HANDBOOK OPERATION AND SERVICE INSTRUCTIONS RAPID ACCESS FILM PROCESSING CONSOLE MODEL RAPC 5-250 FOR(Sanitized)

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Document Number (FOIA) /ESDN (CREST): 
CIA-RDP78B04747A002100060001-2
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RIPPUB
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K
Document Page Count: 
54
Document Creation Date: 
December 28, 2016
Document Release Date: 
June 19, 2001
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1
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REPORT
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Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 DECLASS REVIEW by NIMA/DOD Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Ii7-~:CIDBOOI{ OpEraticn and Service Instructions ' RAPID .ACCESS FILM PROCESSING COI~iSOLE I~~IODEL RAPC 5-250 ' for STATI NTL STATI NTL 1 i Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 1 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Paragraph. Pao~e :LIST ?T ILLUSTRATIONS. . . iii SECTI?N I. ZNT?20DUCTI?N AND DESCRIPTI?T1 1 1-1 .Introduction . , 1 1-4 :Purpose . l 1--6 ~Wharacteristies . 1 ~.-8 :3escription . . 3 SECTI?N II. ~~PERATI?N . . . $ 2-1 i3eneral . . 8 2-3 ~~perational Procedures 8 2-5 :Installation 8 2-11 :[,oadinc~ and Threading 9 2--15 1~7armup . i1 2-16 t~pera~.ion . . . . 11 2-24 'C'h.eory of ?peration 14 SECTI?N III, ;iPECIAL SERVICE TU?LS AND TEST EQUIPMENT 20 3-1 ;special Service Tools 20 3-2 '.Cast Equipment . 20 3-3 ~~pplication of Special Service Tools , , 20 3-6 e~pplication of Test Equipment 20 SECTION IV. :INSPECTION faI~TD LiJYRICATIC7N 21 4~-2 ta~I3eral, . . 21 4-3 ]?re-Flight Inspection 21 4-4 I?eriodic Inspection , 22 4-5 lubrication . . 23 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 t Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 TABLE OF CONTENTS (continued) Paragraph - ~.~ 5ECTION V, MAINTENANCE Page 5-1 General 24 5-5 Cleaning , 24 . . 5-9 Trouble Shooting 26 5-13 Removal, Repair and Replacement 30 . . 5-20 Adjustment , 31 . . SECTION VI, PARTS LIST 32 . . . . . . . . . . . . . . 6-1 Parts Numbering System 32 . . 6-2 ,Assemblies 33 . . . . . . . . . . . . . . . 6-3 :List of Mechanical Parts 34 . . 6-4 :List of Electrical Parts 35 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 1 t Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 LIST OF ILLUSTRATIONS Figure No. Title Frontispiece - Rapid Access Film Processing Console 1-1 Console - Operational Controls 1-2 Console -- Side and Rear 1-3 Processing Assembly (Applicators and Tank - Processing Position - View from Operator's Side) 1-4 Processing Assembly (Applicators and Tank - Processing Position - View from Opposite Side) 1-5 Processing Assembly ( Chemical Supply Tanks Removed) 1-6 Processing Assembly (Applicators in Threading Position} 1-7 Drive Motors and Stepping Switch Assembly 1-8 Loop Sensor Mechanism 1-9 Electronic Chassis 5-1 Maintenance - Front Panel Removed 5-2 System Schematic 5-3 Threading and Film Transport Schematic 5-4 Processing System Schematic Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 t Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 FRONTISPIECE-RAPID ~~CCESS FILM PROCESSING CONSOLE. Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 1-1, INTRODUCTION an display portion of an airborne CRT film recording and displ SECTION I. INTRODUCTION AND DESCRIPTION 1-2. This handbook contains descriptive data and instructions for the operation and servicing of the Rapid Access Film Proces ing Console, The processing console functions as the processin d system. The equipment was produced b for use with a SK-4361 which designated as DPD-2, herein STATI NTL 1 1-3, The Rapid Access Film Processing Console is self-contained and operationally controlled from the front panel, On/off control for the film drive in the - recorder is provided, 1-4. PURPOSE 1-5, The Rapi~~ Access Film Processing Console, herein referred to as the Rapi~9 Film Processor, is intended for use in a C-130B aircraft, It .is designed to accept film emulsion, STATINTL or its equivalent, coated on a white opaque p otographic paper (hard copy), p::ocess the film, present the film for viewing while simultancaously drying it, store the film in a slack box, and recall the film from the slack box upon command, A review platform is provided for examining the film as it is recalled from the slack box, 1-6. CHARACTERISTICS 1-7. Following is a list of the characteristics of the Rapid Film Processor. OPERATION7~L CONTROLS Operation: front panel mounted control switches and side mounted manually operated loading and threading knobs, Control sti~itches include: 1, Powez 2, Heaters (processing chemicals) 3, Dryer 4, Pumps 5, Operate Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 6. Purge 7. Full (Slack Box full indicator and reset) 8. Tank latch release switch (inside tank access door); red ceded 9. Takeu~~ control Manual knobs include: 1. Dance~_ latch - yellow 2. Chemical tank access door - grey 3. Tank :locking knobs ( 2 ) - red 4. Presst:re roller release (2) - green Operation :Cndicators: Indicator lamps are integral with each control sw:.tch, excluding the tank latch release switch and takeup motor control. Manual knobs are color coded, Lamps are colored as follows: 1. Power - red 2. Heatex?s - yellow and green (green indicates ready to F~rocess) 3. Dryer - blue 4. Pumps - yellow 5. Operate - dark green 6. Purge - red 7. Slack box full - red t i Power Input: Standby - 115V, 400 cycle, single phase, 1.5 amp, 28VDC, 1 amp Operate - 115V, 400 cycle, single phase, 10 amp, 28VDC, 2 amp Lubrication - as per section IV, at manufacture for 500 hours of operation Environmental Conditions - Ambient temperature - 32? -120?F Altitude - sea level to 20, 000 feet Slack Loop Storage Capability - 20 feet or 2 minutes operating time Slack Loop :Eteeall Rates - 0 to 8 inches per second Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 t Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Film Motion - continuous, at a nominal fixed rate of 2 inches per second, Subject to d,c, command signal from servo amplifier which synchronizes rate with output rate of recorder. Dump Box c=apacity - in excess of 50 feet of 5 inch film Processing Capability - at least 250 feet of 5 inch - film or paper, without chemical replenishment Takeup Dr:.ve Tension - 3 to 4 pounds Processincl Time - 5 seconds total Keeping Quality - Semi-archival (minimum of one year) Weight - ~~pproximately 90 pounds Chemical f~equirements - Develo~~ing Solution - 1 quart Developer No. 238 Clearir.,g Solution - 1 quart -Clearing Solution No. 193 Rinse ~;olution - 1 quart Rinse Solution No. 174 STATI NTL STATI NTL STATI NTL 1-8. DESCRIPTION (see Frontispiece and Figures 1-1 through 1-9) The Rapid Film Processor consists of three major sub-assemblies: 1) the main console, 2) the processing assembly, and 3) the electronic chassis assembly, The principal components contained within each of these subassemblies and their functions and descriptions are tabulated in the following: Main Conscle - Functions as the basic structural member of ._._. the processor and support for processing assembly and the electronic assembly. Figure Callout Nomenclature Function and/or Description 1-2 1 Bellows Light tight passage between recorder and processor. 1-8 1 Limit Switch, Automatic shutoff for upper recorder if film input from recorder exceeds trans- port capability of processor -3- Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 i Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Fi.qure Callout Nomenclature Function and/or Descri tion 2 Limit Switch, Automatic shutoff if film lower input to processor stops, (Does not de-activate recorded film drive.) 1 Control Panel 1 a.Power Switch Main power switch for entire processor 2 b,Heater Switch Warmup switch for processing chemicals 3 c.Pumps Switch For operating pumps indepen- dently of other processor functions 4 d.Dryer Switch Activates dryer blowers and heater for warmup previous to processing 5. e.Operate Switch Activates all normal processor 6. f,Purge Switch Review Station Viewer/dryer door Slack Box Full Indicator Lamp and Switch functions Purge applicators of process- ing chemicals previous to shutdown. Permits examination and anno- tation of film after recall from slack box. Provides access to film for threading Provides warning that 20 foot capacity of slack box has been exceeded. Contains reset switch. 9 Takeup Control Controls film recall rate from slack box. 1 Tank locking To retain chemical tank knobs 2 Air Inlet 3 Air Exhaust 4 Tank door Dryer air supply To discharge dryer air Access to chemical supply tank 5 Pressure Roller Retract metering roller release pressure roller for threading 6 Pressure Roller Retract takeup roller release pressure roller for threading Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 t Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Figure Ca11oL.t 1-2 1-2 1-7 1-7 Nomenclature Loop Sensor Knob Connector J3 Connector J4 Rear panel Film Metering Roller Film Metering Roller Drive Assembly Pressure Roller Film Takeup Roller Film Takeup Roller Drive Assembly Slip Clutch Stepping Switch Assy. Takeup Motor Potentiometer Slack box Spring Roller Idlers Rack and pinion Bellows Function and/or Description To latch loop sensor roller in down position for thread- ing Power input to processor Interlock connector to Recorder STATINTL Dust cover and support for electronic chassis Drives film at rate proportional to servo amplifier output command signal Motor and gear train to rotate metering roller For metering roller Recall film from slack box Motor and gear train to rotate takeup roller For film takeup roller Circuitry for activating slack box full lamp To vary film recall speed Stores processed film For loop sensor roller Loop Sensor Fixed center rollers in loop sensor mechanism Provides d.c, command signa]_ to servo amplifier To actuate potentiometer A light tight passage between processor and recorder ' Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Processin~x Assembly - F i ure Ca l l~~ut Nomenclature Film Platen Applicator Assembly Plate Retractor Solenoid valve Function and/or Description Support for film during processing Mounting plate for applica- tors. Hinged for threadinct. Contains adjustable appli- cator pressure springs. Retract applicator from film Purge applicators at the completion of processing Pressure Adjust pressure on applica- Developer Applicator Clearing App- Apply appropriate process- licator ing chemical to film Rinse Appli- cator Connector Pl Provides power from console to pump motor, solution heaters, thermistor, purge solenoids and tank latch solenoids Thumbscrews Pump motor Tank latch Tank latch solenoid Pump drive assembly Heaters Thermistor Housing Pumps Solution Tank Secure applicator support plate in operating position Drives pumps through gear train Supports solution tank during installation and removal Release tank latches Gear train from pump motor Heat processing chemicals to operating temperature Housing for processing solu- tion temperature sensing element For processing solution circulation Contains the three process- ing solutions used to rapid process film ' Approved For Release 2001/A$i43 : CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Figure Calloi~t Nomenclature Function and/or Description 1-6 1-6 5 6 Applicator Pins Standoffs Locate applicators in position on film platen Retain thumbscrews 1-6 7 Tubing To circulate chemicals 1-3 5 Yoke Retain applicator on 1-3 6 Springs applicator pins Maintain contact between 1-3 2 Screw film and applicator Applicator pressure adjust- 1-5 6 . Screw, tank ment Clamps and retracts tank 1-5 5 clamp Pins Align tank with baseplate 1-5 4 Baseplate Supports pump drive unit, heaters, pumps Electronic Chassis Assembly - The electronic chassis accepts power from the aircraft and provides the power input and the control circuitry for the electronic components previously described. Provides power to the film metering roller such that film speed is synchronized with the film recorder and propor- tioned to the dancer assembly potentiometer position. Processing solution tempera- ture control circuitry Processing solution temperature control circuitry Heaters and Operate Relays Provides power to take up motor. It is proportioned to manually controlled potentiometer. For low power heating Overload protection Between electronic chassis and main console Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 FIGURE 1 -1 CONSOLE -CiPERATIC)NAL CONTROLS Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 t Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 FIGURE 1-3 PROCESSIPIG ASSEMBLY (APPLICATORS AND TANK IN PROCESSING POSITION-VIEW FROM OPERATOR SIDE) Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 . ~ r ~^^~ ... .... ^~ ...^ .. .. ~^ ~.. ... Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 FIGURE 1-4 PROCESSING ASSEMBLY (APPLICATORS AND TANK IN OPERATING POSITION-VIEW FROM OPPOSITE SIDE) Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 FIGURE 1-b PRCKESSYVG ASSEMBLY APPLICATORS IN THREADING POSITION) Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Appro / or Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 FIGURE 1-7 DRIVE MOTOR AND STEPPING SWITCH ASSEMBLY Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 FIGURE 1-$ LOOP SENOR MECHANISM Approved For Release 2001/08/1~~C1A-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 1 1 1 1 2-1. GENERAL 2-2. The Rapi~~ Access Film Processing Console is controlled entirely by external control panel mounted components. A switched line is provided by the film processor to initiate and maintain t:1e film drive in the film recorder. Limit switches are also provi~~ed to prevent malfunction due to improper film transport. 2-3. OPERATIO]JAL PROCEDURES 2-4. The Rapid Film Processor is considered read for operation after being co::rectly installed in line with the film STATINTL recorder, thre~~ded with film, and loaded with free processing chemicals. Alignment between processor and recorder is critically maintained to assure proper film tracking. Installation of electrical cab:tes from aircraft-to-processor and processor-to- recorder is al:~o required. POWER - Power from the aircraft is routed to the processor through the POWER switch. Initiation of the POWER switch provides 28VDC and 400 cycles to the appropriate internal components. Normally, the 1?OWER switch should be initiated during preparation for operation. 2-6. Mount - "he Film Processor is designed to be mounted on a rigid frame or an equivalent structure which should also be the mount for i;he Film Recorder. Six (6) ~-28 bolt holes in the bottom of the c:onsole are provided for fastening to the frame, 2-7. Dryer Ai1~ - A 2'~" dryer air inlet tube (callout 2, Figure No. 1-2) is located on the right hand side of the console, This provides t;he entry point for air into the film drying section. Drying air may be introduced from a remote point by connecting fle~:ible tubing (not provided) to the inlet tube. Air is discharged from the dryer to ambient just below the inlet (callout 3, Figure No. 1-2). No special provisions for exhausting dryer air are required since the water pickup from the film is relatively small. 2-8. Cables - Connect power cable to the aircraft power supply. Connect signal cable from film processor to film recorder. (NOTE: Power gable is provided unterminated and must be terminated Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 after correct .Length has been determined,) Single cable carries a.c, and d,c, power, 2-9. Access - Access to the Film Processor is required from the front, top an~? right side. Approximately 10 inches of head space abo~~e and 20 inches on the right hand side are necessary for ?threading and loading, Sufficient room in front for an operator: to stand or sit is required for operation, 2-10, PREPARA!CION FOR OPERATION 2-Il. LOADING AND THREADING 2-12. The film processor should be loaded and threaded in accordance with the following procedures 2-13, LOADING CHEMICALS a, Open chemical tank access door on right side of console by turning the gray coded knob countezclockwise. b. Remove tank (callout 3, Figure No, 1-3), by turning the (2) red coc9ed knobs (callout 1, Figure 1-2) clockwise until tank drops onto two (2) latches (callout 4, Figure 1-4). c. Grip bottom of tank and depress red solenoid latch release switch (located inside of tank compartment). This will retract the twc~ latches and permit the tank to be lowered and removed from ttie tank compartment. Note: If "POHER" switch is not actuated, i;he latches may be manually released, STATINTL d. Fill 1three compartment tanks with 1 quart each of the following chemicals - Developer #238B, - Clearing Solut:.on #19 an rose #174B. The compartments are labeled DE~-ELOPERQ CLEARING, and RINSE. Note: They processing chemicals in the solution tank should be at a temperature of 50 F or more to obviate salting-out anti subsequent damage to the solution pumps upon going into opez~ation, If salting-out is experienced the salts ma~ be restored in solution by heating the chemicals to between 70 F and 130?F with concurrent agitation. 'This procedure will not impair chemical activity provided the developing solution is not unduly z~erated. e. InseY~t tank into tank compartment. Raise until guide pins and latchE:s are engaged. The bottom may then be released and the tank r~~ised to its operating position by turning the red coded knob. in a clockwise direction until securely fastened. f, ClosE~ access door and lock into place by turning grey coded knok- clockwise. Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 cover using captive thumbscrews (callout 2, Figure 1-3), b. Retr,~et and lock each of three applicators in a non-~~perative position, This is accomplished by lifting the knurled screws (callout 7, Figure 1-3) and :applying one quarter turn, o. Raise: applicator assembly on its pivot bar and lock in ar.. upright position using the locking pin located in tY:.e front pivot support, Locking is accomplished by sliding the applicator assembly toward the front of the console after it has been raised to a vertical position, 2-~,4, FILM TF:READING (see Figure 5-3) The "POh'ER" switch should be on during this procedure and sufficient film (approximately two feet) made available from the recorder to thread through the loop sensor assembly, a. Remove top dust e, Depress loop sensor roller (callout 4, Figure 1-8) to its extreme bottom position and latch in place using yellow coded knob located on right side of console. f. Manually feed the leading edge of the film between the t~h~o idler rollers (callout 5, Figure 1-8) and over the loop sensor roller, g. Using the film drive override switch in the recorder to feed film from the recorder into t e proce.;sor, thread the film over the processing platen, into t:he dryer sectio h. Retract metering roller pressure roller by turning green coded knob approximately one half turn and threat' film into and out of slack box, Release pressure roller, i. Do NOT retract takeup roller pressure roller, Feed fi3,m through until it emerges on underside of console, Now retract pressure roller and align film in proper path. Release pressure roller, j. Close dryer door - threading is complete. k. Release loop sensor roller. 1, Return applicator assembly plate to operating positi~~n and lock in place with two captive screws, --~ -rr~~..~..~.~ aaSCmoiy plate (callout 1, Figure 1-3) by turning two captive thumbscrews (callout 2, Figure 1-3) in the counterclockwise direction, ewer section sho ld b ~ A u e open t facilitate threading1 ' Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 m. Place three applicators in operating position on the :Film by rotating knob and shaft ~ turn until pin ~9rops through shaft. This is a reversal of procedure described in "b". Note: Be sure 2 yokes (callout 5, Figure 1-3) on the ,ides of each applicator fit over locating pins (callout 5, Figure 1-5) in platen so that the spri~ig loaded applicators are in intimate contact and "floating" on film. n. Rep rice dust cover. After the processor has been loaded with chemicals and threaded, perform the following warmup procedures: a. Init~.ate "POin'ER" switch, if off. b. Initiate "HEATER" switch - yellow lamp will light to indicate chemical solutions heaters are on with full power. H~hen chemicals have reached t~e correct operating temperature (approx. 120 F) the green "READY" lamp will light. c. Approximately sixty seconds before the processor is to be: run, activate "DRYER" switch to permit the air Y:.eaters to warm up, V~ARNING: Do not open dryez?/viewer access door while dryer blowers are activated to prevent film displacement from dryer path. d. Activate "PUMP" switch to establish chemical flow through the applicators. e. Activate "FULL" switch to reset stepping switch circuitry. The processor is now in a condition of readiness for operation. 2-16. OPERATION In the condition of readiness previously described, film will be transported, processes, dried and stored in the slack box when the "OPERATE" switch is activated. Processing will be automatic as long as film input to the processor is in the range of two inches per second within a tolerance of +10%. 2-17. SLACK BOx RECALL Film may be removed from the slack box at a variable rate from 0 to 8 inches per second by means of the panel mounted Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 i takeup control (callout 9, Figure 1-1), With the arm in a completely for~Nard position (toward operator), recall speed is approximately 8 IPS, In the back position (toward console) recall rate is zero and all the processor film will accumulate in the black bc~x, A detent is provided for retracting film from the slack box at a rate approximately synchronous with the nominal proces:~ing speed of 2 IPS, 2-I8, SLACK BOX FULL When the :slack box has accumulated approximately twenty feet of film the_reil "FULL" indicator lamp mill warn the operator to withdraw film i'rom the slack box, Although actual slack box capacity is in excess of 20 feet, in practice this should not be exceeded to preclude jamming of the film. Reducing the quantity of film in the slack box below 20 feet will de-energize the full indicator lamp, 2-19, FILM TAREUP The film takeup roller is driven through an overrunning slip clutch. Hhen all the film has been recalled from the slack box, the takeup roller will continue to drive film into the dump box as fast as it is being processed, ~~ith no accumu- lation in the slack box (at recall rates in excess of 2 IPS). 2-20. INTERMITTENT OPERATION The film transport function may be interrupted at will by deactivating the "OPERATE" switch, Pumps and air heaters will continue to run.For short interruptions (up to 3 minutes), it is convenient to leave these components activated in order that the processor will be maintained in a "READY" condition so that film transport may be resumed without loss of the processing capa:~ility. For longer interruptions, the applicators should be purge~~ and the pumps and dryer deactivated, H~nen resuming operation, go through a normal "t^'ARML'P" procedure as described in Paragraph 2-15, 2-21. PURGE Three solenoid valves are provided for purging the chemicals from the applic~itor during a temporary or "End of Operation" shutdown, To purge the applicators, activate the red "PURGE" switch while thec pumps are running. Maintain this condition for a period of approximately thirty seconds. During this interval the processing solution will drain back into their respective comp2~rtments within the solution tanks. Stop pumps Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 with "P~~'IPS" switch and deactivate "PURGE" switch, Applicators are now sufficiently purged so that they may be retracted, if desired. 2-22, HANDLING OF PROCESSING SECTION AFTER COMPLETION OF SCHEDULED ~,PERATION Upon return to a non-operating condition at the completion of a full 120 foot run, all film will have been processed and dried. To prepare the processing section for the next 120 foot run, proceed as follows: a. Purges the applicators as described in paragraph 2-21, b, Remo~~e dust cover and slokly retract applicator assembly as described in paragraph 2-14, A small quan?~ity of liquid will remain on the platen and in the applicator, c. Using a sponge or paper towels, quickly remove residue processing chemicals from the processing platf~n and applicators, DRY PLATEN THOROUGHLY, d, Using a clean wet sponge, carefully clean the acce;csible surfaces of the three applicators. EXTRF;ME CAUTION SHOULD BE EXERCISED TO PREVENT DAMAGE TO THE APPLICATOR LIPS. e. Clear.. all rubber covered rollers with a cloth (part.icularly metering rollers) saturated ~ ith alcor.ol or acetone to prevent emulsion buildup and subsequent slippage, 2-23. Storage of Rapid Processing Chemicals: Developer - #4027-2388 Cleaning Solution - #4027-193 Rinse Solution - #4.027-1748 The developer in full, well-stoppered bottles has a shelf fife in excess ~~f six months at 60 to 70?F, Sustained storage at above normal room temperature will have a detrimental effect on the developer, resulting in shortened shelf life. The developer shoul~~ be stored in subdued light or preferably in darkness, Storage conditions for the clearing and the rinse solutions are not as crit:Leal as for the developer solution. However, all solutions should be stored in full, well stoppered bottles. High temperatures (above room temperature) are usually more harmful to the keeping qualities of photographic materials Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 than low tempe~~atures. Rapid Processing Solutions will withstand tempE~ratures as ow as -40?F for short periods, provided they ~tre brought to normal temperatures prior to use. At temperaturess 50?F and lower, certain chemicals will begin to "salt out" :n the clearing solution and in the developer solution The chemicals will go back into solution at 75 to 90~F wit~i some stirring or shaking of the bottle. No loss in processing capability is incurred. If adverse' storage conditions do exist for any length of time, the deve~.oper solution will be the first to show deterioration. A sensitometric film test is the only sure method of determining processing capability. This may be accomplished bg- processing an exposed sensitometric film strip in the solution in question and comparing results with an existing type, known to be of optimum quality, under processing conditions (time-temperature) identical to the test. If a sensitometric-a-xposure film test is impractical, any subject matter exposurF: will suffice provided a similar known type, of optimum quaJ.ity, is available for comparison purposes. If the test fiJ.m compares favorably with type, then the processing solution is good and it may be used in the processor. 2-24. THEORY CIF OPERATION ' 2-25. GENERAL ' For the pt~xpose of this discussion, the Theory of Operation is divided intc- three parts: chemical, mechanical and STATINTL electrical. 1 The paper is rapid processed within the processor using film processing chemistry, using high temperature (120oF) e~ve~opment, followed by stabilization, and producing~a good quality photographic hard copy in about five seconds. The process involves three sequential applications: developer, cleaning and rinse solutions which are applied in time increments of: developer-~2 seconds, clearing-2 seconds, and rinse-2 seconds. The high energy, high caustic developer reduces the photo- graphic latent image to metallic silver, rendering it visible. Organic restrainers in the developer limit its action such that the quality of the photographic record is not unduly influenced by variations i.n time-in-process, as may be experienced with variable film transport rate. The clearing solution performs a function similar to a conventional fixing solution, except the unexposed silver Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 is rendered transparent rather than removed. The rinse or stabilizatian solution removes excess clearing solution from the emulsion surface, preventing the formation of a haze due to su:rfaee salting, and it also stabilizes the photographic image, 2-27 , MECHANI~rAL The mechanical system is comprised primarily of the components regixired to 1) transport paper through the processor, Thos includes the mechanism required to provide the input to tree servo amplifier for synchronizing the processor speed to recorder speed, an6 2) apply the processing chemicals to tree paper. 2-28, Film Tr~.nsport - The input of film to the transport system (see Fic?ure 5-3) is through the light tight bellows. It then passes thz~ough a loop sensor roller assembly consisting of two idler rollers, a variable position loop sensor roller, which is maintained under constant tension by a neg'ator spring, and a rack and pinion drive mechanism for the potentiometer, While the film input rate is nomina lly a constant two inches per second, minor variations will change the position of the loop sensor roller which will, in turn, vary the potentiometer position to provide the correct command signal to the servo amplifier for any given film speed, Idler rollers are provided on both the input and output sides of the processing section to maintain the required flat film plane on t'he film platen. The film metering roll drive, which is the output of the servo system, consists of a rubber covered drive r~~ller and a spring loaded teflon pressure roller. The rubber covering has a high coefficient of friction when in contact with the film, and in conjunction with the pressure roller provides the necessary tension on the film to pull it through the pro+:essing applicators, The pressure roller is teflon covered ?_o prevent the film from adhering as it enters the slack box, The takeup roller drive system is similar to the metering roll drive exce~~t that it is overdriven through a friction slip clutch so that .:t is unnecessary to synchronize it with the metering roller, Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 2-29. Application of Film Processing Chemicals - Chemicals are applied to the film by means of multi-chambered rubber lined applicat~~r, one applicator for each chemical. The lengths of the applicators are proportioned to the required time in proces~3. Chemicals are applied to the emulsion side of the film on:Ly and within the five inch f ilm width. Actual processed width if 4-5/8 inches. The applicators are maintained in intimate contact with the film throue operable only if their respective switches are activated. Also, the K2 relay provides a +28VDC voltage input to the mei:ering roller drive motor amplifier A10. Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 2-36, Film Drive Servo Amplifier - The film drive servo amplifier is o~~erated closed loop to synchronize it with the film recorder :Film output rate, The principal electronic components in 1~he servo loop are the servo amplifier A10, the film drive motor B4 and the loop sensor potentiometer R6, The servo ampl:fier consists of transistors Q1 and Q2 which act as voltage and current amplifiers respectively, to the drive motor, w:~th the input signal provided by R6, the sensor potentiometer. Safety interlock limit switches S9 and 514 which are 9 or S14 are actuz-- ted resulting ir- shutdown of processor and/o1~ recorder or inter- mittent operation of recorder 2. Defective transis- tor Ql or Q2 2. Replace relay 1. Replace lamps 2. Check circuitry and remedy 3. Tighten set screw 4. Replace switch or actuator 1. Replace lamps 2. Replace switches 1. Measure voltage out- put of potentiometer R6 at extremes of loop sensor roller travel. If beyond range of 12-27 volts, replace. 2. Replace transistor Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Trouble film slips on metering roller Probable Cause 1, Dirty metering roller Remedy 1, Clean metering roller Takeup roller will not recall film from slack box Film adheres t~~ pressure rolle::s Film jams in slack box Film not dry iii slack box 2, Insufficient pressure roller spring pressure 3. Excessive applicator spring pressure 4. Pressure roller retracted 1. Dirty takeup roller 2. Pressure roller re- tracted 3. Clutch tension too low 4, Defective takeup motor B5 5, Defective gear train 1. Tacky or dirty pres- sure rollers 1, Tacky pressure roller 1. Excessive ambient relative humidity 2, Excessive moisture on film leaving applicator 3, Threading access door open 4, No air flow 5, Drying air not heated 2, Increase spring pressure 3. Reduce applicator pressure 4. Release pressure roller 1. Clean takeup roller 2. Release pressure roller 3, Increase clutch tension 4, Replace motor 5. Repair or replace gear train 1. Clean pressure rollers 2. Clean pressure roller 1, Do not store fimm in slack box; transport directly to dump box 2. Check applicators for improper seating or defective lips replace applicator if lips are defective 3, Close access door 4, Check air blower & associated cir- cuitry. Correct or replace as required. 5, Defective heater- replace. Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 5-12. PROCESSING PROBLEMS The following notes assume that the exposure on the film is correct, the circulatory system is connected properly and that the solutions are installed in the proper sections within the supply tank, Check prior to troubleshooting. Trouble Probable Cause Light transverse streaks in the recording area 1. Excessive air bubbles in the developer section of the appli- cator Longitudinal ~ 1. Low developer flow streaks rate and/or station- in the recordin~~ ary air bubble in area the developer section of the applicator Overdeveloped, ~~r 1. Developer temperature dark appearance, high f og in the areas of low exposure Underdeveloped ~~r light appearance= of the recordin~~ Brown stain over: the recording a::ea High overall fo~~ in the recording a~:ea. Remedy 1. Check applicator, purge valve and circulatory system for air leaks and remecy. Check for improper seatina of developer appli- cator. la. Check applicator and circulatory system for obstruc- tion to flow and remedy. lb. Replace developer pump, 1. Check developer hig~i (should be 120- temperature control 130 F) circuitry and adjust. 1. Developer temperature 1. Check developer low (should be 120- temperature 130oF) control circuitry and adjust. 1. Excessive developer 1. Empty all solutions in rinse solution. from the supply tank, See NOTE above, clean tank thoroughly, and install fresh solutions, 1, Excessive clearing la. Check applicator solution in the chamber lips for developer. See NOTE damage permitting above, a cross flow of solution. Replace applicator if damaged. -28- Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Trouble Probable Cause No developed imeige, 1, Excessive runaway clear recording temp for any one or area all of the three processing solutions Remedy lb. Empty all solutions from the supply tank, clean tank thoroughly and install fresh solutions. 1. Check temperature control circuitry and remedy. 2, Clearing solution 2, Empty all solutions applied before devel- from the supply tank, open. See NOTE clean tank thoroughly, above, and install fresh solutions. Film developed 1. Low clearing solu- la, Check applicator, but not complet-? tion flow, purge valve and cir- ely cleared or culatory system for fixed air leaks and remedy. Check applicator for improper seating. lb. Check applicator and circulatory system for obstruction to flow and remedy, lc. Replace clearing solution pump. 2. Low clearing solu- 2. Check clearing tion temperature solution heater (should be 120 F~ and replace if necessary, Frosted or 1. Low rinse solution la. Check applicator, salted appear- flow purge valve and ance of the circulatory system record for air leaks and remedy, Check rinse applicator for improper seating. 1b, Check applicator and circulatory system for obstruction to flow and remedy, lc. Replace rinse solution PAP 2. Low rinse solution 2. Check rinse solution temperature (should heater and replace if be 70 - 120?F') necessary. Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 t Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 5-13. REMOVAL, REPAIR AND ztEPLACEMENT Servicing c)f the processor is best facilitated by partial or complete remc)val of the appropriate subassembly form the main console. ill subassemblies are readily completely or partially remov~~ble and provide access to all components for servicing. 5-14. PROCESSIIJG ASSEMBLY The procesc~ing assembly is accessible from the top of the console with thca dust cover removed. Complete removal is accomplished by removing four mounting screws. The processing assembly is dowc~led to the main frame to provide automatic alignment when i~he unit is reassembled, Connector P1 which provides power :~s a self alignment automatic disconnect type, 5-i5. ELECTRON:[C CHASSIS The electronic chassis is mounted to the inside of the rear panel and is corap~etely removed when the rear panel is removed. Connector P2 wh:Lch is the electrical interlock between chassis and main consolE~ is an automatic disconnect type and self aligning when the rear panel is replaced. 5-16. DRYER ANI) CONTROL PAP?F~L (see Figure 5-1) Access to 9:he dryer anti control panel is provided by partial removal of the front panel containing the threading access door. Ttie front panel remains tied to the main console by means of an E:lecfirical service loop. The right side panel must be removed before the dryer assembly can be withdrawn from the console. Access is F~rovided by removing the review station panel which carries tie takeup motor speed control potentiometer and the Slack Box Full indicator and reset switch, This assemx~ly consists of the film metering motor and the speed reduc'_ng gearbox. It is bolted to the main frame by four screws vrhich are accessible when the left side panel is removed. Complete removal requires disconnecting wires 3 and 4 on TB3, Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 CONTROL SWITCH ARRAY CQVER FiG~~~r~~ed~~~~~~~a~~0'f/6~P1'~z GRP9~9~i~1A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 r i i L CEk--~J ' 1~E PRE SS FOR T."r:~'.E.~D ING RETI2AC i F'OR OPERATIODi Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 RINSE APPLICAi4R~ PURGE IVALVES 1 VEN'~ VEN\T EVELOPER APPLIC~'~TO App o~~~?~~tSr~e~erase~~/~ ~~~~IA-~~B~~i~~~~Y00060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 5-19. FILM TA:KEUP ROLLER DRIVE ASSEMBLY This assembly consists of the film takeup motor and gearbox and is mounted in an identical manner as the Film Metering Roller Drive Assembly. Complete removal requires disconnecting wires 1 and 2 .in T83. 5-20, ADJUSTM]sNTS 5-21, PROCESS:[NG SOLUTION TEMPERATURE The prooefasing solution temperature has been factory set at 120 - 125 F, The equipment will o erate p properly over a temperature range of 120-130oF. Adjustment is required only if the temperature exceeds these limits. Adjustment is accomplished b~~ means of potentiometer R3 located on the electronic cha.;sis under the servo amplifier. 5-22. APPLICA9'OR The applicator normal force spring pressure is factory set to maintain. the proper contact between the applicator and film. Adjustment is required only if air leaks are introduced into the circulatory system. Increased pressure is obtained by turning the two adjusting screws (callout 2, Figure 1-3) on each applicator counterclockwise an equal amount. If more than two turns are required, the applicator lips should be inspected for damage or insufficient flatness and replaced if defective, 5-23. PRESSURE ROLLER The film metering pressure roller should be increased in pressure if applicator pressure is increased to compensate for the added Mansion introduced into the film transport system. This may be acc~~mplished by turning the two adjusting screws located under t:ze two springs in a clockwise direction. The film t~3keup pressure roller does not require adjustment, 5-24. FILM TAKI~UP CLUTCH Factory sei: at 3 - 4 pounds film tension. Reset if adjusting nut i;~ inadvertently maladjusted. Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 The Rapid Access Film Processing Console is comprised of three mayor assemblies. The major assemblies in turn consist of various subassemblies and individual components, All assemblies, subassemblies and components are identified by part numberf;, The part number system identifies a unit by a two part numk~er separated by a dash. 'lThe first group of numbers which is common to all units, indicates the manufactur- ing control number; in this case, 4501. Following the dash, a letter A and a number indicates an assembly. A hundred series number denotes a manufactured part and a thousand series number denotes a purchased part. For examp]_e, Part No. 4501-A4 is a complete assembly which is in turn comb>rised of subassemblies such as 4501-A3, applicator assembly, manufactured parts such as 4501-102, solu- tion tank and ~>urchased parts such as 4501-1003, solution heater. The breakdown of assemblies is in accordance with paragraph 6-2, The parts list is divided into two sections: mechanical and electrical. The parts listing of mechanical piece parts has been confined to the manufacturer's recommended replacement items, togetheY? with other parts which are readily identifiable and which do nc,t require special fitting in replacement, Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 6-2 ~ ASSEMBLIIsS Assemb.lY No- Nomenclature Rapid Access Film Processing Console Processing Assembly Applicator Assembly Pump and Tank Assembly Pawl Assembly Thermistor Probe Number per Assembly (1) 4501--A4 (a) 4501--A3 (b) 4501-?A2 (c) 4501-?A 14 (d) 4501-?A12 (2) 4501-~A7 (a) 4501-~A10 (b) 4501-All (3) 4501-A6 (a) 4501-A8 (b) 4501-A9 (c) 4501-A13 (d) 4501-A5 Electronic Chassis Film Drive Servo Amplifier Temperature Control Module Main Console Takeup Drive Assembly Metering Roll Drive Assembly Sensor Roller Assembly Dryer Assembly Approved For Release 2001/08/13: CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 mart R"~o. Nomencla.tu~-e Manufacturer quantity Mfd. by Part No. ~:50y -?a_00 .Rol1_er, Yd:Lcr ~.. ay~eteri.ng same as Part No. ~'s501w101 Roller, Metering 2 ?' -.7 02 'rank 1 ??103 Plate, Pump ~upport 3 " _107 ~:cive k?7_atea, i7pper 1 -108 .give Plate, ]:,ower 1 " -110 Spacer, Fur:tp 9 " ?~ 117 Cam, Isieter _Lng Drive 4 " -124 Bels_c~e~s 1 " _:1.31 ;sear d ng, Pump ~~rive 3 " -1~??~, Lousing r~errnictor 1 " ?-?1~??6 ~,ushing 2 `: -'I47 :'oor, ~.IiewE;r/Dryer 1. " -?151 Z:icht Seal I " --155 uidc~, 4" ~~pplir_atar 2 _~y S5 :'~:~i.de, 2" applicator 1 " -163 "~`ee 3 " ...173 vrsrinc~ ? ~~yp~~ _icator 5 " --:i 83 Zack, Loop Sen~.sor 1. 1 " ?-18? Sur_v-orb: 2 " -~?5 Gear ana LE.ver Assembly 1 `: ..,215 ~~ ilm Guide 1 " -231 Vd.1ve Connector 3 " ---232 Cutti~ig Die' 1 " -2344 ??'ear Plate 3 . _, C~~ "_~ , ~ Fearing, `~!.anc~ed ~ Y ~!~ 22 SR168PP " -?'_001 Sr~ur Ges.r, 48 Pitch, 96 teeth 1 G7-96 " -1002 Spur Goar, 48 Pitch, 48 teeth 1 G7-48 ?' -10^v4 Ball Bearing, flanged a x 5/8 4 SFR4PP -1005 Spur gear, 48P, 36T 2 G7-36 " -1006 Clutch, Spring 1 R3-3-50 " -1007 Gear, Disc, 48P, 60T I 3'2-60 -1011 Applicator, 4 inch 2 " -1012 Applicator, 2 inch 1 " -1015 Pump 3 3400500 " -1028 Ball Bearing, flanged '>d x %, 10 SFR 188PP " -103C tear, 48P FiOT 2 G8-60 " -1031 Gear, 48P :30T 2 G7-30 " -1032 Ball Bushing 2 INS'.C'-4812-SS " 1033 Neg'ator S~~ring 2 Sfi-5F15 " --1034 Searing 1 K3L2 " -1035 Rack Dancer 1 AG-3 -1036 :Spur Gear 1 Gi0-25 " -1037 Right Anc lea Drive 2 G1566-1 " -1044 iyiagnetic Sis~ip 1 ~; wide '? -1045 Spring 2 AY-5 " -1051 I:nob 3 BG-7 " -1055 Speed Control Gear 1 P-16_3-85 " ?9105 6 z~,nob 2 BG-1 " -1001 Spring 2 Mtn-122 " -1062 Spring 2 4-031 " -1076 13a11 nearing Flanged 2 MFS3KDD Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 N:tanufacturer Qart L~~'o_ q?501--`i 01.6 " -?1017 " --1003 ?'-1199 " -1024 '? --3.025 " -?1023 " ~? 102 7 " --?1020 " ~?-:i028 " -101?3 " _1060 illotor, Puma l:rive ~_ D1 o~:er, ~ir:~er 2 Geax?head Motor, ~'akcup 1 Gearhead ~~~~tor, :iuJ.ain ~'~rive 1 Capacitor 1 Capacitar 1 Capacitor 2 Laiflp 16 Relay 2 '~'ransistar 1 Tieater Ele~nE~1t 1 rnn.ermistor 1 83A109-?27c4. 528~S 512055 D~~L'1~-92908 C~?N~F4P33 i?~?~tF'4T~~~1 CP5381Lr'205K 3 2 7 FC--400--y 21~,15q~0 SEF'-120 GI341.~2 " -1003-1 " ?-?1003-2 " --1013 " --?1014 " -?J.04.0 " ?-7.0!1 beater, 2G ~ ~;.'~.tt 2 ::~eate.r, 14J watt .I. Valve, Puree ~ 7Z:heastat 1 S~~icroswi~-c-~. 5 P~=:i_crosw__t~.c~~ 1 13.x.0100--1 13E0100-2 :t3rDA9026 0219 2D-26 27~~ " --.1.068 Connector 1 PT02A--14-155 " ?-1026 Potent~i-omcter 1 224~L--]_-202 " -1042 ~v.itch 1 2D33 " -?.i~'?i ~-2 t~iGiuY, X31 t~~;.e__ ~ 1 Q~Q f/~.. 33 " --?i05u ACtLlcitaY" ~_ J'S --2 " -1059 Actuator 1 JS-5 " --1063 `i'ransfoxiue:c 2 HS-442 " -1064 Sv?itch 1 4001 " -All Tempera.tur~~ Control T~o~ule 1 4501-A 11 " -A12 ~~hermistor Probe 1 4501-A12 " -1021 Relay 1 22RJC-25001VG/SxL " -1069 Potentiometer 1 35015 " -1071 Connector 1 DS00-7P " -1022 Relay l 22RJC-5000-G/SxL " -1078 Connector I 26-4200-165 " --1079 Connector 1 26-4100-32P " -2001 Capacitor 1 TA5156K035POF' " --2002 Connector 1 26-4200-1oS " -2003 Connector 1 26-4200-16P " ?2004 Stepping Sj~itch 1 1R-RAS-115 -' " -2005 " 2 1R-705-12P-240 " ?-A10 Servo Motor Amplifier 1 4501-All Approved For Release 2001/08/13 :CIA-RDP78B04747A002100060001-2 C;uantit~ I~'If d ? by