ 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.

�* Mount the RCB board to the elec-trical 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 to J76 on the RCB board (cable is included).

�"� Connect the replenisher console to J76 on the ALMLPLUS board (cable is included).

saml14016a

�, Set the BCD-switch on the MCB board to the following positions:� Pos. 2 for ML without sorter

but with replenisher console.� Pos. 3 for ML with sorter and

replenisher console

>�� -��saml14017a saml14018a

MCB

0

2

1

3

5

4

9

8 7

6

Cable duct Cable duct

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# Close the cable ducts and all covers you have removed.

saml14019a

Connect the replenishment pump with cable P/N 15399.332.0 to the respective connector J32 (film side) and J33 (paper side).

C��D �&��$.�� .�$��&��.��G

Repl. pump microswitch

P/N 15339.332.0

12

J32 /J33

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�%�' ��

�%�'�� 2��

Depending on the Master Lab (Master Lab or Master Lab+), the kind of informa-tion to be printed with the line printer is different:

� With a Master Lab, all setup parameters, production statistics, photo-graphic statistics, scanner values and results of exposure time calcula-tions can be printer with the line printer.

� With a Master Lab+, only the scanner values of a negative can be print-ed with the line printer.

The reason is the remaining memory capacity.

The information to be printed is selected with the menu E14��F�.��.�LLLL

The line printer is connected to the Master Lab/Master Lab+ at the serial inter-face which is located at the lower left rear corner of the machine. The connector is marked with ��

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.

�%�'� ��(��&��

Two DIP switches on the control circuit board in the line printer allow the selec-tion of certain functions. The following configuration has to be set:

� 9600 Baud� 8 Data Bit� 1 Stop Bit� No parity

To set the configuration proceed as follows:

� Turn OFF the main switch of the line printer.

H�;I��-4;�+C�G

�&��=��$��)��!��$�� '�BBG

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The DIP switches have the following setting possibilities:

��-��$��&��

This is a 8 switch unit.

��-��$��&��

This is a 10 switch unit

saml14020a

Remove the cover on the rear of the line printer.

saml14021a

The DIP switches are now visible.1 22

ONON

3 4 5 6 7 8 9 101 3 4 5 6 7 8

ON

OFF

DS1 DS2

�$��&�C�� >�� 4C 4>>

1 Print mode Compressed Pica2 Zero character 03 Character table Graphics Italics4 Printer commands IBM Mode EPSON Mode5 Printer quality NLQ Draft6

International charac-ter set

78

��&��

1��! �$��&�C��* �$��&�C�� $��&�C��"

USA ON ON ONFrance ON ON OFFGermany ON OFF ONEngland ON OFF OFFDenmark OFF ON ONSweden OFF ON OFFItaly OFF OFF ONSpain OFF OFF OFF

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;��$��&��(

The recommended DIP switch setting should look as follows:saml14022a

�%�'�# ��(��&��

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

The right settings to connect the Riteman line printer is as follows:

��-��$��&

�$��&�C�� >�� 4C 4>>

1 Paper select Active Inactive2 Paper length 12” 11”3 Skip perforation ON OFF4 Automatic line feed CR + LF CR only5 Code unit 7 units 8 units6 C.G. font select ATARI / IBM2 ATARI / IBM17 Paper-end detector Inactive Active8 Print mode Emphasized Standard9

Bidirectional Factory set ��=��&��(�G10

ON

OFF

ON

OFF

DS 2DS 1

JumpersDIP-Switch

ON

OFF

1 2 3 4 5 6

1 ON 9600 Baud2 OFF 9600 Baud3 ON 9600 Baud4 ON 8 Data Bits5 OFF Parity: none6 OFF Parity: none

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6��8��9saml14024a

�%�'�% 1��.��

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

Front view

Master Lab/Master Lab+ Line printer25 Pin male, Sub D25 Pin male, Sub D

20

3

7

4

20

3

7

4

DTR - DSR

TxD - RxD

GND

CTS - RTS

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�%�* -��3��

�%�*�� 2��

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.

�%�*� ��

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 pass-port 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.

% Set up a corresponding format channel.

�%�*�# +�5��

C��D �&��5��&��.��&��$��

+��(��(��&��

� Select the menuE14��F�.�-;�C��;�.��C��.��K44�

Press the key below ��+;�.

# Open the front cover.

saml14026a

# Stick the bracket to the recess on the optic box as shown. Press it well to the optic box.

Optic box

Filmdeck

Shielding bracketP/N 36.12.34

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saml14027a

% Check the alignment of the four prints on the paper.

saml14028a

' Loosen the set screw at the lower end of the lens.

saml14029a

* Turn the insert carrying the four lenses until the prints are correctly aligned.

C�� &��!��.��?��&��B��&��.��G

� Tighten the set screw again.

Set screw

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1��(��&��&��

� Remove the light shaft and the film deck.

# Reinsert the film deck and the light shaft.

% Check the position with the menu:E14��F�.�-;�C��;�.��C��.��K44�.

' Press the key below ��+;�.

saml14030a

Turn the screws in the flange ring of the lens in the desired direction.

saml14031a

* Ensure that the position of the prints is as much in the center as possible. Otherwise repeat step 1 to 5.

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�%�� 2��(��&��

�%�� 2��

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.

�%��

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.

�%�" 1�� (��)��

Several upgrade kits allow an improvement of productivity and/or possibilities.

�%�"�� (��)��

2��

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:

� a Master Lab+ 120 to a Master Lab+ 220� a Master Lab+140 to a Master Lab+ 240� a Master Lab / Master Lab+ 320 to a Master Lab / Master Lab+ 520� a Master Lab / Master Lab+ 340 to a Master Lab / Master Lab+ 740

��

For the installation and setup procedure refer to the corresponding description 34.65.07 BV supplied with the upgrade kit.

�%�"� ��)��

2��

There are two speedup kits available:� with P/N 34.65.08 for Master Lab� with P/N 36.46.76 for Master Lab+

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This upgrade kit converts a machine with 200 prints/hour to a machine with 400 prints/hour. It also contains a sorter. It converts:

� a Master Lab+ 120 to a Master Lab+ 140� a Master Lab / Master Lab+ 320 to a Master Lab / Master Lab+ 340

��

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.

�%�"�# ��)��

2��

The speedup kit II (P/N 34.28.79) does the same as the speedup kit I but is with-out sorter. It converts:

� a Master Lab / Master Lab+ 220 to a Master Lab / Master Lab+ 240� a Master Lab / Master Lab+ 520 to a Master Lab / Master Lab+ 540

��


�%�"�% ��(��)��

2��

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)

��


Further information are also found in:� Service Manual ‘Master Lab Digital’ P/N 98.27.15 and� Spare parts list addendum ‘Master Lab Digital’ P/N 98.27.16

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�%�"�' >��(��

2��

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:

� a Master Lab / Master Lab+ 120 to a Master Lab / Master Lab+ 320� a Master Lab / Master Lab+ 140 to a Master Lab / Master Lab+ 340� a Master Lab / Master Lab+ 220 to a Master Lab / Master Lab+ 520� a Master Lab / Master Lab+ 240 to a Master Lab / Master Lab+ 740

��

For the installation and setup procedure refer to the corresponding description supplied with the upgrade kit

�%�"�* 0�(��(��&��:4�+:�.��

The Master Lab SM wet part uses Kodak patented LVTT (�ow-Holume �hin �ank) technology with direct replenishment chemicals delivered from Kodak SM Processing Units (cartridges). The Kodak Processing Units contain the concen-trated 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 auto-matic 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:� Service Manual ‘Master Lab+ SM’ P/N 98.27.91 and� Spare parts list addendum ‘Master Lab+ SM’ P/N 98.27.86

�%�"�� +��8+��9

2��

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 sim-ply inserting them into the entry slot.

This is an optional component within the concept to upgrade a Master Lab to a Master Lab+

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Handling, maintaining and servicing the automatic Densitometer is described in the Operating Manual and the Service Manual supplied with the equipment.

��


�%�"�" ��&��(��)��

2��

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.

��


�%�"�, +-��B�)��

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+:� upgrade kit P/N 37.06.40, upgrading Master Lab+ 220 for APS and In-

dex print� upgrade kit P/N 37.06.41, upgrading Master Lab+ 240 for APS and In-



dex 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+.

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��

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:� Operating Manual Addendum ‘Master Lab+ Advanced Photo System’

P/N 98.27.43 and� Service Manual Addendum ‘Master Lab+ Advanced Photo System’

P/N 98.27.42 and� Spare parts list Addendum ‘Master Lab+ Advanced Photo System’

P/N 98.27.41

�%�, :��

�� :��N -�(��&��

Greeting card 36.16.60 BV 1 to 6

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7��(��&!?�(��!��B 15

�'�� 7��(��&!

�9 ��&��(��-&��(��&��-��(�1&��

Kodak Catalog # CAT 832 1713) Pub. # J-98A

Learn how to safely handle photoprocessing chemicals and to recognize and avoid potential hazards

9 ��+��J��!�T�H��-&��(��&��-��(�>��

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 chemi-cals.

�'� 2��!

+-�

Abbreviation for +dvanced -hoto �ystem. 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.

+��

Abbreviation for +utomatic �ensito�eter. Built-in equipment for automatic mea-surement of the colors on a test strip or test negative,

+��

Abbreviation for +utomatic �op-off �ystem. A system in the wet part of the machine responsible to compensate the los of liquide due to evaporation.

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71�

Abbreviation for 7inary 1oded �ecimal. Methode to use decimal figures in a computer based system.

�-;4�

Device containing a software program which is resident on a PBA to control and /or monitor the function of a particular sub-unit.

��B��

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.

�1�

Abbreviation for �iquid 1ristal �isplay. Type of man-machine interface.

��

Abbreviation for �ight �mitting �iode. A semiconductor device emitting light when current is passed through the element.

��

Abbreviation for �aterial �afety �ata �heet. An informative paper provided by the supplyer of chemicals explaining the characteristics, possible risks under defined conditions, protection and first aid measures

-7+

Abbreviation for -rinted 7oard +ssembly. Indicating a printed circuit board which has components mounted on it. PCB would be the bare printed circuit itself.

;+�

Abbreviation for ;andom +cess �emory. An electronic storage chip allowing the access of an individual position ion the storage area.

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�'�# ��B

AAdjusting

Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196, 221, 300Exposure position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Paper cassette to different paper widths . . . . . . . . . . . . . . . . . . . . . . . . . 215Paper position in X-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . 223Paper position in Y-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . 222Pressure solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195Sensors on panorama feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Aeration pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Agitation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Aligning the lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Analog/Digital converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Automatic top-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282, 324

BBattery

Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57, 106, 114Disposing old batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115, 143, 146, 328Lithium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123, 141Memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Nickel-Cadmium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Rechargeable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Replacing on MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

BeltAdjusting tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196, 221, 300Checking tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259, 300, 307

Bridges (see jumpers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CCable

Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

CalculateFocal length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

CalibratingFilm dryer temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Paper dryer temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Tank temperatures in film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246Tank temperatures in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Calibration strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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CheckingBackup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259, 300, 307Distributor power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228DX-Code diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Knife sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Light barriers on distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Replenishment rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255, 296Sensors of paper extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Sensors on feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Tank temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246, 288Temperature sensors / level sensors . . . . . . . . . . . . . . . . . . . . . . . . 250, 292

Chemistry types in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275Cleaning

Lamp house . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Recommended liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 90

CodeFilm deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184For film insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Paper cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Color dots to identify chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48, 49, 50, 51Compensate temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Conventions used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Conversion kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Customizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

DDensitometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104, 351Detection

DX-Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 190Documentation / Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Drivers

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317, 321Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Dryer heaterIn film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235In paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

DX-Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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EElectrical Programmable Logic Device (EPLD) . . . . . . . . . . . . . . . . . . . . . . . . 125Electronic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Environmental guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 115, 143, 146, 328Exhaust fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

FFan

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Lamp cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 150Pump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Fibre optic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Film cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Film cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Replacing the knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263Film deck code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184Film density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190Film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Filter wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 151, 171First aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Floor

Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Flow sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237, 279Focal length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Focus test film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162, 164Frame scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110, 112, 318, 322, 325

GGraduated cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296Grain finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162, 163Greeting card attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

HHazardous vapors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Heating

Elements in film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Elements in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Home positionOn universal film deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Zoom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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IIndicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113, 315, 319, 323, 326Installation

Film cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Passort lens / Wallet lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Remote control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Replenishment console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

InterfaceMan-machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124, 140, 312Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

JJumpers

CPU configutation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Machines without lens turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154On MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Voltage selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

KKeyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

LLabels in the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Lamp power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Leader card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231LED (Light emitting diode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 317Lens

Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Passport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Wallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Lens code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Level sensor

Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Light attenuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 152Light shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Line printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

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Installing/aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Main shaft paper processor sideInstalling/aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

MainsCable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Supplies of various types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Manuals / Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Master Lab family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Measuring box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170, 175, 177Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

OOptic box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

PPaper cassette

Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Different paper width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Paper transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Passport lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Phases of automatic top-off management . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Phases of heating management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Position

Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191, 197Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Paper in X-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Paper in Y-axis on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Power supplyfor electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109for lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109for stepper motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Power supply for distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Pressure solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195Prime chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275Pump bellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257, 298

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PumpsAeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Agitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Automatic top-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Manually switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238, 280Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

RRA-4 chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275Racks

Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286, 303

ReadingLens code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Replenishment console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Replenishment pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236, 278Replenishment rate

Changing for all chemistries together . . . . . . . . . . . . . . . . . . . . . . . . 256, 297Changing for one tank only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256, 297Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255, 296

Reset logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313Room

Aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

SSafe handling of chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 30Safety stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247, 289, 307Scanning the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Sensors

Automatic top-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Film detection in film loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Flow or vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234, 276Lost liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Measuring the resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293Overview of paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210Panorama feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Paper extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234, 276

Shipping kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Site

Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Transport to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273, 287Specification

Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274technical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Wet part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240Spray pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

TTemperature

Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180Film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175, 234Viewing values in film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246Viewing values in paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Test points on MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Tools

Required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 178Spirit level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Top-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282, 324Transport

Belts on paper deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221In film processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240In paper processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240, 285

Triac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

UUpgrade kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

VVacuum cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Vacuum sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237, 279Vapors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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WWallet lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

ZZoom drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Zoom home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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Althardstrasse 70, CH-8105 Regensdorf, Switzerland, Telephone ++41 1 842 11 11, Telefax ++41 1 842 21 00

Printed in SwitzerlandGRETAG IMAGING AG 98.22.56 SA en 2000/11

982256 sa master lab+

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