TEST AND EVALUATION REPORT (Sanitized) AUTOMATIC 4X5 INCH FILM PROCESSOR

• Document Type: CREST
• Collection: NGA Records (Formerly NIMA)
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78B04747A000300030022-2
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 13
• Document Creation Date: December 28, 2016
• Document Release Date: October 24, 2001
• Sequence Number: 22
• Content Type: REPORT

STATINTL
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2 T E -68 -5
~~~~~~~~
TEST AND EVALUATION REPORT
AUTOMATIC 4x5 INCH FILM PROCESSOR
Declass Review by NIMA/DOD
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
by
STATINTL
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
The purpose of this test and evaluation was to establish the parameters for
acceptance of the 4 x 5-inch Film Chip Processor and to evaluate the design and
operation by use of continuous belt operation from a specially designed magazine
capable of holding thirty-five chip holders. The magazine is designed to receive
holders and exposed film from a prototype printer. After the magazine is loaded
on the processor, the exposed chips are fed into the processor at rates up to ten
chips per minute. The magazine was originally designed to hold thirty-six chip
holders, but, because the holders were redesigned, it will now accept no more than
thirty-five,
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
Section
Title
pale
I
INTRODUCTION
1
II
GENERAL DESCRIPTION
2
A. Design .
2
B. Workmanship and Materials
2
TEST PROCEDURES AND RESULTS
3
A, Mechanical Testing
3
B. Sensitometric Testing
3
IV
CONCLUSIONS
5
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 STATINTL
STATINTL
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
STATINTL
TATINTL
This report is concerned with an objective evaluation of the TATINTL
Automatic 4 x 5-inch Film Processor which was designed and manufactured by -
a division of the
The evaluation considered such factors as design, workman-
ship, materials utilized in the fabrication of the processor, and, in general, engineer-
ing practices and principles. All systems were checked in accordance with the supplied
manual.
-' Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
A preliminary examination of the processor, after uncrating, revealed that both
ends of the lower outer surface of the machine were slightly damaged; the tank inte-
riors contained dried chemicals, miscellaneous parts, and film chips; and the filters
and their containers in both the circulation and injector systems were contaminated
because the liquid had not been drained. In an attempt to align the injector mechanism
in a lateral position, IBM cards had been used as shims, along with a PVC rod. Later
tests revealed that neither of these were required if correct water pressure was used.
All water, power, and air connections were checked and found to meet specifications.
B. WORKMANSHIP AND MATERIALS
Stainless steel, PVC, Delrin, and other plastic work is acceptable and, in general,
all of the fabrications are considered to be good. The wiring is clearly coded, and the
workmanship is excellent. Installation of the processor was accomplished with no diffi-
culties.
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
TEST PROCEDURES AND RESULTS
All testing of the machine was accomplished using only parts and film supplied by
the contracting agency. Type SO-250 film, coated on a 7-mil bas~rTATINTL
especially for the machine, was used. This film is similar to type 8430, which is
coated on a 5.6-mil base. The heavier SO-250 film base was used because the other
is too thin to stay in the holders, due to developing turbulation within the processor
plenums.
Complete testing of the water supply, both for washing with tempered water and
the use of cold water (55? F) for the injector and cooling systems, resulted in the
following operations:
1. Tempered water in the wash section was found to be acceptable. It is rec-
ommended, however, that a support, or heavy duty diverting handle, replace the present
handle and rod between the hypo eliminator -first wash-and the final wash tanks.
2. The testing was done with a relief outlet in the line. Opening of the outlet,
causing a pressure drop, definitely improves the injector operation, as high pressure
causes "chattering" in the solenoid valve.
3. The original mechanical testing was done with all tanks filled with water to
protect the heating system and pumps. Later temperature testing was accomplished with
photographic chemistry.
Room ambient temperatures remained at 72-74? F, with 50% (t3%) relative humidity.
B. SENSITOMETRIC TESTING
Sensitometric testing was accomplished with DK-60A, diluted 1:1. Although limited
in scope due to the lack of temperature control, the following results indicate the prob-
able acceptance of the processor if the recommended modifications are adopted.
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
1. There was good replication, both inter-magazine and intra-magazine, over
a three-day period.
2. The turbulation pattern was generally good.
3. Gamma control was linear, with transport control from 2 through 10 chips
per minute.
All sensitometric step wedges were exposed on the IB
sensitometer within two hours of processing.
STATINTL
.. Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 S1rATI NTL
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
Automatic 4 x 5-inch Film Processor is not totally accept-
able in its present design, but, with certain changes and/or modifications, it can be
utilized in the processing of 4 x 5-inch film chips as originally intended. The following
observations, along with suggested improvements, are the result of this evaluation:
1. Temperature Control
The temperature control system was found to be unacceptable. Although the
information supplied by the manufacturer indicates that the temperature of the supply
water (to the exchanger and ejector line) must be "at least 5 degrees below the chosen
processing temperature", it was established that, even with 55? F water at 55 psi, the
developer temperature could not be controlled at any temperature below 83? F. Even
though the minimum controllable temperature was somewhat lower, the same problem
exists with the short stop and fix tanks. The heat exchanger system is incapable of
maintaining a lower temperature because of the heat created within the processor by
the pumps and dryer, the inadequate removal of this heat to an outside area-
away from the processor, and the small size of the heat exchanger units in the
tanks. The air temperature within the space containing the circulation pumps
climbed very rapidly, after start-up, and stabilized at approximately 140-145? F.
To remedy this, it is recommended that:
a. Reflective thermal insulation be installed between tanks, dryer, and pump
b. The equipment be modified to provide external force-venting of the processor
interior to an outside area.
c. The heat exchanger units in the tanks be enlarged, or another unit for a
larger area of exchange be added.
.~ Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
2. Air Supply
The air supply pressure, filtration, and operation were found to be acceptable.
Since there was no control for the air squeegee as an integral part of the machine con-
trols, the external pressure was regulated to make this procedure adequate.
3. Transport System
The film chip transport system, by means of Mylar belts,, is well-adapted to
this particular requirement, although there is a minor deficiency in the guide pins for
the belts. The pins are imbedded in holes in the guide rollers in the four quadrants. .
Changes in temperature, particularly in the dryer section, cause the PVC guide roller
to expand more rapidly than the stainless steel metal pin. The result is that the pins
loosen and become dislodged from the retaining holes. Our recommendations are:
a. Replace the present tension roller guide wheels with aspring-loaded
guide set and use threaded pins.
b. Use a pin that is serrated or grooved and place into retaining hole with
a suitable cement.
4. Chip Holders
Chip holders, though adequate, have deficiencies that should be corrected. The
chip holder should be machined to a smoother surface finish for one thing. A coating of
silicone sprayed onto contact surfaces greatly reduced frictional forces within the maga-
zine. The resultant ease of magazine loading and ejection into the processor was quite
evident. The transport pick-off carrier hooks performed their function acceptably, after
removal of roughness from the groove hole. What may well be considered the major
problem with the holders involves the film retaining grooves on both sides of the holder.
The edge of the film within these grooves is not adequately dried. Therefore, it is rec-
ommended that the holder be modified or air jets installed in the drying section to direct
higher velocity air at these points of water retention. Tests of the holders in the pro-
cessor indicate that it is necessary for the film to be secure under the three film-end
retaining pins. Also recommended in the modification of the chip holders is that the
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
depth of the grooves be increased by approximately 1 mm to eliminate the excessive
"bow" in the film. It was found that the bow caused the film surface to extend beyond
the plane of the holder surface, causing film damage and displacement within the film
magazine and during the ejection cycle. To adequately dry the film chips, it was nec-
essary to use 130? F - 140? F dryer temperatures. With the modification of the holders,
110? F - 120? F should be adequate at 10 chips per minute.
5. Replenishment S:ystem
The replenishment system is not only inaccurate but has no correlation with
the amount of film being processed. Fed into the tanks by tubing, the processing
chemistry replenisher enters within a few inches of the overflow drain. It is recom-
mended that the position of the replenishment flow be relocated to a more acceptable
position or fed into the turbulation pump tubing,
In its present design, the replenishment flow is constant while processing at 2
through 10 chips per minute, or with no film. After the rate is established for chips
per minute, a solenoid liquid switch should be installed and timed with each chip ejected
by the timing cam.
A,.lso, support of the existing replenishment tubing at the gauges, as well as
recalibration of the present gauges, or replacement of the "percentage" type gauge by
one reading in cc/min., is recommended. The present controls are completely inaccu-
rate, For example, the flow meters read in percentages based on a full flow rate of 580
cc/min. ; at a 50% flow rate, the developer was replenished at a rate of 726 cc/min.,
indicating measurement inaccuracy.
6. Injector-Ejector System
The injector-ejector system was critical in regards to water pressure because
correlation between the injector stroke and the return stroke is dependent upon water
pressure. Injector operation was examined at water pressures ranging from 40-50 psi
to 180 psi, in 5-psi increments. At 100 psi, the return was quite erratic. Optimum
pressure range is 55-65 psi, All subsequent tests were run at 55 psi; this was found
to be the minimum pressure adequate for an even and smooth injector. piston stroke
in both directions.
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
Ejection of the holders into the chute and transport take-off slot was checked,
and, after retiming the microswitch caln that actuates the ejector, the ejection system
worked satisfactorily. The retiming, accomplished by drilling and tapping a new screw-
hole in the cam, resulted in earlier actuation of the ejector so that the holder is seated
in its slot before the take-off arm comes into position to remove the holder.
Thus, the recommendations for this system are:
a. Install a pressure gauge, preferably on the control console. The
gauge should be in line between the water filter and ejector solenoid, and the dial face
should indicate control limits.
b. Replace the present enclosed filter with a transparent type (i, e. , Cuno
or Full-Flo). This is optional if the previous recommendation is adopted, because
th~a gauge will show a pressure drop if the filter becomes contaminated.
7. Electrical System
The electrical system and schematics are acceptable and no modifications are
8. Stacking Operation
The "take-out" stacking operation is satisfactory, except that the warning buzzer
is actuated at thirty-six holders and the magazine only accepts thirty-five. Relocation
of the microswitch trip can easily correct this deficiency.
9. Turbulation Plenums
Turbulation plenums have no access to facilitate cleaning. Small access holes
and redesigning the turbulation pattern, or extension baffle, at "turn arounds" are rec-
ommended. The present pattern causes the chip holders to move in a pendulum-type
motion which sometimes dislodges the film from the holder. The chip holders can also
become wedged against a rough edge of the plenum.
An integral part of the turbulation system is a series of five 1/4-inch holes
located at the bottom of the chip holder "take-out" in the developer section. The high
pressure used to aid the "take-out" of the chip holder by the transport system causes
.~ Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
 Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2
higher densities along the longitudinal axis of the film. Numerous tests have shown
that the central three holes of these five are not required.
10. Processing Tanks
Drain cocks on the bottom rear of the tanks are approximately one inch above
the actual tank bottom and prevent full drainage. Thus, sediment is allowed to settle
in the tanks, resulting in contamination. It is recommended that larger bottom drain
cocks be used, with access from the front (tank end) of the machine.
Occasional loss of film chips, or any foreign particle falling into the tank
creates the necessity, in most cases, of dismantling that section (i, e. , removal of
the transport system, tanks, replenishment and circulation systems). It is recom-
mended that access panels be cut in the tank not only for removal of foreign objects,
but also for easier threading of the transport belt in the event of a break. The panel
would also allow necessary cleaning of tank sections which are not accessible at the
present time.
Approved For Release 2001/11/19 :CIA-RDP78B04747A000300030022-2