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

• Document Type: CREST
• Collection: NGA Records (Formerly NIMA)
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78B04747A002100060001-2
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 54
• Document Creation Date: December 28, 2016
• Document Release Date: June 19, 2001
• Sequence Number: 1
• Content Type: REPORT

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DECLASS REVIEW by NIMA/DOD
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Ii7-~:CIDBOOI{
OpEraticn and Service
Instructions
' RAPID .ACCESS FILM PROCESSING
COI~iSOLE I~~IODEL RAPC 5-250
' for
STATI NTL
STATI NTL
1
i
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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
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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
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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
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FRONTISPIECE-RAPID ~~CCESS FILM PROCESSING CONSOLE.
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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
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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
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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
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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-
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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
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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
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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
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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
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 FIGURE 1 -1 CONSOLE -CiPERATIC)NAL CONTROLS
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FIGURE 1-3 PROCESSIPIG ASSEMBLY (APPLICATORS AND TANK IN PROCESSING
POSITION-VIEW FROM OPERATOR SIDE)
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FIGURE 1-4 PROCESSING ASSEMBLY (APPLICATORS AND TANK IN OPERATING POSITION-VIEW FROM OPPOSITE SIDE)
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FIGURE 1-b PRCKESSYVG ASSEMBLY APPLICATORS IN THREADING POSITION)
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FIGURE 1-7 DRIVE MOTOR AND STEPPING SWITCH ASSEMBLY
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FIGURE 1-$ LOOP SENOR MECHANISM
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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
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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.
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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
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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
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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
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 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
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 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
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 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,
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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.
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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
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 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.
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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-
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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.
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 t
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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,
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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.
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 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,
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 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
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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
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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
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