English

Film Processor
Operation Manual

Machine No.:
Type:
Installation Date:
PROTEC GmbH & Co. KG
Status: 08-2009/1.7
In den Dorfwiesen 14, D-71720 Oberstenfeld, Germany
Telephone: +49-7062-9255-0 e-mail: service@protec-med.com Subject to change
EU-Declaration of Conformity

EU-Declaration of Conformity
PROTEC® declares, that the product

Description: OPTIMAX®2010

Machine type: X-Ray-Film Processor

Model no. 116x-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 61010-1:2001 + 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 GmbH & Co. KG, Lichtenberger Strasse 35, D-71720 Oberstenfeld, Germany
Supplementary guide- • DIMDI: DE / 0000042967
lines:
• WEEE: DE 55471807

Location and date of issue

Oberstenfeld, 2. July 2007, Jochen Krupp (Technical Manager Analogue Systems)

6 OPTIMAX®2010
Table of Contents

Table of Contents
Introduction .......................................................................................................... 7
Intended Use......................................................................................................... 8
Technical Specifications ..................................................................................... 8

English
Safety Instructions............................................................................................... 9
Installation .......................................................................................................... 10
Initial Operation.................................................................................................. 13
Operation
Short Overview and Control Panel .............................................................. 14
Switching the Machine On........................................................................... 16
Automatic mode........................................................................................... 16
Anti-crystallisation function / Time replenishment ....................................... 16
Working Parameters .................................................................................... 17
Machine Cover Safety Disconnection.......................................................... 19
Auto fill Function .......................................................................................... 19
Manual Mode............................................................................................... 20
Water Saving Mode ..................................................................................... 20
Stop Film Transport ..................................................................................... 20
Rollfilms and Paper Films ............................................................................ 21
Use of Memory Function ............................................................................. 21
Care
Daily Care.................................................................................................... 22
Weekly Care ................................................................................................ 22
Thorough Cleaning ...................................................................................... 23
Maintenance / Disposal ..................................................................................... 24
Problems and Solutions
Advice on Film Defects................................................................................ 27
Advice on Machine Errors ........................................................................... 28
Error messages ........................................................................................... 29
Accessories ........................................................................................................ 30
Service Manual as appendix, see page page 33
Optimax 2010 with 2 pumps see starting page 53

Copyright
© 2008 by PROTEC®. All rights reserved. Any reproduction that violates the limita-
tions set forth by copyright law, needs to be authorised in writing by PROTEC®.
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® does not take responsibility for damage caused directly or indirectly by
error, omission or non-conformity of the manual.

Introduction
You are the proud owner of a modern, automatic processor. Due to the precision
roller transport system, both sheet and roll films can be processed. The automatic
film registration is activated immediately when a film is fed in. The film materials are
developed, fixed, rinsed and dried. With the easy to operate micro-processor, the
processing conditions can be adjusted to suit the various film and chemical types.
The developing solutions are temperature-regulated, circulated and automatically
replenished.
These Operating Instructions contain important instructions for installation, opera-
tion and servicing of the machine. Please read the provided information carefully to
ensure reliable and satisfactory operation of your film processor.

OPTIMAX®2010 7
Technical Specifications

Intended Use
The X-ray film processor OPTIMAX®2010 is intended exclusively for the purpose
describe in the introduction above.
X-ray film processors (MDD class I) are employed in “medical” applications (medi-
cal products directive) and “non-medical” applications (electrical appliances and
EMC directives).
Intended use includes observing the operating instructions, the installation instruc-
tions and adherence to the safety notes.
Any application differing from intended use voids the guarantee by PROTEC®.
The owner of the machine will be liable for damages resulting from unintended use
or faulty application.
Intended use includes adherence to all statutory regulations concerning occupa-
tional safety and radiation protection applicable at the operating site.

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 1161: For processing mam-
mography films.
Graphics-art type 1162: With cassette box
(LxWxH) 35x13x12 cm (13.8x5.1x4.7’’) for
processing roll films.
Processing capacity: 129 films 24x30 cm (10x12 “) per hour
(standard unit, film transverse, at 90 s)
Process time: 1.5-3 min.; adjustable in steps of 0.1-min.

Linear speed: 28-56 cm/min., depending on selected cycle time.

Developing time: 25-49 s, depending on selected cycle time.

Tank capacities: Developer, fixer and water tank 5 litres each

Circulation system: Developer and fixer are continuously circulated by

a circulation pump
Replenishment: Automatic by film surface measurement in relation
to processed film; replenishment can be switched
off; time replenishment can be activated.
Developer temperature: Adjustable 28 - 37 °C (82.4 - 98.6 °F)

Fixer temperature: Adjusted to developer temperature by heat

exchanger.
Dryer temperature: Adjustable between 10 - 99% of dryer output, tem-
perature achieved depends on line voltage.
Water connection: Permissible water pressure 2 - 10 bar (29 - 145
psi), permissible water temperature 5 - 30 °C (41 -
86 °F).
Water consumption: 1.9 litre per minute when processing.
Water saving mode: 0.9 litres per minute
Drain capacity: 7 litres per minute

Noise level: Less than 58 dB(A).

Heat emission: During processing approx. 1.4 kJ/s.

8 OPTIMAX®2010
Technical Specifications

Environmental condi- 1 Temperature 18 - 40 °C (51.6 - 104 °F), venti-

tions: lated room, room temperature should be lower
than set bath temperature.
2 Relative humidity lower than 80 % up to 31 °C
(88 °F), linearly decreasing to 50 % at 40 °C
(104 °F)

English
3 Height above sea level less than 2000 m (6666
ft.)
4 Indoor use
Pollution degree: 2

System protection: IP 20

Electrical connections: Electrical specifications are indicated on the model

nameplate.
Type116x-1-y000: 230 V~ ±10 %, 8.8 A, 50 Hz.
Type 116x-2-y000: 230 V~ ±10 %, 8.8 A, 60 Hz.
unit conforms to IEC 1010 (EN 61010, VDE 0411)
overvoltate category II
Type 116x-4-0000: 110 / 120 V~ ±10 %, 12 A, 60
Hz.
unit conforms to UL 3101 and CSA 22.2-1010
overvoltate category II
Power consumption: Stand-by: 0.12 kWh
Processing: 1.4 kWh
Weight (unit): 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)

** Height incl. optional working table or 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: Undiluted chemicals are
caustic. For this reason, chemicals should be handled very carefully. Avoid con-
tact 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. If chemicals have come in your eyes, rinse the
eyes immediately with cold, running water for approximately 15 minutes and con-
tact a medical 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 chemi-
cals should be obtained from the local water authorities and complied with.

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

OPTIMAX®2010 9
Installation

Installation

1. Requirements for installation

a. Fresh water connection: Shut-off tap, thread with 3/4" outside diameter (wash-
ing machine connection), Water pressure 2 - 10 bar (29 - 145 psi).
b. Drainage connection: Plastic tube - inner diameter 50 mm (2”) or larger. A
ventilated syphon which serves as odour preventor should be included in the
planning. The drainage tubes should be installed with a decline of minimum
5 %.
Local Water Authorities regulations should be complied with.
c. Electrical connection: Fused wall socket with earth connection according to
electrical data (see technical specifications, page 9). It is also required to
install an earth-leakage switch (with 25 A / 30 mA nominal error current).

Electrical connections should be carried out according to reg-

ulations by an electrician.

2. Transport
Due to the weight and dimensions of the film processor, OPTIMAX®2010 should
always be carried by two persons. To do so, hold the machine at the sides on the
bottom (see figure). While putting the machine down, watch the position of the lev-
elling feet to prevent damaging these.

3. Set-Up
Unpack the Processor. Remove cover and transport securing brackets on the sides
of the roller racks. Remove roller racks - start with the dryer rack.
The standard version of OPTIMAX®2010 is delivered as a tabletop processor with
a three part base plate. If the machine is upgraded with the optional stand or cabi-
net, the two side parts must be removed from the base plate.
Table-top installation
If the unit is to be set up on a table top or work table, only the four unit feet need to
be screwed out and levelled..

Attention!
Machine should not be installed on table-top without adjusta-
ble feet. as this would block the ventilation openings under the
machine and cause overheating.

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). Remove the two side parts of the base plate before.
Finally the processor needs to be levelled:
Place spirit level across the sidewalls of processor and adjust the levelling feet ac-
cordingly. Replace the racks into the processor and close the latches.

10 OPTIMAX®2010
Installation

4. Connecting the processor

English
min. 70 cm (27.5“)
Drainage
and col-
lecting
containers

Water connection:
Fit water-inlet hose (grey) at the rear of the machine and connect to the prepared
fresh water supply.
Water overflow:
The water overflow hose (∅ = 16 mm) is likewise connected at the rear of the unit.
The hose is installed as described in the next section.
Remark:
There are two options for installation of the water overflow at the front of the unit.
Install the pre-assembled hose in the unit and connect it to the overflow outlet at the
unit front. Upon delivery this outlet connection is a dummy only (see graphics on the
top right).
All other hoses (see diagram page 12): Connect the enclosed hoses according to
colour system onto the front of the machine. Put hose clip (enclosed in accessory
bag) over hose end, before attaching to connection. Warm up hose end (with hot
water or lighter) and push onto the respective connection. Finally push clip 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
clips. Put the suction pipes through the cover opening into the respective replenish-
ment 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 wa-
ter can either be guided into the drainage syphon or into respective collection con-
tainers.

OPTIMAX®2010 11
Installation

Hose Connections
H2O
Overflow FIX DEV FIX DEV FIX DEV

Overflow

Overflow

Replenishment tanks
Replenishment tanks
Outlet

Outlet
Outlet

Optional

Pay attention to the correct colour connections: Replenishment

Developer: red;
Fixer: blue; Overflow
Water: clear
Outlet

Danger of Overflow!
Use the included cable ties (accessory bag) to secure the hos-
es. Fix all hose ends which lead into the syphon or collecting
container, so that they do not drop into the liquid - otherwise
liquid may overflow.

Very important:
The hose piping should be straight (without the hoses going
up and down) with a constant decline. 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.

12 OPTIMAX®2010
Initial Operation

Initial Operation

Test run
Important!
Processor should not be run dry!

English
Upon commissioning and every refilling the pumps must be
vented.

a. Close the three drainage stop cocks and fill the tanks and replenishment con-
tainers with water. Open water inflow tap. Connect electrical socket and
switch the machine on. Water now flows into water tank. The circulation pump
activates, however the hosing of the machine must be ventilated.
b. Ventilation of the replenishment pump:
Switch to the manual mode and switch on the replenishment pump. Let the
pump run until no more bubbles rise inside the tanks.
c. Ventilation of the circulation pump:
The circulation pump runs after switching on the machine and ventilates itself.
If this should not work, a loud running noise will 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 qui-
etly.
d. Check all hose connections for leakage. Switch machine off and drain water
out.

Filling the Processor with Chemicals

Prepare chemicals inside the replenishment containers according to manufacturers
instructions.
Filling the processor manually
By using a suitable container, pour chemicals into the respective tanks. First the fix-
er 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 so-
lution, the developer chemical is destroyed.
Caution! When filling the unit manually, be sure not to allow liquid to flow into the
slot of the cover switch or onto the operating panel. This may damage parts.
Snap each suction pipe into the respective cover of it’s replenishment container and
close it carefully. Place containers under processor.
Using replenishment pump
Filling of processor can also be done by use of the replenishment pump (this takes
much more time). The chemicals containers need to be filled manually with at least
1.0 litres of fresh chemicals, to ensure the pumps will not run dry. Snap each suction
pipe into the respective cover of it’s replenishment container and close it carefully.
Place containers under processor. Activate the filling process by means of the au-
tomatic tank filling function. The function stops automatically as soon as the set lev-
el has been reached. Latest after 20 minutes, the function will shut off automatically.
Limitation: The function may fill up tanks of developer and fixer to different levels. If
this happens, then use a suitable container to fill up the tanks completely.

Warning, hot surface!

OPTIMAX®2010 13
Operation

Operation
Short Overview and Control Panel
Display working parameters
! Arrow button “Up” = increase parameter value
" Arrow button “down” = decrease parameter value 1 3 2

Mode Buttons
# Processing time in minutes
$ Developer temperature in °C
% Dryer output in % 4 5 6 7
& Replenishment time in seconds

Enter Memory Power on Autofill

Recall Store Exit

Important!
Safety function stops film transportation when cover is re-
moved. Therefore keep cover placed on the machine when
processing films.

*When processing roll films in cassettes, pull approx. 15 cm of film out of the cas-
sette and fold the corners (see page 21). Place cassette into cassette box and feed
film into the infeed. Only machines with cassette box.
Light protection cover

Film input

Control panel

*Roll film Developing

cassette
Film
switch

Replenishment Developer
Power switch

14 OPTIMAX®2010
Operation

Attention:
Upon first operation and each refilling of a developer check
the function of the circulation pump and vent the pump if re-
quired (see page 9).

English
Before use...
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 start-cycle has been completed or until Developer temperature
is reached.
6. Run cleaning films through processor.
Working procedure
7. Processing films:
Open the light protection cover, insert the film on the left of the feed tray, dur-
ing the feeding please watch the Film-feed-display “– –”.
After work...
8. Switch the unit off.
9. Close water tap.
10. Open water drainage stop cock

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

Film exit

Do not place any

object on the proc-
essor.

Drying

Fixing Washing

Fresh water inflow

Replenishment fixer Height-adjustable feet

OPTIMAX®2010 15
Operation

Switching the Machine On

Before switching the machine on, open the fresh water tap and close the water
drainage tap (under control panel). Then switch the machine on (main switch is sit-
uated under the control panel). Once the machine is switched on, a “Start-cycle” of
eight minutes duration is activated: A replenishment cycle is carried out, the water
tank fills automatically and the chemical baths heat up. During this “Start-cycle” no
films can be fed into the machine. The display shows two bars “– –” when the proc-
essor is not ready and no films can be fed in. This is the case during the “start-cycle”
and also when the baths have not reached the temperature. Until the developer
temperature is not reached, the developer temperature button (5) is flashing. It is
possible that the chemical bath has not reached the required temperature even af-
ter the “Start-cycle” has been completed. You need to wait until the developer tem-
perature is reached, before inserting films. Wait until the bars “– –” disappear from
the display.

Automatic mode
After completion of the “Start-cycle” and after a film-processing, the machine auto-
matically goes into the stand-by mode. In the stand-by mode the processor can be
started at any time by placing a film into infeed tray. Note that films can only be proc-
essed when the developer temperature is reached. When the display shows two
bars “– –” no films can be fed into the machine. The temperature in the bath is too
high or too low. However, when a film was fed into the machine, two bars with dec-
imal points “–. –.“. To avoid a jamming of films wait before feeding the next film in
until this display disappears (which is also signalled by an acoustic sound).
A film in the feed-tray is registered by two film detection switches and the machine
starts up. The film is pulled into the machine and transported through the developer,
fixer and water baths. The remaining time of processing i.e. until the film finally
leaves the machine is displayed, when no more film is in the infeed-tray and the
processing time button was pressed. Each working-parameter can be called up on
the display by pressing the respective mode-button, however, during processing,
parameters cannot be altered. The temperatures of the developer and dryer are au-
tomatically regulated by the controller. The replenishment rate of developer and fix-
er chemicals is activated according to the processed film-surface (film-surface
measurement). The dryer is heated to the set value. Inside the dryer, the film is
dried and then normally output onto the cover. The machine then goes into the
stand-by mode. To keep the machine in working condition during the stand-by
mode, the electronics have been furnished with two specialities: The Anticrystalli-
sation Function and the Time Replenishment.

Anti-crystallisation function
In stand-by mode, the film transport, the dryer ventilation are activated every
20 minutes for a period of 20 seconds. This prevents the build-up of crystals on the
rollers. This function cannot be switched off.

Time replenishment (Anti oxidation function, Flood

replenishment)
Also during the stand-by, the developer chemicals are subject to change which
causes their deterioration. By means of the time replenishment, a replenishment cy-
cle is activated after 60 minutes without replenishment. With this function, the qual-
ity of the developer chemicals are maintained even when standing idle for long
periods. The time replenishment function can be deactivated.

16 OPTIMAX®2010
Operation

Setting of time-replenishment:
1. Switch the unit off.
2. Press the buttons processing time (4) and replenishment time (7) simultane-
ously and keep pressed.
3. Switch the machine on again and release the pressed buttons.

English
4. Switch the time replenishment on or off with the cursor keys (2 and 3). If you
enter “0”, time replenishment is off, “1” switches it on.
5. Switch the unit off to save the settings.

Working Parameters
The processing machine develops, fixes, rinses and dries the film materials auto-
matically. The film and chemical requirements can be adjusted accordingly and
stored in the control unit.
Display of working parameters:
1. Switch processor on.
2. Press the respective mode button (4-7) and keep it pressed to display the set
value.
Press the respective mode button (4-7) and let it go to display the current actual val-
ue.
Setting the working parameters:
1. Switch processor on.
2. Machine must be in the stand-by mode and no film must be in the processor.
3. Press the respective mode button (4-7) and keep pressed: The display shows
the set working parameter.
4. Change value by means of the arrow buttons (2 and 3) until required value
appears on the display. The upward arrow button (2) increases and the down-
ward arrow button (3) decreases the value.
5. Release the mode button.

Processing time
The processing time, is the time, it takes the front end of a film from the infeed of
the processor until it reaches the film exit. The processing time is set by the speed
with which the film is transported through the machine. Depending on the require-
ments, this time can be varied from to 1.5 minutes (90 seconds) to 3 minutes, ad-
justable in 0.1-minute-steps (Adjusting the processing time: see “Working
Parameters” on page 17).

Processing and developer time relation

Processing time (min) Developer time (s) Infeed speed (cm/min)
1.5 25 56
1.7 28 49
2.0 33 42
2.3 38 37
2.5 41 34
2.7 44 31
3.0 49 28

OPTIMAX®2010 17
Operation

Developer temperature
The developer temperature of the different film-materials depends on the develop-
ing time. The faster a film has to be developed, the higher the temperature must be.
The developer temperature can be set between 28-37 °C according to the individual
requirements (Setting the developer temperature: see “Setting the working param-
eters:” on page 17). If the temperature of the developer bath is lower or higher than
the set value, then the developer temperature button (5) is flashing and the display
shows two bars “– –”. Before feeding a film into the machine, wait until the temper-
ature has been reached and the displayed bars “– –” disappear.
The following chart shows guiding value relations between developer temperatures
and processing times. Variations are possible depending on the various films and
chemicals.

Processing time and developer temperature relation

Total processing time (min (s)) Developer temperature (°C)
1.5 (90) 33 - 35
2.0 (120) 32 - 34
2.3 (138) 31 - 33
2.5 (150) 31 - 33
3.0 (180) 30 - 32

Dryer temperature
The dryer temperature cannot be set in degrees Celsius. However the dryer output
can be set in a range between 10-99 % (100 %), to adapt it to the film material to
be processed. “95” for example, corresponds to 95 % of the maximum output of the
dryer heating. To avoid dryer spots on the film, the dryer output may not be set too
high. Adjust the temperature so that the film just gets dry (Setting the dryer temper-
ature: see “Working Parameters” on page 17).
Remark: Depending on mains voltage, dryer temperatures above 65 °C may under
certain circumstances not be reached. The information in the table below are mere
guiding values. Different combinations of film material, chemicals and ambient con-
ditions may require different dryer output settings.

Processing time and dryer output

Total processing time (min (s)) Dryer output (%)
1.5 (90) 85 - 99
2.0 (120) 75 - 95
2.3 (138) 65 - 85
2.5 (150) 55 - 75
3.0 (180) 45 - 65

Replenishment time
The replenishment of the developer and fixer chemicals is automatic. By means of
the film detection switches at the film-feed, the surface of the processed films is cal-
culated and after 0.25 m2 film a replenishment cycle is automatically activated. The
replenishing volume can be set by means of the replenishment time. The replenish-
ment time may be set in a range of 10-99 s. The replenishment can be switched off
by entering “0”. This is advisable in rare cases only.

18 OPTIMAX®2010
Operation

The chart below shows the replenishment time to be set for the requested replen-
isher rate per m2-film surface. The standard setting is 40 sec. with 600 ml replen-
isher rate per m2 film surface. The replenisher rate has to be adjusted depending
on film material, chemicals and film throughput.

Relation of replenishment time and replenisher volume

English
Replenisher volume Replenishment time Replenisher rate
(ml/m2) (s) (ml per cycle)
150 10 37.5
300 20 75
450 30 112.5
600 40 150
750 50 187.5
900 60 225
1050 70 262.5
1200 80 300
1350 90 337.5
1485 99 371.3
Values for pump setting 100 % supply volume or for to 85 % for 60 Hz supply.

Machine Cover Safety Disconnection

The machine cover may only be removed for service and maintenance purposes.
The processor cannot be started without the cover. In the event that the machine
cover is removed during film-throughput, the film transport will be stopped. On the
display the error message “E1” will be displayed. This will render the film unsuitable.
The error will be reset when the machine cover is reinstalled. Thereafter the motor
may run a little faster for a short time.

Auto fill Function

In case new chemicals have to be filled into the processor (after installation, tank
cleaning), the tanks can be filled automatically by means of the auto fill function.
In the process, the tank is filled for a fixed period of 20 minutes, that is, chemicals
are pumped from the replenishment containers to the tanks. Also the water bath
will be filled (3 min. period). The display will show two symbolized tanks (see
right). When the auto fill function has been completed, the machine enters the
stand-by mode. If the respective baths are full before the time is up, the auto fill
function can be stopped manually. The level switch in the developer bath detect a
full bath and switches the pump off. The automatic tank filling can also be termi-
nated manually.

Starting up the auto fill function:

1. Switch the unit off.
2. Press and hold the replenishment time button (7), switch the unit on.
Manual cancellation of the Auto fill function:
1. Press and hold the replenishment time button (7) and press “arrow down” but-
ton (3).

OPTIMAX®2010 19
Operation

Manual Mode
In the manual mode, the processor works without the film detection switches. The
film transport has to be started and stopped manually. All the set values in the man-
ual mode are also valid in the automatic mode. Please note that the Infeeding-film-
display (“– –”) is deactivated. Replenishment continues to operate based on detec-
tion of the film surface processed. Only if the film detection switches are activated,
will film measurement be performed. In the manual mode, a replenishment cycle
can also be activated manually.
Switching to manual mode:
Switch the machine on. During stand-by, press the arrow-buttons “up” (2) and
“down” (3) simultaneously. When in manual mode the display is flashing.
Switching back to automatic mode:
In manual mode with film transport off press both arrow-buttons “up” (2) and “down”
(3) simultaneously.
Manual starting and stopping the film transport:
1. Switch to manual mode.
2. Press the processing time button (4) - the button illuminates.
3. Start the film transport by pressing the arrow-button “up” (2) or stop the film
transport by pressing the arrow-button “down” (3).
Manual replenishment:
1. Switch to manual mode.
2. Press the replenishment time button (7) - the button illuminates.
3. Start the replenishment cycle by pressing the arrow-button “up” (2) or cancel
the replenishment cycle by pressing the arrow-button “down” (3).

Water Saving Mode

The water saving mode reduces the water consumption. If the water saving mode
is activated, exactly 50 % less water is consumed.
Activating the water saving mode:
1. Switch the unit off.
2. Press and hold the buttons processing time (4) and dryer output (6) simulta-
neously.
3. Switch the machine on again and release the pressed buttons.
4. Switch the water saving mode off or on with the arrow buttons (2 and 3). If you
enter “0”, the water saving mode is off; if you set “1”, it is on.
5. Switch the unit of to save the settings.

Stop Film Transport

In a case of a film-jam inside the machine, the film transportation can be manually
interrupted. To stop the film transport press both arrow-buttons (2 and 3) simulta-
neously. Related topics:
see “Manual starting and stopping the film transport:” on page 20
see “Film is caught up in the racks” on page 29

OPTIMAX 2010 with 2 pumps see description starting on

page 53.

20 OPTIMAX®2010
Operation

Rollfilms and Paper Films

Roll films with a polyester lead of at least 10 cm length can be transported. The
adhesion must be chemical resistant.
Roll films without lead and paper-films must be folded on the corners, as shown
in the diagram, before being fed into the machine.

English
Use of Memory Function
In the memory two sets of parameters can be stored and be recalled to the oper-
ating memory.

Store processing parameters

1. Set machine to preferable parameters e.g. bath temperature, processing 1 3 2
time etc. (see manual).
2. Press buttons 4 and 5 “Enter Memory” simultaneously to enter the memory
mode.
3. Use the buttons 2 and 3 “Select” to select the parameter memory (P1 or P2). 4 5 6 7

These save the parameters, old values will be overwritten.

4. Press the button 5 “Store” to store parameters and to leave the memory Enter Memory
Recall Store Exit
Power on Autofill

mode.
Recall processing parameters
1. Press buttons 4 and 5 “Enter Memory” simultaneously to enter memory
mode.
2. Use the buttons 2 and 3 “Select” to select the parameter memory (P1 or P2)
from which the parameters are to be recalled.
3. Press button 4 “Recall” to recall parameters (copy into the operating mem-
ory) and to leave the memory mode.
To leave memory mode without change
Press button 6 “Exit”.
Choose the same bath temperature for all stored programmes. Of course differ-
ent bath temperatures can be stored too, but when changing the programme you
always have to wait until the changed bath temperature is reached.

OPTIMAX®2010 21
Care

Care

Daily Care
Before use...
1. Remove dirt and dust from film-infeed with soft cloth.
2. Run 2 - 3 cleaner films through the processor to remove all accumulated dirt
and dust from the rollers.
3. Check the liquid level in the replenishment containers and if necessary refill.
After use...
When working has been completed at the end of the day, the water must be drained
from the machine. This reduces the growth of algae in the water bath. For that pur-
pose open the water drainage stop cock (see page 12 bottom).

Attention: Do not let any liquid drop inside the processor or

run over the control. Liquids may cause damage to the proc-
essor.

Weekly Care
The developer chemicals cause residue build-up in the machine. This residue has
a negative effect on the developing process of the film material. For this reason the
processor has to be regularly cleaned of this residue.
Do a weekly clean of the roller racks, which only takes a few minutes.
1. Switch machine off and remove cover.
2. Loosen the securing latches of the roller racks (red, blue and beige) of the
drive shafts of each roller rack at the right side.
3. Rinse all racks thoroughly under warm running water and then leave to drain
off. Use a soft sponge (do not use a scouring-pad, as this would scratch the
rollers!) and remove the dirt from the rollers. During this procedure, the rollers
can be turned by turning the drive shaft.
4. Wipe the infeed-roller-pair (first roller-pair of developer rack) dry.
5. Replace the racks: red = developer, blue = fixer, beige = water / dryer. 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 casing with damp cloth. Do not use aggressive clean-
ers or solvents.

Please note:
When removing the rinsing / drying roller-rack, ensure that no
water gets into the film dryer air channel.

22 OPTIMAX®2010
Care

Thorough Cleaning
Depending on the quantity of films processed, a thorough cleaning is necessary
every 3 - 6 months. Tank cleaners are available for developer and water baths. The
fixer bath is cleaned with water. When preparing chemical tank cleaners, follow
manufacturer's instructions explicitly.

English
How to proceed:
1. Switch the machine off and empty all tanks by opening the stop cocks.
Attention! Machine will not drain off, if it is switched on.
2. Remove machine cover. When all tanks are emptied, close stop cocks again.
Now fill the fixer-tank with water. Prepare cleaner solutions for developer and
water baths and fill into respective tanks.
3. Remove suction pipes from the replenishment containers and place them in a
water filled bucket. Attention! Do not add chemical cleaners here!
4. Close machine cover and switch machine on.
5. Start the film transport (see “Manual starting and stopping the film transport:”
on page 20) and keep running for 10 to 20 minutes. During this the installed
roller racks will be cleaned.
6. Important: After completion of tank cleaning, the tank should be rinsed thor-
oughly with clean water. To do this, fill the machine with fresh water twice and
each time, let the machine run for a 10 minute period. Empty the tanks and re-
close the stop cocks.
7. Take out the roller-racks and rinse them thoroughly with running water.
Remove remaining dirt from the rollers by using a sponge and clean thor-
oughly. Doing this, the rollers can be turned by turning the drive shaft. Wipe
the infeed-roller-pair (first roller-pair of developer rack) dry. Replace the racks.
8. Refill the tanks with respective chemicals. This can be done by hand or auto-
matically (see “Auto fill Function” on page 19). Replace the suction pipes into
the replenisher containers. In certain circumstances the circulation system
must be ventilated: see “Test run” on page 13 item b).
9. For quality check, process test films.
Before you go on holiday...
or in the event that your processor will not be in use for longer than two weeks, all
the chemicals have to be emptied out of the tanks. In case you don't want to do a
complete tank cleaning at once, then fill the tanks after emptying, with water.

Attention: Do not use alcohol containing solvents to clean the

machine!

The colour changes in the baths is normal; it is caused by the

properties of the chemicals!

OPTIMAX®2010 23
Maintenance / Disposal

Maintenance / Disposal

Maintenance Protocol
Installation
Name: Machine type: Serial number:
Technician: Training: by:
Telephone: Date: Guarantee until:

Parameters Set
Developer temp.: Dryer temp.: Cycle time:
Dev. reg. volume: Dev. reg. volume: Anti-oxidation:
Developer: Fixer: Film type:
Changed by: Date:

Developer temp.: Dryer temp.: Cycle time:

Dev. reg. volume: Dev. reg. volume: Anti-oxidation:
Developer: Fixer: Film type:
Changed by: Date:

Developer temp.: Dryer temp.: Cycle time:

Dev. reg. volume: Dev. reg. volume: Anti-oxidation:
Developer: Fixer: Film type:
Changed by: Date:

Maintenance work performed (see page 25)

Maintenance work Maintenance work Maintenance work Maintenance work Maintenance work
performed performed performed performed performed
Date: Date: Date: Date: Date:
Name: Name: Name: Name: Name:
next maintenance: next maintenance: next maintenance: next maintenance: next maintenance:

Maintenance work Maintenance work Maintenance work Maintenance work Maintenance work
performed performed performed performed performed
Date: Date: Date: Date: Date:
Name: Name: Name: Name: Name:
next maintenance: next maintenance: next maintenance: next maintenance: next maintenance:

Maintenance work Maintenance work Maintenance work Maintenance work Maintenance work
performed performed performed performed performed
Date: Date: Date: Date: Date:
Name: Name: Name: Name: Name:
next maintenance: next maintenance: next maintenance: next maintenance: next maintenance:

24 OPTIMAX®2010
Maintenance / Disposal

Attention:
Never start the machine up unless it is filled with liquid!

Recommended Maintenance Work:

English
1. Functional check
film intake / film transport / replenishment / bath heating / dryer heating / water supply
2. Cleaning
2.1. Switch off machine, remove cover
2.2. Empty all three tanks
2.3. Close drain cocks and fill tanks with water
2.4. Install cover, switch machine on
2.5. Fill two additional vessels with water, put suction pipes into these vessels and activate replenishment for at
least two minutes (to remove residues of chemicals from replenishing hoses)
2.6. Switch machine on for a few minutes
2.7. Switch machine off
2.8. Empty all tanks
2.9. Prepare tank cleaning agent for developer and water tank according to manufacturer´s instructions

Attention:
Do not use chlorine containing cleaning agents!

2.10. Fill developer and water tank with tank cleaning agent (do not use the replenishment pumps to do so)
2.11. Fill fixer tank with water
2.12. Place suction pipes into empty tanks
2.13. Install cover, switch machine on
2.14. Wait until the operating temperature is reached, approx. 30 °C (observe information concerning temperature,
time, cleaning procedure contained in the data sheet of the tank cleaning agent)
2.15. Activate manual programme and transport
2.16. After approx. 15 minutes (observe information concerning temperature, time, cleaning procedure contained in
the data sheet of the tank cleaning agent) switch film transport off
2.17. Remove cover, neutralise developer tank (observe information concerning temperature, time, cleaning proce-
dure contained in the data sheet of the tank cleaning agent)
2.18. Switch machine off
2.19. Empty all three tanks
2.20. Fill machine with water and switch it on
2.21. Put suction pipes into vessels with water
2.22. Activate regeneration pumps for at least five minutes
2.23. Check all pumps for tightness
2.24. Switch machine off
2.25. Drain tanks
2.26. Fill tanks 3/4 with water
2.27. Switch machine on
2.28. Activate replenishment pumps manually until tanks overflow
2.29. Activate film transport for a few minutes
2.30. Switch machine off and drain all three tanks

OPTIMAX®2010 25
Maintenance / Disposal

2.31. Repeat item 2.20 to 2.30 if required (observe information e. g. concerning temperature, time and cleaning pro-
cedure outlined in tank cleaner data sheet)
2.32. Remove roller racks from the machine and remove dirt under flowing water using a soft rag or sponge
2.33. Clean all toothed gear wheels, axles, bearings and rollers, check them for damage (replace if required)
2.34. Demount the cover sheet of the film intake and clean it using a soft rag
2.35. Clean inlet plate using a soft rag
2.36. Mount the cover sheet of the film intake
2.37. Align roller racks and re-insert them in machine
2.38. Fill machine with chemicals
2.39. Switch machine on
2.40. Adjust bath temperature to previously adjusted value
2.41. Feed cleaning film (approx. 4 pieces)
2.42. Check function as described under item 1
2.43. Approx. 15 minutes after reaching of the set bath temperature, measure it for confirmation and re-calibrate if
required (see operating manual page 39)
2.44. Perform sensitometric test

Be sure to dipose properly of used machines.

Used machine contain valuable materials that should be recycled
and turned over for proper treatment. Please be sure to turn used
machines over to approved recycling centres.

26 OPTIMAX®2010
Problems and Solutions

Problems and Solutions

Advice on Film Defects

Your processor has been constructed for long term use. However, if irregularities
occur, you will find help to locate the problem below. Please check the listed points,

English
before calling your service-technician.

Films do not have enough density

• Bath temperature is too low.
• Developing time too short.
• Exposure time is too short.
• Replenishment rate of developer too low.
• Developer chemicals are exhausted: Renew.
• Fixer solution has been mixed into developer: Renew. Clean and rinse bath
well before refilling.
• Circulation is broken down.

Too high a density

• Bath temperature too high.
• Developing time too long.
• Exposure time is too long.
• Replenishment rate of developer too high.
• Developer chemicals are too high diluted: Renew.
• After renewing chemicals: Starter is missing.
• Circulation is broken down.

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 polluted. Clean tanks and roller racks.

Cloudy film
• Level in developer is too low.
• First guide bar of fixer rack is dirty (condensate or crystals). Clean roller-
racks.
• Developer is old or circulation not working.
• Try processing films by infeeding them with emulsion side up.

OPTIMAX®2010 27
Problems and Solutions

Advice on Machine Errors

Unit does not switch on
• Ensure that electrical plug is firmly inserted into socket. Ensure that the elec-
trical socket is supplying power by testing with an appliance e.g. a table light.

Rinsing water does not flow

• Open water inflow tap.
• The water pressure in the water supply system is too low: Pressure in the
plumping system too low: Minimum pressure has to be 2 bar (29 psi).

Replenishment rate too high

• Check the programmed times of replenishment cycle and replenishment time.

Replenishment rate too low

• Check the programmed times of replenishment cycle and replenishment time.
• Check whether the machine can be started by means of each of the two film
detection switches in the feed slot. If one of the film detection switches is
defective, call your service technician. In the meantime, double the pro-
grammed replenishment time.

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. The replenishment
hose is aspirating air. Check the hose connections.

Water tank overflows

• Water drainage hose (overflow) is bent. The hose end should be positioned
above the drainage level in the syphon.›‹›‹
• Check water drain opening in the tank and the hose for blockage and resi-
dues. 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.

Film cannot be fed, the display shows “E1”

• Close machine cover securely, paying special attention that the switch on the
rear of the control panel is actuated.

Film is in the infeed and nothing happens

• Display is flashing: Control is in the manual mode. Switch back to Automatic
Mode (see page 20).
• Insert the film into the film feed so it passes the film detection switches. Feed
the film to activate one of the switches. If the unit should not start, activate the
other switch. If the processor still does not start, call your service technician.
In the meantime, with limitations the processor may be operated in the Man-
ual Mode (see page 20).

28 OPTIMAX®2010
Problems and Solutions

Film is caught up in the racks

• Switch machine off and remove cover.
• Check in which rack the film is caught up in and remove the respective rack.
• If possible, catch hold of the film end by hand and by manually turning the
drive-shaft, pull the film out of the rack.

English
• Replace the rack and secure with fastener. Replace machine cover and
switch the machine on again.
• If a film is caught up in the machine due to a power cut, it can be transported
out of the machine by activating the transport with a film in the infeed
(machine can also be started up in the manual mode, see “Manual starting
and stopping the film transport:” on page 20).

Important notes:
Ensure correct seating of roller racks; keep the lock closed at
all times.
Don’t operate processor with empty replenishment tanks.
After a long machine shut down check bath level and refill if
necessary.

Error messages
Machine errors are shown on the display as abbreviations. The cause of error is ex-
plained below. For service technician: problem solution see “Trouble shooting” in
service manual.

Display Cause and possible correction

E1 Cover switch is not actuated. Place cover correctly on the

machine and ensure that the cover switch behind the control
panel is actuated. If the error cannot be corrected, then the
cover switch may be broken.

UU Too low level of the developer bath. Check the level and fill up
by pumping manually or refilling manually.

OPTIMAX®2010 29
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.

Technical 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

30 OPTIMAX®2010
Accessories

English
At last you can breathe again
AIRCLEAN® 200 cleans the air from your processor. Unpleasant chemical odours
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.

Technical 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®2010 31
Accessories

32 OPTIMAX®2010
Service Manual
Table of Contents
Installation Data ................................................................................................. 34

English
Trouble Shooting ............................................................................................... 36
Spare Parts List.................................................................................................. 41
Electric Diagrams............................................................................................... 48
OPTIMAX 2010 NDT ........................................................................................... 54

OPTIMAX®2010 33
Installation Data

Installation Data

Optional worktable or
closed cabinet (accesso-
ries)

1. Wall socket
220-240 V, 16 A resp. 110 V, Darkroom
15 A (depending on machine 7
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.
2. Fresh water connection 3/4”
with stop cock, permissible
pressure 2-10 bar, water tem-
perature 5-25 °C. 1 2
3. Drainage plastic pipe PVC
∅ 50 mm (2“) incl. syphon.
4. Drainage resp. collecting con- 8
tainers for used developer.
Sink
5. Drainage resp. collecting con- 60 x 40 cm (24 x 16“)
tainers for used fixer.
6. Storing space for replenish-
ment tanks: Below machine or
externally. 4 5
7. Ventilation of darkroom is nec-
essary.
3
8. Sink with freshwater and flexi- 6
ble hose. Interior dimensions
minimum (LxWxH)
60x40x30 cm (24x16x12“).

Measures and positions are recommendations

34 OPTIMAX®2010
Installation Data

Through the wall mounting “film output”

- Film output to the light room for OPTIMAX®2010 type 116x-y-6000

Blind plate
All dimensions in mm.
1266-0-0001
Heights applicable in connection with PROTEC® worktable

English
1267-0-0030.

Counter plate
1266-0-0002

Counter sunk screw M4x12

3079-8-5033
Detail X

Film exit height

Wall break through

for film exit
Bottom edge of
wall plate

1. Wall opening according to drawing.

2. Fasten wall plate 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 wall plate and place foam rubber light protection
between processor and wall plate.
5. Hang in film catch basket at wall plate from the backside.
6. Check mounting-set for light im-permeability and function.

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

OPTIMAX®2010 35
Trouble Shooting

Trouble Shooting

Summary
1 Algae ............................................................................................................ 36
1.1 Excessive algae growth in water tank.................................................... 36
2 General......................................................................................................... 37
2.1 Unit does not switch on.......................................................................... 37
2.2 No display but circulation pumps run..................................................... 37
3 Drive ............................................................................................................. 37
3.1 Film transport does not run, film processing has started ....................... 37
3.2 Machine does not start automatically .................................................... 37
3.3 Machine doesn't stop automatically, motor and fan run continuously ... 37
3.4 Drive motor does not run ....................................................................... 37
4 Baths ............................................................................................................ 38
4.1 No circulation in bath ............................................................................. 38
4.2 Developer temperature too high ............................................................ 38
4.3 Developer temperature too low.............................................................. 38
4.4 Developer temperature too low, fixer temperature too high................... 38
4.5 Developer bath temperature too high or too low
(display shows values of 21 °C or 40 °C) .............................................. 78
4.6 Switch-over from °C to °F ...................................................................... 38
4.7 Calibration of bath temperature / actual bath temperature is different from
displayed value ...................................................................................... 38
4.8 Developer level switch constantly displays “UU” ................................... 39
5 Film Defects................................................................................................. 39
5.1 Films will not dry .................................................................................... 39
5.2 The film does not transport correctly ..................................................... 39
5.3 Scratches, pressure marks, dirt on film ................................................. 39
6 Replenishment ............................................................................................ 40
6.1 Replenishment pump does not work or works insufficiently .................. 40
7 Dryer............................................................................................................. 40
7.1 Dryer fan does not run or runs with too low speed ................................ 40
8 Water ............................................................................................................ 40
8.1 Rinsing water does not flow................................................................... 40
8.2 Water tank overflows ............................................................................. 40
8.3 Rinsing water constantly switches on and off ........................................ 40

1 Algae
1.1 Excessive algae growth in water tank
Algae growth inside the water tank is not only annoying, it causes increased clean-
ing work and leaves residue on the films. When algae growth increases, counter-
measures are in demand:
• 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 resi-
due 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 directly be connected 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).

36 OPTIMAX®2010
Trouble Shooting

2 General
2.1 Unit does not switch on
• Ensure that the power socket conducts power.
• Check machine fuses.

For replacement exclusively use PROTEC® gold cap fuses.

English
These fuses are optimized for use under existing conditions.

• 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, replace the electronics. If there is no volt-
age: check the cable.

2.2 No display but circulation pumps run

• Check input voltage of 5 V at the contacts no. 1 and 8 of the 8-pole-plug X18
from the control panel PCB. If voltage is present, then replace the control
panel.
• Disconnect the temperature sensor of the developer bath (X15) and check
display again.

3 Drive
3.1 Film transport does not run, film processing has started
• Display “E1”: see “Error messages” on page 29.
• Check screwing of chain wheel on motor- and driveshaft.

3.2 Machine does not start automatically

• When the machine is switched on, insert a film into the feed. If the display
shows two bars with decimal points, then at least one of the film detection
switches is in order. Check the function of both switches, replace as needed.
• The display shows “E1”: The cover switch is not actuated by the latch on the
cover. Cover switch has no current passage when activated: Replace.

3.3 Machine doesn't stop automatically, motor and fan run continuously
• Display is flashing: Control is in the manual mode. Switch back to Automatic
Mode (see page 20).
• The display continuously shows two bars with decimal points: Actuator of the
film detection switch is jammed. Readjust the switch or replace it. If the
switches are defective, the machine can still be used in the manual mode (see
page 20).
• The power output section may be defective, if so replace it.

3.4 Drive motor does not run

• Display “E1”: see “Error messages” on page 29.
• No continuity of cover switch when activated: Replace.
• Check drive motor: If voltage can be detected on motor, then motor is defec-
tive.

OPTIMAX®2010 37
Trouble Shooting

4 Baths
4.1 No circulation in bath
• Circulation pump works but no circulation in bath: Air lock in heating and cir-
culation system. Vent the pump.
• 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 posi-
tioned on tube and completely covered with foam rubber.
• Check sensor: Check voltage on sensor between pin 3 (green) and pin 2
(brown). At room temperature the tension must reach approx. 0.3 V.
• If the sensor has no fault then electronic is defective.

4.3 Developer temperature too low

• Check circulation pump. Air lock in the circulation pump: Ventilate pump (see
page 13). If no circulation can be detected: Check electrical connection of
recirculation pump; pump may be defective.
• Bath is not heated: Check temperature safety switch on heat-exchanger.
Check heating element: impedance across the element should reach approx.
66 Ω.
• Check temperature sensor (see 4.2).
• If no error can be found, then the electronics may possibly be defective.

4.4 Developer temperature too low, fixer temperature too high

• Air lock in the developer circulation pump: ventilate circulation (see page 13).

4.5 Developer bath temperature too high or too low

(display shows values of 21 °C or 40 °C)
• Check temperature sensor. Sensor is either not connected or defective.

4.6 Switch-over from °C to °F

The developer temperature can be displayed in either °C or °F.
Switch-over of temperature unit:
1. Switch the unit off.
2. Press and hold the buttons processing time (4) and developer temperature (5)
while switching the unit on.
3. Select the desired unit of measure with the arrow keys (2 and 3). C for Celsius
and F for Fahrenheit.
4. Switch the unit off to save the unit displayed.

4.7 Calibration of bath temperature /

actual bath temperature is different from displayed value
Differences between displayed temperature and measured value in the devel-
oper bath can be adjusted. An adjustment may be necessary after replacement
of a bath temperature sensor. An adjustment is recommended when the devi-
ation exceeds ±0.5 °C and is mandatory if the deviation exceeds ±1,5 °C.

38 OPTIMAX®2010
Trouble Shooting

Calibration process
1. Switch the unit off. Press and hold the developer temperature button (5) and
switch the unit on. The display indicates the developer temperature measured
by the sensor in 1 degree increments.
2. Measure the actual temperature inside the developer bath using a calibrated
thermometer.

English
3. Adjust the displayed value in 1-degree-steps to the thermometer value, using
the arrow buttons (2 and 3). Display of the digit after the decimal point is acti-
vated by pressing the developer temperature button (5). Adapt the value after
the decimal point to the thermometer value, using the arrow buttons.
4. Switch the unit off to save the calibration.
4.8 Developer level switch constantly displays “UU”
• Observe notes under 6.1 “Replenishment pump does not work or works insuf-
ficiently”, page 40.
• The developer level switch is not positioned correctly. The switching point is
below the developer overflow. Readjust the height of the level switch.
• The level switch is defective (e.g. closed permanently).
• If all of the above points are okay, replace the, control unit.

5 Film Defects
5.1 Films will not dry
• Check the set dryer output (“99” corresponds to maximum, that is full heating
output).
• No air comes out of air channel: check the connections of the fan, e. g. fan
defective.
• Cold air comes out of air channel: check the connections of the heating ele-
ment in the air channel, the heating element may be defective (resistance
must reached approx. 45 Ω ).
• 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.

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 splint
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 infeed direction indicate faulty guide elements.
Check each rack and straighten up the guide elements. If mechanically dam-
aged, replace the guide elements.
• Pressure marks caused due to polluted or damaged rollers. Check rollers for
visible damage. Rubber rollers sometimes swell up. Exchange defective roll-
ers.

OPTIMAX®2010 39
Trouble Shooting

6 Replenishment
6.1 Replenishment pump does not work or works insufficiently

• Clean valves inside connection tube of pump.

Install valve-insert correctly: Pay attention to flow-through di-

rection!

• Check filter in the suction pipe (repl. container) and clean it if necessary.
• Replenishment hose aspirates air. Check connections.
• Check eccentric position. Flow rate is 240 ml/min at maximum eccenter posi-
tion 100%.
• (60 Hz: 240 ml/min at 85 %!)
• Measure the voltage at the connection X6 (replenishment pump) on the power
output section while the replenishment is switched on (in manual mode). If no
voltage can be registered - replace the power section PCB. Remark: 2 pump
version: developer replenishment pump at X6 and fixer replenishment pump
at X5.

7 Dryer
7.1 Dryer fan does not run or runs with too low speed
• Check the correct connecting of the fan cables: bl = blue; bk = black; br =
brown.
• If the fan supply lines have been transposed, the dryer fan will run at half the
nominal output only.

8 Water
8.1 Rinsing water does not flow
• The water pressure in the water supply system is too low: Minimum pressure
2 bar (29 psi).
• The valve opens, but no water flows through: filter at inflow is blocked.
• Check the green water inlet hose inside the machine.
• The water level switch is not positioned correctly: switching point is too low
(below the overflow level), therefore no fresh water is supplied.
• The level switch is defective (e. g. permanently open).
• Start the unit in manual mode and measure the voltage at the connection X4.
If no voltage can be registered, replace the power output section PCB.
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 drain opening in the tank and the hose for blockage and resi-
dues.
• When extreme algae growth is noticed, the overflow can be connected
directly at the back of the water tank.

8.3 Rinsing water constantly switches on and off

• At regular intervals (approx. 1 minute on and 1 minute off): The water saving
mode has been activated.
• At short intervals: th level switch is not positioned correctly (exactly on the
overflow level). Insert the rack. If the error continues to occur, readjust the
height of the level switch.

40 OPTIMAX®2010
Spare Parts

English
8 9 10

2 11

7
6

Pos. Order No. Description:

1 1160-0-0200 Cover complete
2 2006-0-0005 Drain stop cock 10 mm
3 1170-0-2000 Replenishment tank 12 l dev.
1170-0-2100 Replenishment tank 12 l fix.
4 1170-0-1760 Suction pipe with filter for 12l tank, round
6 2004-0-0010 Electrical power lead 220-240 V
2004-0-0021 Electrical power lead 220-240 V
7 2018-0-0001 Water inlet tube
8 1267-0-0030 Processor stand
- 1267-0-0040 Closed base cabinet
9 1101-0-2000 Replenishment tank 25 l dev.
1101-0-2100 Replenishment tank 25 l fix.
10 1101-0-1700 Suction pipe with filter for 25l 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
- 2018-0-0021 Hose 9 x 2 mm, red, transparent
- 2018-0-0022 Hose 9 x 2 mm, blue, transparent
- 2022-0-0014 Tube clamp Snap
- 2022-0-0019 Wire tube clamp
- 2022-0-0027 Wire tube clamp
- 2022-0-0028 Wire tube clamp
- 2022-0-0005 Wire tube clamp
- 1101-0-4600 Floating balls, 300 pcs.
- 1101-0-4800 Floating balls, 200 pcs.

OPTIMAX®2010 41
Spare Parts

28

(52)

20b (20b)

21
20a

(30)

26

27

20 25

20

24
23 22
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 Conical valve f. pos 20
20b 0202-5-0002 Replenishment pump KBR-3X, 220-240 V, 50/60 Hz
0202-6-0002 Replenishment pump KBR-3X, 115 V, 50/60 Hz
21 2002-1-0016 Circulation pump 220-240 V, 50/60 Hz
2002-6-0016 Circulation pump 110 V, 50/60 Hz
22 2028-0-0023 Main switch 220-240 V
2028-0-0036 Main switch 110 V UL
23 2010-0-0004 Fuse holder
- 2010-0-0010 Fuse slow blow in gold, T 10A/250V
- 2007-0-0004 Cover for fuse holder
22+23 2028-0-0036 Device switch, therm. 110-120 V UL
24 1160-0-0702 Angle connection (aluminium)
25 0160-5-1300 Electronics 220-240 V
0160-6-1300 Electronics 110-120 V
- 1160-0-0705 PVC panel (control unit)
26 0170-0-2400 Micro switch (Cover)
0170-4-2400 Micro switch (Cover) UL
27 2007-0-0010 Actuator f. micro switch
28 2021-0-0001 Screw-in connector

42 OPTIMAX®2010
Spare Parts

34 38 33 32
35

37

English
31

35
30

40
39

Pos. Order No. Description:

30 2001-1-0004 Main drive motor 220-240 V, 50 Hz
2001-2-0004 Main drive motor 220-240 V, 60 Hz
2001-6-0004 Main drive motor 120 V, 50/60 Hz
31 1170-0-1101 Motor bracket
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 Split pin 2.0 x 20 mm, A4
39 2012-0-0013 Level switch
40 1120-0-1502 Bracket for level switch

OPTIMAX®2010 43
Spare Parts

54

50
62

63
53
51

Housing

61

64
56
57
58

55
52
59

Pos. Order No. Description:

50 1170-0-1301 Air channel
51 0170-0-1300 Heating element 230 V, 1100 W
0170-6-1310 Heating element 110 V, 900 W
52 2008-5-0007 Dryer fan 220-240 V, 50/60 Hz
2008-6-0007 Dryer fan 115 V, 50/60 Hz
53 1160-5-1900 Solenoid valve 220-240 V, 50/60 Hz
1160-6-1900 Solenoid valve 115 V, 50/60 Hz
54 2007-0-0015 Film detection switch
55 1160-0-0105 Film feed tray
56 2003-5-0002 Heating element 230 V, 800 W
2003-6-0002 Heating element 120 V, 400 W
57 1130-0-2101 Heat exchanger
58 2005-0-0005 Temperature safety switch mounted on heat exchanger
59 0190-0-2200 Temperature sensor
61 1170-0-1302 Channel dryer heating
62 1160-0-0801 Support bracket for film detection switch
63 2027-0-0012 Strain relief
64 1160-0-0710 Hose stub, rubber

44 OPTIMAX®2010
Spare Parts

100

103
112

English
108
111
102

113

117 104

110
121

114 119

115 120

116

109 122

103
123

106

107
105
104

104

Standard roller racks

OPTIMAX®2010 45
Spare Parts

Pos. Order No. Description:

Standard Processor
- 1170-0-0300 Roller rack, developer
- 1170-0-0400 Roller rack, fixer
- 1170-0-0600 Roller rack, dryer
Mammography Processor
- 1171-0-0600 Roller rack, dryer
Graphic Arts Processor
- 1172-0-0300 Roller rack, developer
- 1172-0-0600 Roller rack, dryer
100 0170-0-0301 Dryer side plate left w. shafts
1170-0-0301 Side plate, dev. (right)
0170-0-0401 Dryer side plate left 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 Worm wheel
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

131

The light protection cover can be removed. This is necessary to gain access to the
film detection switches and the developer level switch. To remove it, pull off the blind
(131) on the right side (!) of the cover and then pull the indexing bolt (130) from the
130 support toward the inside. The cover can now be removed to the top. Remark: The
left indexing bolt remains completely installed.

46 OPTIMAX®2010
Spare Parts

132 133
Attention!
The heat sink is not
earthed!

Once the operating panel PCB has been

removed, the control unit can be
removed. Please do not lift the control unit

English
out further than shown in the illustration. A
guide on the top edge allows to position
the control unit for service purposes.
Guide slot

Pos. Order No. Description:

130 1160-0-3103 Indexing bolt
131 1160-0-3106 Blind for light protection cover
132 2011-0-0137 Control panel foil
- 2011-0-0139 Operating membrane, 2 pump version
133 0160-9-1200 Control panel

Tips and Tricks

Removal of control PCB

To reach the screws of the control PCB, remove the film covering the buttons by
approx 20 mm on the top and bottom edges (lift it, see illustration top left).

Stop start-cycle
The start-cycle (after switching the machine on) can be manually interrupted. To
stop start-cycle, press both arrow-buttons (2+3) simultaneously. The start-cycle
may only be interrupted for service purposes.

Display of machine information

When during the start-up cycle one of the arrow-buttons is pressed then various
machine information will be displayed.
Arrow button “Up”:
The software version is displayed as long as you press the button.
Arrow button “Down”:
The number of film cycles is displayed as long as you press the button. Not the dec-
imal point. Since the display has two digits only, the value needs to be converted:
XX : value x 10 = number of films
XX. : value x 100 = number of films
X.X : value x 1,000 = number of films
X.X. :value x 10,000= number of films
9.9. : more than 990,000 films

OPTIMAX®2010 47
48
2. Film- Niveau
erfassung Entwickler
2. Film- niveau
infeet developer

Bad- Motor-
Niveau 1. Film-
drehzahl
Wasser temp. erfassung
variable
niveau bath- speed 1. Film-
water temp. motor infeet
Electric Diagrams

Bediensteuerteil
X17 X16 X15 X14 X13 X12 X11 control PCB
B1 B1 (1160-9-1200)
B2 B2
Aus-
B3 B3
schalter B4 B4
main B5 B5
B6 B6
switch B7 B7
B8 B8
Leistungssteuerteil
Sicherung
2xT10A/250V Power PCB
fuse
slow blow
2x 10A/250V (1160-5-1300)
Luftschacht
air channel

Gehäuseboden
1 pump version:
body bottom plate X6=FIX+DEV
2 pumps version:
Abdeckung Bedienteil X5=FIX, X6=DEV
cover control PCB
Pumpenplatte
X1 X2 X3 X4 X5 X6 X7 X8 X9 X10
pump plate serielle
Schnittstelle
Filmeinlaufblech
film infeet plate

bk
br
bl
Wärmetauscher
heat exchanger
Umwälzpumpe
circulation pump Motor
Zweite Re- motor
Motor Trockner- Temp.begrenzer
Gebläse generier-
pumpe heizung temp.limitor
motor dryer fan
second dryer-
Halter Hauptschalter Replenish- heating
Bracket Main Switch ment pump

Umwälz- Magnet-
Regenerier-
pumpe ventil
pumpe Diese Zeichnung ist ausschließlich unser Eigentum. Maßstab 1:1
circul.- solenoid- Replenish- Ohne unsere vorherige Zustimmung darf sie weder
DIN ISO
vervielfältigt noch Dritten zugänglich gemacht werden.
Pump valve ment pump Wir behalten uns alle Rechte vor, auch für den Fall der
Patenterteilung oder Gebrauchsmustereintragung. 2768 T1-m Optimax 2010
Bad- Datum Name
Bearb. 15.11.01 DK
heizung Gepr.
Stromlaufplan
bath- Norm
heating Wärmetauscher current flow chart
exchanger Blatt
1
1 Bl.
Zust. Änderung Datum Name

OPTIMAX®2010
Electric Diagrams

English

OPTIMAX®2010 49
Electric Diagrams

50 OPTIMAX®2010
Electric Diagrams

English

OPTIMAX®2010 51
Electric Diagrams

52 OPTIMAX®2010
Differences between OPTIMAX 2010 Standard (1160-1-0000)
and OPTIMAX 2010 with two pumps (1160-1-2000)
1. Control panel

English
Display working parameters
! Arrow button “Up” = increase parameter value
" Arrow button “down” = decrease parameter value
Mode Buttons
1 3 2
# Processing time in minutes
$ Developer temperature in °C
% Dryer output in %
& Replenishment time developer
' Replenishment time fixer 4 5 6 7 8
2. Replenishment time D F
I
E
V X
The replenishment function and adjustment of the replen-
Enter Memory Power on Autofill
ishment time are identical with the standard version. Recall Store Exit

3. Spare Parts List

1. In the service manual page 42, pos. 20: replenishment
pump with bellows: 0202-5-0002 (pos. 20b).
2. EPROM: 1160-0-0001

OPTIMAX®2010 53
OPTIMAX 2010 NDT
Order No. 1163 - X - Y000

X: 1 50 Hz Y: 0 Version with 1 pump

2 60 Hz 2 Version with 2 pumps

The film developer OPTIMAX®2010 has been extended by a further unit version.
Introduction
Processing time and developer temperature of the OPTIMAX®2010 NDT processor
have been adjusted to the requirements of NDT-films. This results in the following
modifications compared with the OPTIMAX®2010 standard version.
General
To maintain constantly good film quality the NDT-roller (upper roller of last roller pair
of developer rack) must be replaced every 3 - 6 months, depending on the quantity
of films processed, the chemicals and films used. 1 spare roller is supplied with the
unit. This roller must be considered a wear part and is excluded from the guarantee.

Important!
Please take care that the film does not carry any dirt into the
processor.

Technical Specifications (compare page 8)

Processing capacity: 129 films 24x30 cm (crosswise), at lowest

processing time
Process time: 1.5 - 10 min

Linear speed: 8.4 - 56.0 cm/min

Developer time: 25-164 s

Developer temperature 26 - 37 °C / 78 - 99 °F

Processing time (compare page 17)

Processing time from 1.5 - 10.0 min

Processing and developer time relation

Processing time (min) Developer time (s) Infeed speed (cm/min)
1,5 25 56
1,7 28 49
2,0 33 42
2,3 38 37
2,5 41 34
2,7 44 31
3,0 49 28
5,0 82 17
8,0 131 11
10,0 164 9

Developer temperature (compare page 18)

Adjustable 26 - 37 °C / 78 - 99 °F)

54 OPTIMAX®2010
OPTIMAX 2010 NDT
Spare parts list (compare page 41)

Pos. Order No. Description:

25 0163-5-1300 Power output section OPTIMAX 2010 NDT 230V
- 0163-6-1300 Power output section OPTIMAX 2010 NDT 110V
- 1163-0-0300 Roller rack developer NDT
- 1163-0-0400 Roller rack fixer NDT
- 1163-0-0600 Roller rack water/dryer NDT
124 1163-0-0307 Roller NDT (output roller top of developer rack)

English
125 1161-0-3900 Guide rail 2, bent without ribs
126 1161-0-4000 Guide rail 2, bent with nose, without ribs
127 1101-0-0317 Bearing bush, large, black

Developer (red) Fixer (blue)

Water/dryer (beige)
125 Guide rail 2, bent without ribs
1101-0-3900

126 Guide rail 2, bent with nose, without ribs

1101-0-4000

127 Bearing bush, large, black

1101-0-0317

124 Roller NDT

1163-0-0307

OPTIMAX®2010 55
56 OPTIMAX®2010