English

Film Processor
Operation Manual

Machine No.:
Type:

PROTEC Medizintechnik GmbH & Co. KG

Lichtenberger Strasse 35, D-71720 Oberstenfeld, Germany
Telephone: +49-7062-9255-0 e-mail: [email protected]

Date of Installation:
Issued:

April 2003/3.3

Subject to technical alterations

EU-Declaration of Conformity

EU-Declaration of Conformity
PROTEC Medizintechnik declares, that the product
Description:

OPTIMAX

Machine type:

X-Ray-Film Processor

Model no.

117x-y-0000
x is a number between 0 and 9, y is a number between 1 and 9

conforms to the following harmonized standards:

Safety:

IEC 61010-1:1990 + A1:92 + A2:95; DIN 1988 T4:12/1988; UL 3101-1; CSA 22.2-1010-1

EMC:

EN 50081 Part 1, 03/1993; EN 50082 Part 1, 03/1993

according to the regulations of:

the Medical Device Directive 93/42/EEC class 1,

the Low Voltage Directive 73/23/EEC and the

EMC Directive 89/336/EG

PROTEC Medizintechnik GmbH & Co. KG, Lichtenberger Strasse 35, D-71720 Oberstenfeld, Germany

Place and date of issue

Oberstenfeld, January 3, 2001

Frank Baisch (R&D Manager)

OPTIMAX

Table of Contents

Introduction .......................................................................................................... 3
Technical Specifications ..................................................................................... 4
Safety Instructions............................................................................................... 5
Installation ............................................................................................................ 6

English

Initial Operation.................................................................................................... 9
Operation
Short overview and control panel ................................................................ 10
Switching the machine on............................................................................ 12
Stand-by mode ............................................................................................ 11
Bath temperature......................................................................................... 12
Display Film feed....................................................................................... 12
Manual pumping .......................................................................................... 12
Anti-crystallisation function / Time replenishment ....................................... 12
Automatic replenishment ............................................................................. 13
Rollfilms and paper films ............................................................................. 13
Care
Daily Care.................................................................................................... 14
Weekly Care ................................................................................................ 14
Thorough Cleaning ...................................................................................... 15
Problems and Solutions
Troubleshooting Film Defects ...................................................................... 16
Troubleshooting Machine Errors ................................................................. 17
Accessories ........................................................................................................ 18
Service Manual as appendix, see page 21

Copyright
2001 by PROTEC Medizintechnik. All rights reserved. Any reproduction, out of
the limitation by the copyright law, needs written authorization by PROTEC Medizintechnik.
Information on Liability
This manual has been checked for correctness. The instructions and specifications
were correct at the time it was published. Future models may have modifications
without prior notice. PROTEC Medizintechnik does not take responsibility for damage caused direct or indirect by error, omission or non-conformity of the manual.
Caution (U.S.)
Federal Law restricts this device to sale by or on the order of a medical professional.

Introduction
The OPTIMAX processor is a compact, automatic table-top processor. Due to the
precision roller transport system, both sheet and roller films can be processed. The
film materials are developed, fixed, rinsed and dried. The OPTIMAX incorporates
an automatic film-registration and a Stand-by mode. The developing solutions are
temperature-regulated, circulated and automatically replenished.
This Operation Manual contains the most important instructions for installation, operation and servicing of this machine. Please read the provided information carefully to ensure reliable and satisfactory operation of your OPTIMAX.

OPTIMAX

Technical Specifications

Technical Specifications
Film transport:

Continuous roller transport system

Film formats:

In general: Sheet and roll films up to 35.8 cm

(14.1)(width;
roll films with leader from 70 mm (2.8) width;
smallest film format 10x10 cm (4x4).
Mammography Type 1171: For processing Mammography Films.
Graphic-Arts Type 1172: With cassette box
(LxWxH) 35x13x12 cm (13.8x5.1x4.7) for
processing roll films.

Processing capactiy:

129 films 24x30 cm (10x12) per hour (standard

model, film fed in crosswise)

Process time:

Standard 90 s
Mammography 135 s
*Option 167 s

Linear speed:

Standard 56 cm/min. (22 in/min)

Mammography 37 cm/min (14.5 in/min)
*Option 30 cm/min (11.8 in/min)

Developer time:

Standard 25 s
Mammography 37 s
*Special 46 s

Tank capacities:

Developer, fixer and washing 5 litres each (1.3 gal)

Circulation system:

Developer and fixer are continiuously circulated by

a circulation pump

Replenishment:

Automatic replenishment by film detection, in relation to film length

Developer temperature:

Adjustable 28 - 37 C (82.4 - 98.6 F)

Fixer temperature:

Adjusted to developer temperature by heat

exchanger.

Water connection:

Permissible water pressure 2 - 10 bar

(29 - 145 psi), permissible water temperature
5 - 30 C (41 - 86 F).

Water consumption:

1.9 litres per minute (0.5 gal/min) when processing.

Drain capacity:

7 litres per minute (1.85 gal/min)

Noise level:

Less than 58 dB(A).

Heat emission:

Stand-by: 0.1 kJ/s Processing: 1.4 kJ/s

Environmental conditions:

1) Temperature 5 - 40 C (41 - 104 F), ventilated

room, room temperature should be lower than set
bath temperature.
2) Relative humidity lower than 80% up to 31 C
(80 F), linear decreasing to 50% at 40 C (104 F)
3) Height above sea level less than 2000 m
(6666 ft.)
4) Indoor use

Pollution degree:

OPTIMAX

System protection:

IP 20

Power source:

Electrical specifications are indicated on model

nameplate.
Type 117x-1-0000: 220 - 240 V~, 8.8 A, 50 Hz.
Type 117x-2-0000: 220 - 240 V~, 8.8 A, 60 Hz.
Machine tested for overvoltage category II according to IEC 1010 (EN 61010, VDE 0411)
Type 117x-4-0000: 110 / 120 V~ 10%, 15 A,
60 Hz.Machine tested for overvoltage category II
according to UL 3101 and CSA 22.2-1010

Power consumption:

Stand-by: 0.12 kWh

Processing: 1.4 kWh

Weight (processor):

Empty 35 kg (77 lbs)

Filled 50 kg (110 lbs)

Dimensions (LxWxH):

77x59x42 (** 112) cm 30.3x23.2x16.5 (** 44.1)

Floor space required:

0.45 m2 (4.8 sqft)

English

Technical Specifications

* Depending on machine type and used gears processors have different speeds.
** Height incl. optional working table resp. base cabinet.

Safety Instructions
To ensure the safe operation of this processor, installation and use should
always conform to the instructions contained in this manual.
The developer and fixer chemicals used in the processor should be handled
according to the manufacturers instructions. In general: Non-diluted chemicals
are caustic. For this reason, chemicals should be handled very carefully. Avoid
contact with skin, always wear protective clothing, gloves and glasses when handling the chemicals - for example, when mixing and refilling. Also when taking the
racks out for cleaning or servicing. In case of chemicals getting into the eyes,
rinse eyes immediately with cold, running water for approximately 15 minutes,
and contact a doctor afterwards. Inhalation of chemicals can be dangerous to
your health and should be avoided. For this reason, always ensure that the room
in which the processor is installed is adequately ventilated.
Environmental regulations regarding the storage and disposal of waste chemicals should be obtained from the local water authorities and complied with.

Before opening the processor switch off the unit and unplug it from the electrical
socket. Service and repairs must be performed by trained service technicians
only. Use only manufacturers replacement parts.

OPTIMAX

Installation

Installation
1. Requirements for installation
a.

Fresh water connection: Stop cock with 3/4" outer-thread diameter (washing
machine connection), Water pressure 2 - 10 bar (29 - 145 psi).
Drainage connection: Plastic tube - inner diameter 50 mm (2) or larger. A
ventilated syphon which serves as odor preventor should be included in the
planning. The drainage tubes should be installed with a fall of minimum 5 %.
Local Water Authorities regulations should be complied with.

b.

Electrical connection: Fused wall socket with ground connection according to

electrical data (see Technical Specification, page 5). It is also required to
install a ground fault interrupt (with 25 A / 30 mA nominal error current).
Electrical connections should be carried out according to regulations by an electrician.

2. Set up of processor
Unpack the Processor. Remove cover and transport securing brackets on the sides
of the roller racks. Remove roller racks - start with the dryer rack.
In 220-240 V version the OPTIMAX is delivered as a tabletop processor with a two
part floorplate. If the machine is upgraded with the optional stand or cabinet, the
small plastic strip has to be removed.
In 110-120 V version the OPTIMAXis delivered as a tabletop processor with a
three part floorplate. If the machine is upgraded with the optional stand or cabinet,
both small plastic strips and the metal plate have to be removed and a special main
plate must be reconnected.
Table-top installation
In the event that the processor is to be installed on a work top or table, the adjustable feet should be levelled.
Attention!
Machine should not be installed on table-top without adjustable feet, as this would block the ventilation openings under the
machine and cause overheating.
Installing on processor stand or base cabinet
In the event that the processor is to be installed on the stand or cabinet (optional
accessory), the processor will be mounted directly to it. Mount processor according
to manual included with stand or cabinet (the adjustable feet inside the accessory
bag are not required).
Finally the processor needs to be leveled:
Place level across the sidewalls of processor and adjust the leveling feet accordingly. Replace the racks into the processor and close the latches.

OPTIMAX

Installation

min. 70 cm

English

3. Connecting the processor

Drainage and
collecting
containers

Water connection: Connect the water hose which comes out from the processors
back to the fresh water supply.
All other hoses (see diagram page 8): Connect the enclosed hoses according to
color system onto the front of the machine. Put hose clamps (enclosed in accessory
bag) over hose end, before attaching to connection. Warm up hose end (with hot
water or lighter) and push onto the respective connection. Finally push clamp over
hose and connection.
Cut hoses to required length. Then integrate the stop cocks into the three drainage
hoses in such a position, that they are easy to reach.
Connect the suction pipes to the hose ends for the replenishment tanks using hose
clamps. Put suction pipes through cover opening into respective replenishment
tanks and snap them in.
The overflow and drainage hoses from the developer and fixer should be guided
into their respective collecting containers.
The overflow and the drainage of the water can either be guided into the drainage
syphon or into respective collection containers.

OPTIMAX

Installation

Pay attention to the correct color connections:

Developer:
red
Fixer:
blue
Water:
clear

Outlet

Outlet

Water (clear)

Outlet

Fixer (blue)

Overflow

Developer (red)

H2O

Overflow

FIX

Replenishment tanks

DEV

Overflow

Replenishment tanks

Hose connections

Replenishment
Overflow
Outlet

Danger of Overflow!
Use the included cable ties (accessory bag) to secure the hoses. Fix all hose ends which guide into syphon or collecting
container, so that they do not drop into the liquid.

Very important:
The hose piping should be straight (without the hoses going
up and down) with a constant fall. The hoses should be as
short as possible and without bends and kinks. This is very
important for the water overflow hose. Bad piping work will
cause the machine to overflow!
Inform yourself of the local water board regulations regarding
drainage. These regulations may differ from information in
this manual, but they should be complied with.
If the machine is installed table-top, ensure that the table is
stable enough and does not wobble.

OPTIMAX

Initial Operation

Initial Operation
1. Test run

a.

Close the three drainage stop cocks and fill the tanks and replenishment containers with water. Open water inflow tap. Connect electrical socket and
switch the machine on. Water now flows into water tank. The circulation pump
activates. If fluid does not flow, an air lock may be present. Momentarily open
the drain hose valves to ventilate the system.

b.

Ventilation of the replenishment pump:

Set temperature dial to position Manual pumping. Keep dial to this position
until no more air bubbles rise in the tanks.

c.

Ventilation of the circulation pump:

If air is in the circulation pump, a loud running noise can be heard. Switch the
machine off again. Open the stop cocks of the developer and fixer for five seconds and switch machine on again. Repeat this procedure until no more air
bubbles are visible in the developer and fixer baths and until the circulation
pump runs quietly.

d.

Check all hose connections for leakage. Switch machine off and drain water
out.

English

Important!
Processor should not be run dry!

2. Fill processor with chemicals

Prepare chemicals inside the replenishment containers according to manufacturers
instructions.
Fill up processor manually
By using a suitable container, pour chemicals into the respective tanks. First the fixer and then the developer. Caution: when filling, be sure that chemicals do no
splash from one bath into another. When fixer solution is mixed with developer solution, the developer chemical is destroyed.
Snap each suction pipe into the respective cover of its replenishment container and
close it carefully. Place containers under processor.
Using replenishment pump
Filling of processor can also be done by use of the replenishment pump (this takes
much more time). Snap each suction pipe into the respective cover of its replenishment container and close it carefully. Place containers under processor. Now set
temperature dial to Manual pumping. Keep dial in this position until tanks are filled.
After 20 minutes this function stops automatically - to restart a cycle, turn dial to another position and return to Manual pumping. Limitation: The function may fill up
tanks of developer and fixer to different levels. This may be due to different causes.
If this happens, then use a suitable container to fill up the tanks completely.

OPTIMAX

Operation

Operation
Short overview and control panel
LED displays

Film feed
Wait with the next film until light goes off.

Power
When power is on the LED lights up.

30

31 32

29

Bath temperature
Flashes when temperature is not reached.

33

28

34

Temperature dial

35
37 36

Manual pumping

Important!
Safety function stops film transportation when cover is removed. Therefore keep cover placed on the machine when
processing films.
*Only machines with cassette box:
When processing roll films in cassettes, pull approx. 10 cm of film out of the cassette and fold the corners. Place cassette into cassette box and feed film into the
infeed. Notice that on processors with cassette box, the film switch is located in the
middle of the infeed.
Film input

Light protection cover

Control panel

Developing
*Roll film cassette

Film
switch

Replenishment Developer
Power switch

10

OPTIMAX

Operation

1.

Close water-drainage stop cock.

2.

Open water tap.

3.

Switch processor on.

4.

Check liquid level in replenishment and drainage collecting containers.

5.

Wait until the developer temperature is reached. If the temperature has not
been reached, the bath temperature light is flashing.

6.

Run cleaning films through processor.

English

Before use...

Working procedure
7.

Processing films:
Open light protection cover. Important: Put film first on left side of feed tray
and then feed in. During processing films please watch the display Film
Feed. If this is lit, wait until it goes off again and an audible tone can be
heard, before inserting the next film.

After work...
8.

Switch processor off.

9.

Close water tap.

10. Open water-drainage stop cock and drain water out of the machine.

Stand-by mode
When no film is being processed, the machine switches to Stand-by. The chemicals
remain at a constant temperature. The film transport and water inflow activate at intervals to avoid crystallization of the chemicals on the transport rollers. Entry of the
next film is possible at any time.

Film exit

Drying

Fixing

Washing

Do not place any

object on the processor.

Fresh water inflow

Replenishment Fixer

OPTIMAX

11

Operation

Switching the machine on

The processor is switched on at the main power switch on the front side. After
switching on, the water tank will be filled up and a replenishment cycle will be carried out. The developer will be heated up. Until the tempearture is reached the LEDdisplay Bath temperature will be flashing. When the processor is ready and the
bath temperature reached, a long signal tone can be heard.

Bath temperature
The processor heats up the chemicals automatically to the dial-set temperature.
When this temperature is reached for the first time after switching on the machine,
a long signal tone can be heard. This is also the case when the temperature is
changed by the dial switch.
If the difference between actual and dial-set temperature is more than 1 C, the
bath temperature LED will flash. If a film has been fed in and the temperature is not
reached, a warning sound will be heard.

Display Film feed

If films are fed into the processor without clearance one after an other, then this may
cause a film jam. The light Film feed is on during feeding of a film. After the film
has been fed in completely the light goes off. Additionally an audible tone indicates
that the next film can be fed in.

Manual pumping
The function Manual pumping activates the replenishment pump and it pumps
chemicals into the tanks in addition to automatic replenishment. Turn the dial to the
position Manual pumping and chemicals will be pumped into the tanks. This function is only available during stand-by (no film in process). If the dial is left in this position, the pumping function is stopped automatically after 20 minutes. To restart a
cycle turn dial to a temperature and return to Manual pumping.
Please note: Films cannot be processed when dial is set to Manual pumping. Also
bath temperature is set automatical to 28 C during Manual pumping. After ending
the manual pumping the temperature must be set again by turning the dial. It takes
some time until the temperature is reached (look at the bath temperature display).
Both chemical pumps - fixer and developer - are driven parallel
by only one motor and therefore they operate in unison.

Anti-crystallisation function
During the stand-by mode, the film transport, the dryer ventilation, the dryer heater
and the water inflow are activated every 20 minutes for a period of 20 seconds. This
prevents the build-up of crystals on the rollers.

Time replenishment (Anti oxidation function, Flood replishment)

During the stand-by, the developer chemicals are subject to change which causes
their deterioration. By means of the time replenishment, a replenishment cycle is
activated after 60 minutes without replenishment. The pump runs for 15 seconds.
With this function, the quality of the developer chemicals are maintained even when
standing idle for long periods.

12

OPTIMAX

Operation

Automatic replenishment

English

Depending on the processed amount of films the chemicals are replenished automatically. This is done by pumping chemicals from the replenishment containers.
By means of the film-detection switch at the film feed tray, the surface of the processed films are calculated and after 20,25 m2 a replenishment cycle of 40 seconds
duration is automatically activated. The replenishment quantity per cycle (at pump
setting 100 %) amounts to 150 ml. The chart below shows the replenishment rate
in ml per m2 surface in reliance on film width and setting of the pump.
Replenishment Rates
Film width

Setting of replenishment pump*

100%** (85 %)

75 % (62 %)

35 cm

600 ml/m2

450 ml/m2

24 cm

870 ml/m2

650 ml/m2

18 cm

1150 ml/m2

875 ml/m2

*Setting at 50 Hz current resp. settings at 60 Hz current are in brackets

**Standard setting

Rollfilms and paper films

Rollfilms can be transported into the machine when a leader film (10x10 cm) is attached, that has been prepared with a chemical resistant adhesive tape.
Rollfilms without leader films and paper should be folded on the corners as per
diagram displayed on the right.

OPTIMAX

13

Care

Care
Daily Care
Before use...

Remove dirt and dust from film feed tray with soft, lint-free cloth.

Run 2 - 3 cleaner films through processor to remove all accumulated dirt and
dust from the rollers.

Check the fluid level in the replenishment containers and if necessary refill.

Leave light protection cover open when no film is in the processor. This avoids
condensation on feed tray.

After use...

When work has been completed at the end of the day, drain water out of the
machine. This avoids the growth of algae in the water.
Attention: To prevent damage to the processor, avoid liquid
contact, except for designated areas such as the processor
tanks. Use extreme care to prevent any liquid contact with the
processor controls.

Weekly Care
The developer chemicals cause residue buildup in the machine. This residue has a
negative effect on the developing process of the film material. For this reason the
processor should be regularly cleaned. Proceed as follows:
1.

Switch machine off and remove cover.

2.

Loosen the securing latches (red, blue and beige) of the drive shafts of each
roller rack at the right side.

3.

Remove the roller-racks. First of all remove the large dryer-rack (beige). The
racks are easier to remove and insert when they are slightly tilted. Use the
grey drip catcher forms to ensure that no chemicals splash when being carried. Then remove the fixer (blue) and developer (red) racks in sequence.

4.

Rinse all racks thoroughly under warm running water and then leave to drain
off. It is advisable to use a soft sponge (do not use scouring-pad, as this
would scratch the rollers) and remove any dirt from the rollers.

5.

Replace the racks: Red = Developer, Blue = Fixer. Beige = Washing/Drying.

Ensure that the racks are firmly installed and do not forget to close the securing latches on the drive shafts.

6.

Replace machine cover and ensure it is securely closed.

7.

Clean processor outer shell with damp cloth. Do not use aggressive cleaners
or solvents.
Please note: When removing the Rinsing / Drying roller-rack,
ensure that no water gets into the film dryer air channel.

14

OPTIMAX

Care

Thorough Cleaning
Every three months (maybe earlier) a thorough cleaning is necessary, depending
on the quantity of films processed. Tank cleaners are available for developer and
water baths. The fixer bath is cleaned with water. When preparing chemical tank
cleaners, follow manufacturers instructions explicitly.

2.

Remove machine cover. When all tanks are emptied, close stop cocks again.
Now fill the fixer tank with warm water. Prepare cleaner solutions for developer and water baths and fill into respective tanks.

3.

Remove suction pipes from the replenishment containers and place them in a
deep container filled with warm water. Attention: Do not add chemical cleaners here!

4.

Close machine cover and switch machine on.

5.

Start film transportation and keep running for 10 to 20 minutes. To start the
film transport, place a film on the feed tray so that it activates the film switch
but will not be pulled into the processor. During the operation with water, the
installed roller racks will be cleaned.

6.

Important: After completion of tank cleaning, the tank should be rinsed thoroughly with clean water. To do this, fill the machine with fresh water twice and
each time, let the machine run for a 10 minute period. Empty the tanks and reclose the stop cocks.

7.

Take out the roller-racks and rinse them thoroughly with running water.
Remove remaining dirt from the rollers by using a sponge and clean thoroughly. Doing this, the rollers can be turned by turning the drive shaft.
Remove the sheet metal covers from the dryer rack and clean the rack in
warm water diluted with dishwashing soap, and rinse well after cleaning.
Reinstall the roller-racks in the machine.

8.

Refill the tanks with respective chemicals. To avoid accidental contamination,

carefully refill the fixer tank first. If any fixer inadvertendly spills in the developer tank, thoroughly clean the developer tank and then refill the developer
tank. Replace the suction pipes into the replenishment containers. In certain
circumstances the circulation system must be ventilated: see page 9, item 1c.

9.

For quality check, process test films.

English

How to proceed:
1. Switch the machine off and empty all tanks by opening the stop cocks.

Before You Go on Holiday...

When the processor will remain off and unused for periods longer than 2 weeks, the
processor tanks should be emptied. Immediately after draining the chemistry from
the tanks, the drain valves should be closed and water should be added to each
tank. Upon return and prior to use, the processor should be cleaned and filled with
fresh chemistry.
Attention: Do not use alcohol containing solvents to clean the
machine!

Colour changes in the containers are caused by the properties

of the chemicals and no cause for concern!

OPTIMAX

15

Problems and Solutions

Problems and Solutions

Troubleshooting Film Defects
Your processor has been constructed for long term use. However, if irregularities
occur, the following information can help to solve the problem. Please check the following items before calling for service.

Films are too light, not enough density

Bath temperature is too low.

Developing time too short.
Exposure time is too short.
Replenishment rate of developer too low.
Developer is exhausted or over-diluted: Drain and replace old developer with
fresh developer.
Fixer solution has been mixed into developer: Renew. Thoroughly clean and
rinse the developer tank before refilling.
Circulation system is not operating properly.

Films are too dark, too much density

Developer temperature too high.

Developing time too long.
Exposure time is too long.
Replenishment rate of developer too high.
Developer chemicals are too concentrated, mix with new developer.
After replacing the chemicals: Starter is missing.
Circulation system is not operating properly.

Films will not dry

If warm air comes out of air channel in the dryer, chemicals and film type
should be checked.
Fixer solution is exhausted or diluted.

Film has a yellow-green surface.

Not fixed correctly. Check the film type and fixer chemistry.
Fixer solution is exhausted or diluted. Replenishment rate of fixer is too low.

Scratches, pressure marks, dirt on film

Prior to processing films, run cleaner films through the processor.

Pressure marks caused by careless handling, finger nails etc.
Rollers are dirty. Clean tanks and roller racks.

Cloudy film

16

Level in developer is too low.

First guide bar of fixer rack is dirty (condensation or crystals). Clean rollerracks.
Developer is old or circulation not working.
For single emulsion film, feed films emulsion (dull) side up.

OPTIMAX

Problems and Solutions

Troubleshooting Machine Errors

Machine does not switch on
Ensure that electrical plug is firmly inserted into socket.
Ensure that electrical socket has power supply by testing with an appliance
(e.g. tablelight).

English

Film will not feed in but the dyer fan works

Place cover firmly on machine, ensuring that the cover switch on the right
front side has been activated.

Machine does not start automatically

Film switch, located on the left side of the feed tray, has not been pressed
down. Feed in the film to activate the switch.

Developer temperature too low

The temperature dial is set between two positions.

Replenishment pump does not pump

Check whether the replenishment containers are full and that the end of the
suction pipe is positioned under the liquid level.
Check whether there is air in the replenishment pipes. If this is the case, then
check the pipe connections.

Rinsing water does not flow

Open water ball valve.

Water pressure in the water system is too low: Minimum pressure 2 bar (29
psi).

Water tank overflows

Water drainage hose (overflow) is bent. The hose end should be positioned
above the drainage level in the syphon (see diagram on page 8).
Water drainage in the tank, hoses and connections should be checked for
blockage and dirt/residue build-up. The drainage hoses should have a constant fall.

The film does not transport correctly

Film is fed in and gets caught in the machine: Check the positioning of the
racks in the machine and make sure that the latches are closed.
Important notice:
Ensure that the racks are firmly installed and keep the securing latches on the drive shafts closed.
Dont operate processor with empty replenishment tanks.
After a long machine shut down check developer and fixer levels and refill if necessary.

OPTIMAX

17

Accessories

The PROMIX A40 is a fully automatic chemical mixing machine for preparing
developer and fixer bath chemicals of either powder form or liquid concentrates.
All stages are guided and controlled by means of a microprocessor. Thanks to a
large reserve tank, up to 3 machines can be connected and continue to operate,
without having to interrupt the working process.
Due to its patented construction, the PROMIX A40 is easy to operate, reliable,
fast and virtually service free.
The PROMIX A40 replaces the usual replenishment tanks in the darkroom.
Ask your local dealer for more information.

Specifications
Tank capacities:

each 20, 25, 30 or 40 litres

Reserve tank:

each 13 litres

Water connection:

3/4", 2 - 10 bar (29 - 145 psi)

Pump capacity:

38 l/min

Mixing times:

variable, 2, 3, 5, 10, 15, 20, 25, 30 minutes

Power source:

220-240 VAC, 200 W, 50/60 Hz

Fuse: sb 2 A / 250 V

Weight:

28 kg empty, 108 kg full

Dimensions:

(WxHxD) 65 x 93 x 44 cm

18

OPTIMAX

English

Problems and Solutions

At last you can breathe again

AIRCLEAN 200 cleans the air from your processor. Unpleasant chemical odors
are absorbed through the large active charcoal filter. Allergies are prevented and
you can breathe again freely.
Simple installation directly on to the processor (no breaking through the wall).
Filter exchange cheap and fast approx. every 3 months.
Ask your local dealer for more information.

Specifications
Cleaning capacity:

approx. 200 m3/hour

Filter:

Active charcoal

Power consumption:

43 W

Power source:

220-240 V, 50/60 Hz

Weight:

7 kg

Casing:

Stainless steel, plastic coated

Casing dimensions:

(WxHxD) 21 x 63 x 17 cm

OPTIMAX

19

Accessories

20

OPTIMAX

Service Manual
Table of Contents

English

Installation Data ................................................................................................. 22

Trouble Shooting ............................................................................................... 24
Spare Parts List.................................................................................................. 29
Electric Diagrams............................................................................................... 35

OPTIMAX

21

Installation Data

Installation Data
59 cm (23.2")

70 cm (27.6")

cm (29.5")
7575
cm
(29.5)

Fresh water connection 3/4

with stop cock, permissible
pressure 2-10 bar, water temperature 5-25 C.

3.

Drainage plastic pipe (PVC)

50 mm (2) incl. syphon.

4.

Drainage resp. collecting containers for used developer.

5.

Drainage resp. collecting containers for used fixer.

6.

Storing space for replenishment tanks: Below machine or

externally.

7.

Ventilation of darkroom is necessary.

8.

Sink with freshwater and flexible hose. Inner dimensions

minimum (LxWxH)
60x40x30 cm (24x16x12).

7
5050cm
cm (20)
(20)

Sink
60x40
cm (24x16)
60x40cm
(24x16)

4 5
20 cm (8)
20cm (8)

2.

Darkroom

85 cm
(34)
85cm
(34)

Wall socket
220-240 V, 16 Aresp. 110 V,
15 A (depending on machine
model). Power lead should be
equipped with Earth-Leakage
Switch, 25 A / 30 mA nominal
error-current. In addition, a
power control switch can be
installed.

30cm
(12)

1.

59 cm
cm (23.2")
59
(23.2)

130
cm (51)
(51)
130cm

Optional working table or closed base

cabinet (accessory)

70 cm (27.6)

42
(16.5)
42 cm
cm (16.5")

77 cm (30.3")

Measures and positions are recommendations

22

OPTIMAX

Installation Data

Through the wall mounting film output

Film output to the light room for OPTIMAXprocessor
Type 117x-y-6000

705 mm
(27.7)
705 (27,7)

553 (21,7)

All dimensions refer to PROTEC

base table OPTIMAX
(1267-0-0000)
Dimensions in mm

Strap
1253-0-0203

Blind plate
1176-0-0607

653 (25,7)

653 (25,7)
553 (21,7)

50 (1,96)

655 (25,8)

Lower edge of wall plate

655 mm (25.8)

1040 mm (40.9

Wall break through

for film exit

553 (21,7)

50 (1,96)

Screw
M4x20
3079-8-5043

Film
exit
(40,9)
mmheight
1.040

min. 100 (3,9)

English

553 (21,7)

1.

Wall opening according to drawing.

2.

Fasten wallplate with enclosed eight screws (note markings).

3.

Fix blind plate with screws and straps on the film outlet (Detail X).

4.

Push processor up against wallplate and place foam rubber light protection
between processor and wallplate.

5.

Hang in film catch basket at wallplate from the backside.

6.

Check mounting-set for light imper-meability and function.

Please notice:
Pull sealing wedge off before removing machine cover.

OPTIMAX

23

Trouble Shooting

Trouble Shooting
Summary
1
2
3

7
8

Algae ............................................................................................................ 24
1.1 Excessive algae growth in water tank.................................................... 24
General......................................................................................................... 25
2.1 Machine has no power........................................................................... 25
Drive ............................................................................................................. 25
3.1 Filmfeed out of order, dryer-fan is working ............................................ 25
3.2 Machine does not start automatically .................................................... 25
3.3 Machine doesn't stop automatically....................................................... 25
3.4 Drive motor does not run ....................................................................... 25
3.5 Transport stops before film comes out, changing the cycle time........... 25
3.6 Processing time and developer temperature relation ............................ 26
3.7 Changing the transport speed ............................................................... 26
Bath .............................................................................................................. 26
4.1 No circulation in bath ............................................................................. 26
4.2 Developer temperature too high ............................................................ 26
4.3 Developer temperature too low.............................................................. 27
4.4 Developer temperature too low, fixer temperature too high................... 27
4.5 Removing the turning knob.................................................................... 27
4.6 Calibration of developer temperature .................................................... 27
Film defects ................................................................................................. 27
5.1 Films will not dry .................................................................................... 27
5.2 The film does not transport correctly ..................................................... 27
5.3 Scratches, pressure marks, dirt on film ................................................. 27
Replenishment ............................................................................................ 28
6.1 Replenishment pump does not pump or does not pump sufficiently ..... 28
6.2 Replenishment rates are too high or too low ......................................... 28
6.3 Adjust replenishment pump ................................................................... 28
Dryer............................................................................................................. 28
7.1 Dryer fan does not function or runs with reduced speed ....................... 28
Water ............................................................................................................ 28
8.1 Rinsing water does not flow................................................................... 28
8.2 Water tank overflows ............................................................................. 28

Algae

1.1 Excessive algae growth in water tank

Algae growth inside the water tank is not only anoying, it causes increased
cleaning work and leaves residue on the films. When algae is present, corrective measures are required:

When work has been completed at the end of the day, drain water out of the
machine.

Clean dryer-water rack regularly. Use soft sponge and soap to remove residue from the rollers.

Install a particle filter system in the fresh water supply for the processor.

If water tank overflows due to algae growth blocking the overflow hose, then
the overflow hose can be attached directly to the connection at the water tank
inside the machine.

If no other solutions can be found, then usage of Anti-Algae-Agents can be a

great improvement (automatic dispensers work the best). However, it is
known that cleaning agents containing chlorine may corrode rubber rollers
and high-grade steel in the tank area (check before use).

24

OPTIMAX

Trouble Shooting

General

Check machine fuse in main power switch.

While power switch is on, check the following components: Voltage on contact
of main switch - if no voltage - change main switch. Check input voltage at
electronics. If the voltage is normal, exchange the electronics. if no voltage
check the cable wiring harness.

English

2.1 Machine has no power

Ensure that electrical socket has power supply.

As replacement fuses, please excusively use PROTEC gold

fuses. These fuses are optimally adapted to the existing conditions.

Drive

3.1 Filmfeed out of order, dryer-fan is working

When placing processor cover on, the cover switch should be activated, readjust if necessary.

Cover switch has no current passage when activated: Replace.

Check screwing of chain wheel on motor- and driveshaft.

3.2 Machine does not start automatically

Film switch is not correctly positioned or operator wire is bent. Re-adjust film
switch and operator wire.

Check following parts: Film switch, wiring of film switch and microprocessor
board.

Check wiring from electronic to the connections of components (motor, fan,

dryer heating, solenoid valve). If the connections have no fault then electronic
is possibly defective.

3.3 Machine doesn't stop automatically

Display film feed is permanently illuminated: Wire band of film switch is

jammed. Readjust wire.

Check following parts: Film switch, wiring of film switch and microprocessor
board.

3.4 Drive motor does not run

Check cover switch.

Check drive motor: If voltage can be detected on motor, then motor is defective.

Dryer fan runs but no voltage on motor: Interruption in the wiring.

3.5 Transport stops before film comes out, changing the cycle time
The cycle time is the processing time which turns off after a film has passed the film
switch. Activate the switch in the feed tray with a film and remove the film. Measure
the time until the processor stops automatically.
Following times can be measured (+/- 5%):
Standard machine:

125 s

Jumper 2-3

Mammography:

155 s

Jumper 1-2

Optional type:

190 s

Jumper removed

Change cycle time if necessary. This can be accomplished by changing the position
of the jumper on the upper side of the electronics.

OPTIMAX

25

Trouble Shooting

3.6 Processing time and developer temperature relation

The following chart demonstrates guide value relations between developer temperatures and processing times. Variations are possible depending on the various films
and chemicals. Changing the transport speed see 3.7.
Processing time "Dry to Dry"

Developer temperature

105 s

32 C - 34 C

118 s

32 C - 34 C

135 s

31 C - 33 C

143 s

30 C - 32 C

167 s

30 C - 32 C

3.7 Changing the transport speed

The processing speed can be changed by changing the gear wheels. To do this the
tanks need to be emptied and the machine be turned over. After removing the drive
motor the chain gears can be changed. Please note that the jumper on the PCB
needs to be placed to the indicated position.
Following gear combinations are available:
220-240 V, 50/60 Hz-Versions
110-120 V, 50 Hz-Versions

110-120 V, 60 Hz Versions

Gm

Gs

Jumper
position

Developer time
(s)

Infeed
speed
(cm/min)

Gm

Gs

Jumper
position

Developer time
(s)

Infeed
speed
(in/min)

105

t=17

t=16

2-3

29

48

105
(90)

14

16

2-3

29

18.9

118

t=16

t=17

1-2

32

43

113

14

17

2-3

31

17.6

135

t=14

t=17

1-2

37

37

124

12

16

1-2

34

16.0

143

t=14

t=18

removed

39

35

132

12

17

1-2

36

15.0

167

t=12

t=18

removed

46

30

139

12

18

1-2

38

14.3

t = Processing time in seconds

Gm = Chain gear on motor shaft
Gs = Chain gear on drive shaft

Bath

4.1 No circulation in bath

Circulation pump works but no circulation in bath: Air lock in heating and circulation system. Ventilate pump (see Page 9).

Particles in the pump chamber. The pump chamber can be easily opened by
removing the four clips. When closing again ensure that the rubber seal is
positioned correctly and not damaged.

Check connection of pump, circulation pump possibly defective.

4.2 Developer temperature too high

Check attachment of temperature sensor. This should be firmly positioned on

tube and completely covered with foam rubber.

Check sensor: At ambient temperature voltage between pin 3 (green) and

pin 2 (brown) must be between 0.1 and 0.5 V.

If the sensor has no fault then the microprocessor board is defective.

26

OPTIMAX

Trouble Shooting

Developer is not heated: Check temperature safety switch on heat-exchanger.

Check heating element: Current flow resistance should read approx. 66
(120 V-heating: 36 ).

Check temperature sensor (see 4.2).

If no error can be found then the microprocessor board is possibly defective.

English

4.3 Developer temperature too low

Check circulation pump. Air lock in the circulation pump: Ventilate pump (see
Page 9). If no circulation can be detected: Check wiring of circulation pump,
pump possibly defective.

4.4 Developer temperature too low, fixer temperature too high

Air lock in the circulation pump: Ventilate circulation (see Page 9).
Do not exchange PCB without removing knob!

4.5 Removing the turning knob

Pull the toggle off the knob by help of a flatnose pliers.

Open the screw of the collet (Attention: dont open completely) and pull the
knob out.

When reinstalling the knob turn axis on PCB to end position counter clockwise. Fix the knob in that the pointer is at position of Manual pumping.

4.6 Calibration of developer temperature

Deviating temperatures within +/- 1.5 C can be calibrated by a potentiometer on
the PCB. It can be reached after removing the turning knob (see 4.5) from above.
Turning clockwise decreases the temperature.

Film defects

5.1 Films will not dry

No air comes out of air channel: Check wiring of dryer fan, fan is possibly
defective.

Cold air comes out of air channel: Check wiring of heating element in the air
channel, heating element possibly defective.

Hot air comes out of air channel, but the film is still not dried to satisfaction.
Check chemicals and film type. If this leads to no solution then the transport
speed of the machine can be reduced (see Changing the transport speed,
page 26).

30

31 32

29
28
C

33
+

34
35

37 36

5.2 The film does not transport correctly

Check the positioning of the racks in the machine and make sure that the
latches are closed.

Check the roller racks: Position of the guide elements, rollers are in correct
position and are not loose, flat springs are not bent, all gears are in place.

Motor runs: The worm gear of the drive shaft should be secured with a cotter
pin (see page 29, pos. 38) to avoid twisting. Check the screws and positioning
of the chain and chain wheel.

5.3 Scratches, pressure marks, dirt on film

Straight scratches in the feed direction indicate faulty guide elements. Check
each rack and straighten up the guide elements. If mechanically damaged,
replace the guide elements.

Pressure marks caused due to dirty or damaged rollers. Check rollers for visible damage. Rubber rollers sometimes swell. Exchange defective rollers.

OPTIMAX

27

Trouble Shooting

Replenishment

6.1 Replenishment pump does not pump or does not pump sufficiently

Clean valve inside connection tube.

Install valve insert correctly: Pay attention to flow-through direction!

Check filter in the suction pipe (repl. container) and clean it if necessary.

Replenishment pump sucks air in. Check hoses and connections.

Check eccentric position. Capacity approx. 240 ml/min at setting to 100 %.

(60 Hz: 240 ml/min at 85 %)

Activate the Manual pumping and while on, check the voltage of connection
X2 on the power PCB. If no voltage can be registered - exchange power PCB.

6.2 Replenishment rates are too high or too low

The replenishment rate can be changed by adjusting the stroke of the pump.
To do this, the eccentric on the replenishment pump must be adjusted. Maximum pump capacity is 240 ml/min(100 %).
6.3 Adjust replenishment pump

For the adjustment of the eccentric first open the allan screw on the big
eccentric with the red line. If the screw is not reachable, then start the Manual
pumping (dial switch) for a short time. If the screw is not reachable, momentarily rotate the temperature switch to Manual pumping. When the screw is
reachable, quickly turn the temperature switch back to a temperature position.

Turn the eccentric so that the red line will be at the desired position and fasten
the allan screw.
Minimum setting must not be below 75 %.

Dryer

7.1 Dryer fan does not function or runs with reduced speed

Check the correct connecting of the fan cables: bl = blue; bk = black;

br = brown.

If the fan is connected improperly, then the fan runs only half power.

Water

8.1 Rinsing water does not flow

Water pressure in the water system is too low: Minimum pressure 2 bar
(29 psi).

Valve activates, no flow passage - filter at inflow is blocked.

Check green water inlet hose inside the machine.

8.2 Water tank overflows

Water drainage hose (overflow) should have a constant fall. The hose end
should be positioned above the drainage level in the syphon.

Check water drainage in the tank and hose for blockage and dirt/build-up.

When extreme algae growth is present, the overflow can be connected

directly onto the fitting of the water tank.

28

OPTIMAX

Spare Parts List

English

10

11
3
7
6

Pos.

Order No.

Description

1170-0-0200

Cover complete

2006-0-0005

Drain stop cock 10 mm

1170-0-2000

Replenishment tank 12 l dev.

1170-0-2100

Replenishment tank 12 l fix.

1170-0-1750

Suction pipe w. filter f. 12 l tank

2004-0-0003

Electrical power lead 220-240 V

2004-0-0021

Electrical power lead 110-125 V

2018-0-0001

Water inlet tube

1267-0-0000

Processor stand

1267-0-0010

Closed base cabinet

1101-0-2000

Replenishment tank 25 l dev.

1101-0-2100

Replenishment tank 25 l fix.

10

1101-0-1700

Suction pipe w. filter f. 25 l tank

11

1101-0-4100

Floating cover, developer

2018-0-0012

Hose 10 x 2 mm, clear, reinforced

2018-0-0009

Hose 10 x 2 mm, blue, reinforced

2018-0-0008

Hose 10 x 2 mm, red, reinforced

2018-0-0005

Hose 4 x 1 mm, green

2018-0-0003

Hose 9 x 2 mm, clear

2022-0-0004

Tube clamp

2022-0-0019

Wire tube clamp

2015-0-0001

Floating balls

OPTIMAX

29

Spare Parts List

21
29
(53)

20a
(61)

28

(30)
26
27

(58)

20

25
20
22-23

24

Pos.

Order No.

Description

20

0202-1-0008

Replenishment pump 2KBA 220-240 V, 50/60 Hz

0202-6-0008

Replenishment pump 2KBA 115 V, 50/60 Hz

20a

0002-1-0008

Valve insertion f. pos. 20

21

2002-1-0013

Circulation pump 220-240 V, 50/60 Hz

2002-6-0013

Circulation pump 110 V, 50/60 Hz

22

1170-0-1400

Main switch combi 220-240 V

23

2010-0-0010

Fuse, slow blow in gold, 10 A / 250 V

22+23

2028-0-0036

Main switch 110-120 V

24

1170-0-0702

Angle connection (grey)

25

1170-5-1300

Electronic 220-240 V

0170-6-1300

Electronic 110-120 V

26

0170-0-2400

Micro-switch (cover) 230 V

0170-4-2400

Micro-switch (cover) 115 V

27

2007-0-0010

Operator for micro-switch

28

1101-0-0704

Angle fitting

0016-0-0002

PU - glue kit

29

2021-0-0001

Screw-in connector

1170-0-1250

Wiring harness V2 230 V

1170-0-1251

Wiring harness V2 115 V

30

OPTIMAX

Spare Parts List

34

38

33

32

37

31

35

30

Pos.

Order No.

Description

30

2001-0-0003

Main drive motor 220-240 V, 50 Hz

2001-2-0003

Main drive motor 220-240 V, 60 Hz

2001-6-0003

Main drive motor 120 V, 50/60 Hz

1170-0-1101

Motor bracket

31

English

35

32

1170-0-1501

Drive shaft worm-gear

33

1170-0-1503

Worm-gear

34

1170-0-1502

Bearing block

35

1170-0-1506

Chain wheel t=12

1170-0-1504

Chain wheel t=14

1170-0-1505

Chain wheel t=16

1170-0-1102

Chain wheel t=17

1170-0-1507

Chain wheel t=18

37

2037-0-0002

Chain 6 mm with coupler link

38

3000-9-4013

Cotter pin 2.0x20 mm, inox

OPTIMAX

31

Spare Parts List

55
54

64

50

56
58
51

65
60

61
62
59
63

Pos.

Order No.

Description

50

1170-0-1301

Air channel

51

2003-5-0006

Heating elment 230 V, 1100 W

2003-6-0007

Heating element 110 V, 900 W

standard model

2003-5-0008

Heating element 230 V, 1000 W

2008-5-0007

Dryer fan 220-240 V, 50/60 Hz

2008-6-0007

Dryer fan 115 V, 50/60 Hz

53
54

53

0170-5-1900

Solenoid valve 220-240 V, 50/60 Hz

0170-6-1900

Solenoid valve 115 V, 50/60 Hz

55

1101-0-0121

Securing bracket

56

0170-0-0800

Micro-rotary-switch for film-detection with operator

58

1170-0-0804

Bracket for micro-rotary-switch

59

1170-0-0105

Film feed tray

1172-0-0105

Film feed tray graphic arts

60

2003-5-0002

Heating element 230 V, 800 W

2003-6-0002

Heating element 120 V, 400 W

61

1130-0-2101

Heat exchanger

62

2005-0-0005

Temperature safety switch mounted on heat exchanger

63

0190-0-2200

Temperature sensor

64

1170-0-1303

Plate for air channel

65

1170-0-1302

Channel dryer heating

32

OPTIMAX

Spare Parts List

100

English

103

112

108
111
102

113
117

104

110
121
119

114

120

115
116

109

122

103
123
106
107

105

104

104
Standard roller racks

OPTIMAX

33

Spare Parts List

Pos.

Order No.

Description
Mammography Processor

1171-0-0600

Roller rack, dryer

Graphic Arts Processor

1172-0-0300

Roller rack, developer

1172-0-0600

Roller rack, dryer

Standard Processor

1170-0-0300

Roller rack, developer

1170-0-0400

Roller rack, fixer

1170-0-0600

Roller rack, dryer

100

0170-0-0301

Side plate dev. w. shafts (left)

1170-0-0301

Side plate dev. (right)

0170-0-0401

Side plate fix. w. shafts (left)

1170-0-0401

Side plate fix. (right)

102

1140-0-3800

Guide bar straight, short

103

1140-0-4500

Guide bar with nose

104

1140-0-3700

Guide bar, curved

105

1170-0-0304

Flat spring 55

106

3079-8-5013

Screw M4x10, A4

107

3009-3-4023

Hexagon nut M4, A4

108

1140-0-0301

PU-roller 35 ground

109

1170-0-0310

Drive shaft rack

110

1101-0-0302

Gear t = 16, D-hole

111

1101-0-0304

Gear t = 32, round hole

112

1101-0-0303

Gear t = 32, D-hole

113

1170-0-0302

Wormgear

114

1101-0-0305

Bearing bush

115

1101-0-0317

Bearing bush, black

116

2014-0-0001

Circlip

117

0170-0-0601

Dryer side plate left w. shafts

1170-0-0602

Dryer side plate right

119

1140-0-0302

Rubber roller 35

120

1140-0-0605

Air jet (35)

121

1170-0-0604

Dryer plate, large

122

1170-0-0603

Dryer plate, small

123

1170-0-0303

Flat spring 35

0170-0-0004

Maintenance set

34

OPTIMAX

OPTIMAX

35

English

Wiring Charts

Controller

Wiring Charts

36

OPTIMAX

Controller

English

Wiring Charts

OPTIMAX

37

Controller

Wiring Charts

38

OPTIMAX