SUBCOURSE EDITION

SS0520 5

OPERATION OF AUTOMATIC FILM PROCESSORS

 US ARMY STILL PHOTOGRAPHIC SPECIALIST
MOS 84B SKILL LEVEL 1 COURSE

OPERATION OF AUTOMATIC
FILM PROCESSORS

SUBCOURSE NO. SS0520-5

US ARMY SIGNAL SCHOOL

FORT GORDON, GEORGIA

Three Credit Hours

GENERAL

The Operation of Automatic Film Processors subcourse, part of the Still

Photographic Specialist Skill Level I course, is designed to teach the
knowledge necessary for performing tasks related to the operation of automatic
film processors. Information is provided for general operation of this type of
equipment and on specific models such as the Versamat 11C-MW. The subcourse is
presented in two lessons each corresponding to a terminal objective as
indicated below.

Lesson 1: PREPARE CONTINUOUS FILM PROCESSOR FOR OPERATION

TASK: Describe the function, internal systems, preparation procedures, and

safety precautions for the automatic film processor.

CONDITIONS: Given information about the function, preparation for operation,

and safety precautions associated with the automatic film processor.

STANDARDS: Demonstrate competency of the task skills and knowledge by

responding to the multiple-choice test covering function, internal systems
preparation procedures, and safety precaution for the automatic film processor.

(This objective supports STP Task 113-578-3044, Prepare Automatic Film

Processor for Operation.)

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Lesson 2: OPERATE CONTINUOUS FILM PROCESSOR

TASK: Describe the operation of the automatic film processor.

CONDITIONS: Given information about systems and operating procedures of the

Versamat 11C-MW Processor.

STANDARDS: Demonstrate competency of the task skills and knowledge by

responding to the multiple-choice test covering operation of the automatic
print processor.

(This objective supports STP Task 113-578-3045, Operate Automatic Film

Processor.)

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 TABLE OF CONTENTS

Section Page

TITLE PAGE.......................................................... i

TABLE OF CONTENTS................................................... iii

INTRODUCTION TO AUTOMATIC FILM PROCESSORS........................... vi

Lesson 1: PREPARE CONTINUOUS FILM PROCESSOR FOR OPERATION........... 1

Learning Event 1: Describe the Function, Capability, and

Operation of the Automatic Film Processor....................... 1

Learning Event 2: Describe the Major Systems of the

Automatic Film Processor........................................ 3

Learning Event 3: Identify Basic Areas of Safety................ 14

Learning Event 4: Identify the Steps Necessary to Prepare

Film Processor for Operation.................................... 14

Practice Exercise............................................... 17

Answers to Practice Exercise.................................... 18

Lesson 2: OPERATE CONTINUOUS FILM PROCESSOR......................... 19

Learning Event 1: Describe the Versamat 11C-MW Film

Processor....................................................... 19

Learning Event 2: Describe the Major Systems of the Versamat

11C-MW Film Processor........................................... 22

Learning Event 3: Locate and Describe the Functions of the

Controls and Indicators with Versamat 11C-MW Film Processor..... 29

Learning Event 4: Describe the Preoperational Inspection,

Daily Start-up, and Shutdown Procedure.......................... 31

Practice Exercise............................................... 36

Answers to Practice Exercise.................................... 38

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 *** IMPORTANT NOTICE ***

THE PASSING SCORE FOR ALL ACCP MATERIAL IS NOW 70%.

PLEASE DISREGARD ALL REFERENCES TO THE 75% REQUIREMENT.

Whenever pronouns or other references denoting gender appear in this document,

they are written to refer to either male or female unless otherwise indicated.

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THIS PAGE INTENTIONALLY LEFT BLANK

v
 INTRODUCTION TO OPERATION OF AUTOMATIC
FILM PROCESSORS

This subcourse contains two lessons on the operation of continuous film

processors. These processors are becoming more common in Army laboratories
throughout the world. Your understanding of their operation will help make you
a better still photographic specialist.

Lesson 1 deals with the preparation of a processor and Lesson 2 explains how to
operate the processor.

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 LESSON 1
PREPARE CONTINUOUS FILM PROCESSORS FOR OPERATION

TASK

Describe the function, internal systems, preparation procedures, and safety

precautions for the automatic film processor.

CONDITIONS

Given information about the function, preparation for operation and safety
precautions associated with the automatic film processor.

STANDARDS

Demonstrate competency of the task skills and knowledge by responding to the

multiple-choice test covering function, internal systems preparation
procedures, and safety precaution for the automatic film processor.

REFERENCES

NONE

Learning Event 1:
DESCRIBE THE FUNCTION, CAPABILITY, AND OPERATION OF THE AUTOMATIC FILM PROCESSOR

1. In an attempt to produce standardized products of top quality at high

speeds, many types of automatic processors have been designed and tested. It
would be impractical to teach the operation of each individual type of machine.
However a basic understanding of the fundamentals common to these processors
will be helpful. Many of these fundamentals can be applied to any type of
machine a soldier may encounter. In this lesson you will become familiar with
the Versamat 11C-MW Continuous Film Processor.

2. The function of a processing machine is to transport film through various

solutions for a specific length of time. This function must be repeatable.

3. Continuous film processors are designed for the rapid processing and drying
of black and white film, color negative and positive transparency slide film.
Continuous processors can process both roll and sheet film. Keep in mind that
no one machine can process both black and white and color film. Continuous
processors are designed either for black and white film only or color film
only. A color processor could process black and white film if it were
modified. However, this would be wasteful in time and money. There are also
new processors coming on the market that will process

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both film and paper. These require a change in chemistry when going-from one
medium to the other.

4. The processor is designed to be installed outside the darkroom, with the

film entrance inside or against a light-tight opening into the darkroom wall.
This allows darkroom personnel to feed unprocessed film directly into the
processor without exposing it to light.

5. The operation of a processor is as follows:

a. Film is fed into the feed entrance (fig 1-1(1)).

b. Film enters the developer tanks (fig 1-1(2)).

c. It is carried to the tank bottom and back to the top (fig 1-1(3)).

d. It then goes onto the fix tanks and the remaining tanks in the same
manner (fig 1-1(4)).

e. The dryer section receives the film from the squeegee assembly and
transports it downward and then upward between air tubes, which direct hot air
onto both sides (emulsion and base) of the film (fig 1-1(5)).

f. The processed and dried negative or transparency then passes into a

receiving bin (for sheet film) or onto a take-up adaptor (for roll film) (fig
1-1(6)).

Figure 1-1. Basic operating procedure of a film processor

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Learning Event 2:
DESCRIBE THE MAJOR SYSTEMS OF THE AUTOMATIC FILM PROCESSOR

1. Film drives and transport systems.

a. Probably the most important area of machine design is the film drive
system. The film must be transported through the solution tanks at a constant
speed. The operator must be able to adjust this film drive speed as the
situation warrants. Also, the speed must be reproducible. In other words, if
a particular type of film is to be processed at speed of 10 feet per minute, a
second roll at 20 feet per minute and a third at, again, 10 feet per minute,
the first and third rolls, (both processed at 10 feet per minute) must produce
identical results.

b. An ideal transport system would be one in which the film is moved

through the processing machine without the film being touched by the processor;
it could never be damaged. Research is being conducted on a liquid bearing
transport which would do exactly that: move the film through the processor
without contact between them. An ideal drive system would provide a uniform
rate of speed throughout the system, one in which there would be no slack or
stress on the film at any point. Finally, an ideal drive system would also be
exact, one in which the speed of travel could be set with considerable
accuracy. Many film drive and transport systems approach these ideals,
particularly in the areas of uniformity and accuracy. Drive systems generally
consist of a motor, a variable speed transmission, and a drive chain which
produces rotation of the transport rollers, usually through a system of
clutches.

c. The type of transport system found in a processor is dependent on the

size (width) of the film to be processed and the desired quality of the end
product. In processors designed for narrow film widths, the film is generally
transported by gangs of rollers. If the film being processed is perforated,
sprocket drives may be employed to transport the film. In other cases the
rollers are flanged and the film is guided between the flanges. If
misalignment of this type of roller occurs because of a worn shaft or bearing,
the film could climb the flange causing crimped edges, creases lengthwise along
the film or, in severe cases, film breaks due to the film running off the
roller.

d. On the other hand, processors designed for larger (wider) sizes of film
usually have single roller transports instead of ganged rollers. These single,
wide rollers depend on proper alignment for accurate film tracking. Because of
their width some lateral movement of the film is possible, allowing the film to
"find its own path" through the processor. This lateral movement, however,
increases the possibility of side strain on the film. If the rollers become
misaligned, one edge of the film may rise up off the roller resulting in damage
to the film.

e. Another factor to be considered is the diameter of the individual

rollers. Smaller diameter rollers use considerably less space, allowing more
of them to be placed within a small area. The disadvantage of smaller rollers
is that they exert more strain on the film as it bends around them. The

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converse is true of the larger diameter rollers: they exert less strain on the
film but occupy more space in a processing machine. Some processors have
rollers of different sizes and it is important for a technician to know these
sizes and their locations. This will frequently make it easier to pinpoint the
cause of a mechanical processing defect. For example, if an abrasion appears
approximately every three inches on a roll of film, the cause could be a small
(one-inch diameter) roller. If, on the other hand, the defect is found every
nine inches, the smaller rollers could be eliminated as the cause and the
larger (three-inch diameter) rollers would be inspected.

2. Machine Threading Systems.

a. Leader Type. Most processing machines are pre-threaded with a leader

which may be thick or thin acetate, mylar, or in some instances, clear film,
thereby rethreading the machine for the next processing run.

b. The threading pattern used most often with wide film (over 70mm wide)
is the "over-under system." Normally when this pattern is used, the emulsion
side of the film touches only the bottom rollers which are always wet with the
processing solutions (figure 1-2). However, one processor now being used is
operated with the film emulsion down which means the emulsion side touches the
top rollers and the base side touches the bottom rollers.

Figure 1-2. Over-under threading

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 c. Another threading system is the "loop" type. In this system, the film
is threaded in a loop around the rollers and only the film base touches the
rollers (fig 1-3).

Figure 1-3. Loop type threading

d. Leaderless Machines. These machines do not require threading with a

leader, but transport the film through the machine by another means. This
transport method is a double row of rollers that are closely spaced to each
other, and to the opposing row. The film is first spliced to a stiffening tab,
usually called a "bullet." The bullet with the film attached is inserted into
the machine and is transported between the rows of rollers and through the
machine by friction. More will be said about this type of transport system
later (fig 1-4).

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Figure 1-4. Leaderless transport system

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3. Agitation Systems.

a. The purpose of an agitation system is to move the processing solution

within the tank so that fresh solution is always brought into contact with the
film. Continuous processing machines employ numerous types of agitation
systems.

b. Immersion. The immersion method of agitation is perhaps the oldest and

most widely used system. In this system, the film travels through various
tanks containing solutions and receives agitation solely from its movement
through the tank. Another way of stating it would be that instead of solution
being brought into contact with the film, the film, instead, is being brought
into contact with the solution. The immersion system is the least expensive
and, obviously, the easiest agitation method to maintain. Figure 1-5 shows a
typical immersion processing tank.

c. Spray System. The spray processor consists of empty tanks through

which the film passes. As film moves through the tanks, solution is sprayed
against the emulsion. Spray heads are often mounted on both sides of the film
so that spray pressures are equalized and film will not be pushed to one side
(fig 1-6).

Figure 1-5. Schematic of a typical Figure 1-6. Schematic of a typical

immersion processing tank spray processing tank

(1) There are two main spray processing configurations. One sprays
fresh solution which is used once and then drained away. The other employs a
sump in which the solutions accumulate to be pumped through the spray system

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onto the film and back to the sump. Both systems are in common use. Each has
its advantages and disadvantages. When spray processing, the oxidation process
is speeded up, since the exposure of developer to air is accelerated. This is
why some systems use the developer only once, after which it is drained.

(2) In systems where the solution is used again, the machine is equipped
with a replenishment system to offset the effects of oxidation. In either
system, it helps to use a developer formula with a high preservation content.
There are some complex systems in which the air within the machine developing
tank is evacuated and replaced with nitrogen gas. Nitrogen gas does not
support oxidation, and developer used in a nitrogen environment may be
recovered and used again and again.

d. Spray-immersion. This is a third agitation system and as the name

implies, a combination of the preceding two. In a spray-immersion system the
spray bars are submerged in the solution so that the film receives agitation
from both the spray action and immersion in the solution.

e. Gaseous Burst. Another method is called the gaseous burst system. In

this system a photographically inert gas (nitrogen) is bubbled through the
solution from a perforated grill in the bottom of the tank at short intervals.
The gas bubbles rising through the solution keep it in motion to bring fresh
solution into contact with the film. Another method is called turbulation.
This is a system where the solution is pumped out of the tank, usually near the
top, and back into the tank, usually near the bottom. Keeping the solution in
motion again provides fresh solution to the film surface. Many processors use
several of these agitation methods at the same time.

f. There are advantages and disadvantages to each major chemical system.

The spray concept gives excellent rapid processing. However, adjustment of the
spray fan to minimize streaking is critical. In the spray processor, the
cabinet doors may be opened making all cabinet areas accessible for cleaning.
Since solutions do not remain in the cabinets, there is no drastic buildup of
chemical byproducts in the machine. Deposits which are formed can be removed
by wiping with a sponge. In an immersion type system, the operator cannot
reach the bottom of the tanks and must rely upon chemical cleaning agents to
remove chemical deposits. When the spray machine is used, milliliter of
solution can be filtered before it is repumped into the machine. Developer,
however, is oxidized rapidly and requires a large amount of replenishment. The
rapid exhaustion of the developer, and consequent high rate of replenishment,
makes the spray processor expensive to operate.

g. Other considerations are the man-hours required to mix this replenisher

and the storage space the replenisher occupies. Most processors used by the
Army are immersion machines.

4. Recirculation Systems.

a. Recirculation systems perform four important functions in processing

machines. The recirculation system:

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 (1) Filters the solution.

(2) Controls the temperature of the solutions.

(3) Provides a logical place to add replenisher to the solutions.

(4) Provides a certain amount of agitation to the solutions. Figure 1-7

shows a typical recirculation system.

Figure 1-7. Typical recirculation system

b. Filtration. Solutions are generally filtered before they are

reintroduced into the machine. Continuous filtration of this type, at least
during machine operation, is generally regarded as preferable to batch
filtration. This filtration is usually accomplished through the use of screen
or cartridge filters. The particle size passed by the filter is of prime
importance. Most processors use filters that filter out all particles larger
than 10 microns. Wash water must be filtered to the same degree as the
chemical solutions. Instruments used on the solution filter system should
include pressure gauges on the inlet and outlet of the filter to indicate the
pressure drop across the filter system. The pressure drop will signal when the
filters are becoming clogged and need cleaning or replacing.

c. Temperature Control. One of the most critical elements of the color

photographic process is solution temperature. Temperature must be controlled

9
for consistent and reproducible results. The developer is the most critical
solution and should be held within ± 1/4 to 1/2°F (± 0.1 to 0.25°C). Other
solution temperatures are less critical, but should be controlled to within 2°F
(l.1°C) of the developer temperature. In black and white film processing the
temperature of the developer is not as critical as in color processing. The
temperature can range from 65°F to 75°F and the other solution temperatures
should be controlled to within 2°F of the developer temperature.

d. Heat Exchanger. The heat exchanger incorporates refrigeration coils

and electrical heating elements. The developer and fixer solutions are pumped
through separate exchangers. The chemicals are adjusted to the proper
temperature, and reintroduced into the processing machine. A temperature
sensing probe, located within the processing machine tank, monitors solution
temperatures and transmits this information to the solution thermostats. If
solution temperature is too high, the refrigeration compressor is turned on.
This drives the refrigerant through coils within the heat exchanger and cools
the solution. If the solution in the tank is too cold, the heaters located in
the heat exchanger are turned on. This heats the solution. The operator sets
the solution thermostats at the desired temperature and the solution
temperature is automatically controlled.

e. Replenishment. Replenisher is generally introduced to existing

solutions in the recirculation system. It is mixed with the partially
exhausted solutions and, therefore, does not enter the machine in its raw,
undiluted state. If raw replenisher were added directly into the solution
tanks, uneven development and/or fixation could occur before the replenisher
mixed with the solutions already present.

f. Agitation. The agitation systems used in continuous processors have

already been discussed at length. Some of these systems, specifically the
turbulation method, the spray-immersion method, and the spray method in which
the solution is reused, rely on the processor's recirculation system to pump
the solution out of the tank, treat it (filter, heat/cool, and replenish), and
pump it back in.

5. Replenishment System. The purpose of replenishment is to maintain the

activity of the solution at a constant level throughout processing operation.
This becomes necessary due to the fact that as solutions are used their
activity decreases. Replenisher may be added to solutions in one of two ways.

a. Topping off.

(1) After a certain amount of film is processed, a quantity of solution

is removed and another quantity of replenisher is added. The quantity of
replenisher is usually greater to allow for carryover and evaporation. For
example, a processing tank holds 8 gallons of developer. After processing a
roll of film, only 7.8 gallons remain, the .2 gallon has been carried out by
the film or has evaporated. Additionally, the remaining 7.8 gallons is
partially exhausted.

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 (2) To replenish using the topping-off method, .3 gallons might
additionally be removed from the tank and replaced with one-half gallon
replenisher solution, bringing the activity and the physical level of the
solution back to its original state.

(3) While this is a fairly simple method of replenishment, it does not

adapt well to continuous processors. If a long (500 - 1000 ft) roll of film is
being processed, the solution activity would gradually decrease during
processing. As a result, the end of the roll would receive less development
than the beginning.

b. Bleed System.

(1) In order to maintain the activity at a constant level during

processing, the bleed system is used. In this system the replenisher solution
being added forces a proportional amount of used developer solution out of the
tank through an overflow at the top. This method, therefore, provides
continuous replenishment during processing, and, if the replenishment rates are
properly established, the gamma of the film at the start of processing and the
gamma at the end will be the same.

(2) The replenishment rates used are dependent on many factors. Among
them are: the chemical composition of the solution, the type of film being
processed, the size (width) of the film, the machine processing speed (time),
and the overall density of the film. If a film is overexposed and produces a
dense negative, it will use up developer more rapidly than a normally exposed
film. Since this is frequently not known until after the film is processed,
adjustments may be necessary after processing or during the next run. If a
film is underexposed (thin negatives), normal replenishment would be excessive
and, again, adjustments will be necessary.

6. Squeegees.

a. As the film is transported from tank to tank, solutions are carried

over which will cause contamination or dilution. A squeegee is used to remove
most of the fluid from the film surfaces to minimize carryover. It is also
very important to remove excess water from the film before it enters the drying
cabinet.

b. There are three general types of squeegees: blade, roller, and air.
Their use will depend on the complexity of the particular processor.

(1) Blade squeegee. This type consists of two rubber blades which
resemble miniature windshield wipers mounted so that the film passes between
them.

(2) Roller squeegee. Depending on the processor, this type will have
two or more rollers to remove the liquid as the film passes between them.

(3) Air squeegee. The film passes between two closely spaced nozzles
with high pressure jets of air being directed at the film.

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 c. Since the first two types of squeegees come into direct contact with
the film, it is imperative that they be kept absolutely clean. A chemical
deposit or an abrasion on the squeegee will seriously damage the film. The air
squeegee, although it never touches the film, must also be used with caution.
The compressed air must be clean and free of oil used in many types of
compressors.

d. Washing the film is done in the last two tanks of the processor and the
movement of the film in water provides adequate agitation.

7. Drying Systems.

a. The drying of film is a complex, two-fold operation. So that moisture

may be removed from the thickness of an emulsion, it must first migrate to the
surface and then evaporate in the air. The rate at which this takes place
depends upon the thickness of the emulsion, the amount of hardening it
received, the density of the developed image, the temperature, relative
humidity, and movement of ambient air reaching the film.

b. The air is heated to expand it, to lower its relative humidity, and to
accelerate the evaporation of moisture. These factors are directly
proportional to the temperature. The temperature must be held within certain
limits. If it is too low, evaporation is slowed and drying marks result, and
if it is too high, the emulsion may become brittle and crack. The exact limits
are governed by the kind of material being dried, how it was processed, and the
type of dryer being used.

c. The reason air should be kept moving is that air at the surface of the
wet emulsion soon becomes saturated and will not take up additional moisture.
The saturated air must be replaced by unsaturated air if drying is to continue.
Of course, even still air is in constant motion, and an emulsion will dry
eventually, but the drying will most likely be more rapid at the edges than in
the center. Thus, any considerable change in the drying conditions that
persists for comparatively long periods of time will leave visible lines at the
wet-dry borders. This condition is apt to occur in certain types of dryers.

d. Parallel-flow dryers utilize a series of reverse-bend ducts to conduct

warm dry air across the film as it moves through the drying cabinet. Figure
1-8 shows schematically a typical arrangement.

(1) In order to prevent the drying marks mentioned above, parallel-flow

dryers should be operated at rather high air velocities. The temperature
should not be excessive, and the relative humidity of the air should not be too
low.

(2) The exact conditions must be adjusted to the climate in which the
dryer is being used. Different settings would be required for coastal areas
than, for example, the desert.

e. One of the most common methods of drying is called impingement drying.

In this method, jets of air are applied at right angles to the

12
emulsion and base of the film simultaneously. The schematic, fig 1-8b, shows
the relation of the film to the air plenums in the drying compartment of a
continuous processor.

(1) Air is heated to temperatures ranging between 100°F and 150°F (37.8°
to 65°C) and is directed against the film at velocities of from 5000 to 6000
feet per minute. An efficient squeegee must be used since surface liquid
remaining on the film will result in non-uniform drying.

(2) As with any other type of dryer, the condition of temperature and
velocity must be adjusted to the local climate. Otherwise, the film will dry
more rapidly at the edges causing drying marks.

(3) Some types of film tend to become excessively brittle when dried
rapidly by this method. This is due to reduced relative humidity rather than
overdrying.

Figure 1-8a. Parallel-flow dryer Figure 1-8b. Impingement dryer

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Learning Event 3:
IDENTIFY BASIC AREAS OF SAFETY

1. There are three basic areas of safety: chemical, electrical, and

mechanical. When working with a continuous processor you will be confronted by
all three areas simultaneously.

a. Chemical. When working with photographic solutions, always assume that

they will be harmful. Never try to determine the contents of a bottle by
sniffing. If in doubt, safely discard the contents according to the local SOP
and obtain one you are sure of. When mixing chemicals, wear appropriate
protective clothing and follow the manufacturer's instructions. Remember AAA-
ALWAYS ADD ACID OR ALKALI. That is, add acid to water. NEVER add water to
acid.

b. Electrical. Electrical equipment always presents the possibility of

shock. Make sure the electrical equipment is properly grounded. If in doubt,
have it checked by qualified personnel.

c. Mechanical. Processing machines are filled with gears, chains, drive

shafts, and other moving parts. Keep hands away from these parts while the
machine is running. Be especially careful of loose-fitting clothing and long
hair. Either remove loose clothing, or roll up sleeves, tape them tight and
wear a hat or some other device to keep hair away.

2. Remember that safety is a continuing job. If you find an unsafe condition

report it to your supervisor. It's always better to be safe now than sorry
later.

Learning Event 4:
IDENTIFY THE STEPS NECESSARY TO PREPARE FILM PROCESSOR FOR OPERATION

1. The first step is to flush all rollers and crossover assemblies with warm
water to remove any foreign matter. Then wipe down the wet tanks using a damp
sponge.

2. Remove the side panel to gain access to the plumbing section. Remove the
panel by lifting up on the stainless steel edging and disengaging the bottom of
the panel from the processor. Then pull the panel from the processor. Inside
the plumbing section are five tank drain valves that must be closed.

3. Connect the replenisher lines from the storage tanks to the inlets on the
front of the processor. Make sure the proper line is connected to the proper
inlet. See figure 2-10 for the proper inlet location.

4. The processor is now ready for the installation of the roller racks and
crossover assemblies. Place No. 1 rack into the first developer tank by
sliding the rack into the tank until it seats firmly. Under NO circumstances
should you try to jam the racks into place. After the rack has seated, check
to make sure the roller rack drive gear engages the worm gear on the drive

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Figure 2-10. Processor, Versamat 11C-W overall view

Figure 2-11. Numbered racks and crossovers

15
shaft. Install the rest of the rack assemblies and then install the cross-
overs. Each rack and crossover is numbered or identified as to its position.
Figure 2-11 shows the correct positioning.

5. You are now ready to install the roll-feed adapter (or magazine assembly)
and roll film take-up assembly if they are required.

6. The processor should be filled with chemicals using the required developer
and fixer. It must be filled to the proper level using an external source.
The replenisher system is not designed for initial filling of the chemical
tanks. Once the tanks are filled, check the replenisher system for operation.
To do so, proceed as follows:

a. Make sure the lines are connected to the inputs and the storage tanks
are filled with solutions.

b. Turn the replenisher switch to the MANUAL position.

c. Open the bleed valve inside the plumbing chamber to remove the air from
the lines. When the solution flows, close the valve.

d. Open flow meter control valves and allow the solutions to flow through
the flow meters to the tanks.

e. Adjust the flow meters to the desired replenishment rate.

f. Turn the replenisher switch to the OFF position.

7. Replace the side panel for the plumbing compartment and allow 5 to 10
minutes for the developer and dryer assembly to come up to the required
temperature. Turn on the cold and hot water and adjust the mixing valve to the
recommended water temperature (slightly less than the recommended developer
temperature). The water temperature is indicated by a thermometer on the
mixing valve. Before the initial processing operation, check the developer
temperature with a process thermometer to ensure the machine thermometer is
correct. After the initial check and correction, this check is performed
periodically during the maintenance inspections.

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 PRACTICE EXERCISE

1. What is the function of a processing machine? ____________________________

__________________________________________________________________________

2. Continuous film processors are designed for rapid processing and drying of
what types of film? ______________________________________________________
__________________________________________________________________________

3. Where in the laboratory are film processors installed? ___________________

__________________________________________________________________________

4. What two film transporting methods are used in continuous film processors?
__________________________________________________________________________

5. What are the two threading systems used in a leader-type processor? ______
__________________________________________________________________________

6. What threading system is most often used with 70mm or wider film? ________
__________________________________________________________________________

7. What is the purpose of the agitation system? _____________________________

__________________________________________________________________________

8. What are the three types of agitation systems? ___________________________

__________________________________________________________________________

9. What gas is used in the gaseous burst system? ____________________________

__________________________________________________________________________

10. What is the purpose of this gas? _________________________________________

__________________________________________________________________________

11. Temperature control in color processing is very critical and must be

controlled for consistent results.

A. True B. False

12. Chemical, electrical, and mechanical are the three basic areas of ________
__________________________________________________________________________

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 ANSWERS TO PRACTICE EXERCISE

1. Transport film through various solutions

2. Black and white film, color negative and positive transparency slide film

3. Outside the darkroom

4. Leader and leaderless

5. Overunder and loop threading

6. Overunder system

7. To move the processing solution so that fresh chemistry is always in

contact with the film

8. Immersion, spray system, and spray immersion

9. Nitrogen

10. To keep the solution in motion

11. A

12. Safety

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 LESSON 2
OPERATE CONTINUOUS FILM PROCESSOR

TASK

Describe the operation of the automatic film processor.

CONDITIONS

Given information about systems and operating procedures of the Versamat 11C-MW
processor.

STANDARDS

Demonstrate competency of the task skills and knowledge by responding to the

multiple-choice test covering operation of the automatic print processor.

REFERENCES

None

Learning Event 1:
DESCRIBE THE VERSAMAT 11C-MW FILM PROCESSOR

1. Semiautomatic continuous processing machines for film and/or paper are

utilized throughout Army laboratories where large amounts of intelligence or
motion picture work are performed. One of the processors most likely to be
encountered in the lab is covered in this lesson.

2. Versamat 11C-MW. The "Kodak Versamat" film processor.

a. This processor (fig 2-la) is an automatic, rapid-processing machine

designed to handle black and white roll film in width from 16mm to 241.3mm (9.5
inches) in any lengths and cut film ranging from 101.6mm by 127mm (4 by 5
inches) to 279.4mm by 355.6mmm (11 by 14 inches). The Versamat can also
process two rolls of 70mm or 90mm, or three rolls of 16mm or 35mm film
simultaneously.

b. Operating speed of the processor ranges from 2 1/2 to 25 feet per

minute. On some models of the Versamat processor, a modification of the drive
system is necessary to increase the speed to 25 feet per minute.

c. Figure 2-1b is an inside view of the major parts of the Versamat 11C-
MW.

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 Figure 2-1a. Processor, Versamat 11C-MW overall view

3. Operating principles.

a. The Versamat is self-threading and does not need a leader to pull the
film through the machine. Instead, the film is transported through the
processor by a series of roller-driven assemblies called racks. However, when
processing roll film, a tab of thick-based material (acetate, mylar, or
processed X-ray film) must be attached to the head of the roll of film to guide
it through the processor. This leader tab is referred to as a bullet (fig 2-2).

b. Once the exposed film is placed in the feed end of the Versamat
processor, the film transport system automatically takes over. The film is

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 1. Number 1 developer tank 11. Dryer thermostat pilot lamp
2. Number 2 developer tank 12. Damper control knobs
3. Number 1 fixer tank 13. Dryer temperature gauge
4. Number 2 fixer tank 14. Overflow
5. Number 3 fixer tank 15. Fixer inlet (A-type chemistry)
6. DEV thermostat pilot lamp 16. Fixer inlet (B-type chemistry)
7. Developer thermostat 17. Number 1 wash tank and rack
8. Weir block 18. Number 2 wash tank and rack
9. Dryer food light switch 19. Squeegee assembly
10 Dryer thermostat 20. Dryer flood light

Figure 2-1b. Versamat major parts

conveyed through the various processing solutions by the racks, which are
located in each of the seven stainless steel tanks.

(1) The rack leads the film to the bottom of each tank, through a
turnaround, and back up. These racks also serve the purpose of providing
effective agitation so that byproducts of development can be removed and fresh
developer solution brought to the surface of the film. Once the film reaches
the top of the rack, it travels to the next rack by means of a crossover
assembly.

21
 Figure 2-2. Bullet with a 35mm roll of film attached

(2) The crossover also acts as a squeegee by removing most of the liquid
adhering to the film's surface. The film passes from the feed end through all
seven processing tanks in this manner. The operator may, however, bypass any
tank by using a Skip Rack Crossover.

(3) The final tank before the dryer compartment is a cascade spray wash
which removes any remaining solutions from the surface of the film.
Immediately after the last wash tank, the film passes through a roller squeegee
assembly which removes most of the surface water.

(4) From here the film enters the dryer compartment and is directed
downward between a series of rollers. Once it reaches the bottom it passes
through another turnaround assembly and back up, again between a series of
rollers. While the film is in the dryer compartment warm air is directed at
both sides from a series of air tubes. The processed and dried film then
passes into either a receiving bin (for sheet film) or a take-up adapter (for
roll film).

Learning Event 2:
DESCRIBE THE MAJOR SYSTEMS OF THE VERSAMAT 11C-MW FILM PROCESSOR

1. Description. The Versamat 11C-MW film processor is constructed as a light-

tight, self-contained film processor. It has a leaderless drive system, a
replenishment chemical system, and an impingement dryer system for complete
processing during one operation. The processor has seven wet tanks--two for
developer, three for fixes, and two for cascade spray wash. A vertical roller
rack in each tank leads the film to the bottom of the tank and back to the top.
The film then goes to the rack in the next tank through crossover rollers.
From the wet section the film is passed to the dryer through a squeegee

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assembly. Here, the film is transported downward and then upward between air
tubes that direct hot air onto both surfaces of the film. The processed and
dried film is then passed to a receiving bin, or a roll film take-up system.
The processor measures 58 inches in length, 25 inches in width, and 54 inches
in height. Maximum weight of the unit, without processing solutions, is 1200
pounds. Although no more than 11 square feet of floor space is needed for
installation of the processor unit, additional space may be needed to
accommodate the floor-mounted, 30-gallon replenisher storage tanks. To operate
and service the Versamat processor, a space requirement of 2 feet is necessary
on both sides and at both ends of the unit.

2. Systems Description. The major systems of the Versamat 11C-MW processor,

described below, combine to perform the necessary stages in film processing.

a. Main drive system. The main drive system consists of a single,

variable speed motor, sprockets, drive shaft, chains, and gears which drive the
entire transport system. The system is activated by a rocker switch on the
control panel, and the speed is varied by a speed control potentiometer. The
set speed is automatically kept constant by a drive control.

b. Developer recirculation system. The developer recirculation system,

(fig 2-3), continuously pumps the developer from the developing tanks through a
filter, heat exchanger, thermostatically-controlled heater, and back to the
tanks. An ON-OFF switch operates the pump and energizes the thermal control
system. NOTE: The fixer solution is not recirculated in the Versamat processor.

Figure 2-3. Developer recirculation system

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 c. Water circulation system. The water circulation system on the Versamat
11C-MW (fig 2-4) operates from regulated pressure, through a water mixing valve
and flow meter. It provides fresh water to the deep wash and spray tanks
through the jacket side of the heat exchanger. Water temperature for the wash
water and heat exchanger is regulated by a thermostatically controlled valve in
the mixing valve.

Figure 2-4. Water circulation system

d. Developer and fixer replenishment system. The developer and fixer

replenishment systems (fig 2-3 and 2-5) pump developer and fixer to the
processing tanks from the storage tanks. The replenisher pumps can be operated
continuously or automatically controlled by a detector roller system. Both
systems are energized by a rocker switch, AUTO-ON-MAN. NOTE: The weir blocks
shown in figure 2-5 control the direction of flow for the fixer.

e. Air circulation system. The air circulation system is designed to

circulate heated air through the dryer section of the processor. The air is
heated by thermostatically controlled heaters. A blower, located beneath the
processing tanks, forces the air through the system. Make-up air is added
through a grill at the dryer end of the processor, and an equivalent amount of
moist air is discharged through the dryer exhaust to maintain proper relative
humidity in the dryer. Approximately 250 cubic feet per minute of

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 Figure 2-5. Fixer replenishment system

air is replaced. The blower and heating element power is controlled by a

switch on the control panel, and a thermostat in the dryer section regulates
the temperature.

f. Drainage system. The drain used for the Versamat must be a 4-inch,
open drain capable of handling 4 gallons per minute during normal operation, or
8 gallons per minute when draining the tanks.

g. Roller transport system (fig 2-6). The transport system consists of a

film detector assembly, seven racks, eight crossovers, a squeegee assembly, and
two crossovers, transport rollers, and turnaround in the dryer. Each roller
rack consists of a series of chain-driven rollers mounted in a staggered path.
The rotation of the rollers moves the film through the processor. As the film
reaches the bottom of the rack, a turnaround assembly turns the film 180°. When
the film reaches the top of the rack, a crossover assembly conveys the film to
the next rack. This process continues through each rack assembly until the
film is transported to the dryer assembly. In order to transport film in
continuous lengths, the surface speed of the rollers is slightly increased in
certain locations in the processor. This enables the transport system to
prevent any slack that could be built up due to normal film swelling. Slight
increases of speed occur in the following locations:

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 * Squeegee assembly
* Dryer entrance crossover
* Dryer down-path
* Dryer turnaround
* Dryer up-path
* Dryer exit crossover

Figure 2-6. Roller transport system

h. Dryer transport system (fig 2-7). The dryer transport system consists
of an entrance and exit crossover, two vertical rows of belt-driven rollers, a
turnaround, and air tubes mounted between the transport rollers. The air tubes
direct air onto both surfaces of the film. Guide pins mounted on the air tubes
direct the film from one roller to the next.

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 Figure 2-7. Dryer transport assembly

i. Electrical system. The electrical system of the processor requires an

input power of 120/208-volts, 3-phase, 4-wire service. The electrical design,
however, allows conversion to either 115/230-volt, 1-phase, 3-wire or 230-volt,
3-phase, 3-wire service. If it is necessary for you to convert

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the power connection from the normal service, consult the applicable technical
manual for correct hookup requirements.

j. Standard Equipment. Standard equipment includes:

(1) Basic processor with racks

(2) Film guide assembly

(3) Crossovers and turnarounds

(4) Film bin

(5) One splash guard

(6) Two weir blocks (to direct fixer flow)

(7) Four stainless steel floor plates

k. Accessories. The Versamat can be used with the following accessories:

(1) Roll-feed adapter--permits processing of roll films of various

sizes.

(2) Roll-feed takeup--used with roll and adapter to take up the film as
it leaves the processor.

(3) Developer bypass--allows the bypass of the first developer tank when
only one tank is required, as for shorter development time.

(4) Skip rack--allows the bypassing of any intermediate rack as dictated

by the film requirements.

(5) Two 30-gallon replenisher tanks complete with dust covers and
compression fittings.

(6) Two strainers (one for developer replenisher and one for fixer
replenisher).

(7) A thermostatically controlled mixing valve, strainers, and

temperature gauge, tubing and clamps for connecting replenisher tanks to
processor.

(8) A combination film magazine.

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Learning Event 3:
LOCATE AND DESCRIBE THE FUNCTION OF THE CONTROLS AND INDICATORS ON THE VERSAMAT
11C-MW FILM PROCESSOR.

1. Controls and indicators. Before you operate the Versamat processor, you
must understand the location and functions of the controls and indicators.
During the following discussion, refer to Figures 2-8 and 2-9.

a. Dryer fan switch. The dryer fan switch operates the blower and applies
power to the dryer heater circuit. When the dryer thermostat calls for heat, a
pilot lamp illuminates.

b. Main drive switch. The main drive switch, protected by the 12-amp
fuse, applies power to the main drive motor and speed control circuits. The
motor starts immediately, but there is an approximate 3-second delay before the
transport system begins to drive. This allows the motor to reach operating
speed and the other electrical components to warm up before operation.

c. Replenisher pump switch. This switch controls the power to the

replenisher pumps. The switch has three positions, MANUAL, OFF, and AUTO. In
AUTO, the replenisher pump is energized by a microswitch under the detection
roller as film is fed between the rollers. The AUTO mode is used primarily in
processing sheet film. In the MANUAL position the replenisher pumps operate
continuously for processing continuous lengths of thin base film. The
replenishment assures a fresh flow of chemicals to the machine. To prevent
unnecessary waste of chemicals, turn the pump switch OFF immediately after the
processing is completed.

Figure 2-8. Control panel

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 d. Speed indicator light switch. This switch is provided to illuminate
the speed indicator and the developer and fixer flow meters. Illumination is
provided as long as the switch is ON. To prevent fogging undeveloped film,
preset the speed before processing begins.

e. Speed indicator. The tachometer speed indicator records the number of

feet per minute (fpm) the film is traveling through the processor.

f. Speed control knob. Rotating the knob clockwise increases the speed of
film transport system.

Figure 2-9. Drying cabinet control panel

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 g. Accessory outlet. The accessory outlet operates in conjunction with a
timer circuit. The outlet can be used to plug in a recommended safelight, or a
statice liminator over the processor. Also located on the front of the
processor are the flow meters, developer temperature thermometer, water inlet,
silver recovery connector, drain outlets, replenisher inlets and the air
exhaust.

h. Dryer lamp switch. The dryer lamp switch (fig 2-9) controls the flood
lamp, which provides illumination for the dryer cabinet.

i. Dryer thermostat. The thermostat controls the minimum required

temperature in the dryer cabinet. There is also a safety device (backup
thermostat) that rings a bell and turns off the dryer heaters if the
temperature exceeds 160°F. The normal range of temperature selection by the
thermostat is up to 155°F. When the heaters are ON, a pilot lamp illuminates.

j. Dryer thermometer. The thermometer indicates the temperature of the

air in the dryer cabinet, in centigrade, fahrenheit, or both.

k. Damper controls. The damper controls can be positioned from 0 through

8 to control the amount of air admitted to the air tubes. Position 0 is fully
closed, and position 8 is fully open.

2. The only other control you need to adjust is the developer temperature
control, located under the plumbing splash guard. The control knob sets the
thermostat to the desired developer temperature.

Learning Event 4:
DESCRIBE THE PREOPERATIONAL INSPECTION, DAILY STARTUP, AND SHUTDOWN PROCEDURE

1. Operation. Begin the operation of the processor by checking the squareness

of the feed tray. You place a sheet of 8 by 10 inch film on the tray and then
push it forward until it is in contact and square with the feed and detector
rollers. To square the tray, loosen two wing nuts under the tray and move the
tray as necessary.

a. The Versamat has detector rollers that sound a buzzer if two

thicknesses of film or a damaged film is fed into the processor. If the buzzer
sounds during an operation, pull the film from the rollers to prevent a
possible failure later in the processing cycle.

b. The bottom detector roller, shown in Figure 2-10, activates micro-

switches to activate the double thickness alarm (one switch on each end of the
roller) and the replenisher system (center switch). As the film passes between
the rollers, the center switch closes, turning on the replenisher pumps. When
the film exits the rollers, a bell signals that the next film may be fed into
the processor. If two thicknesses of film enter the feed rollers, a switch on
the end of the roller closes, turning on the warning buzzer. During MANUAL
operation of the replenisher system, the center switch is removed from the
circuit and the pumps run continuously.

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 Figure 2-10. Detection rollers and micro-switches

c. Check for proper film movement by inserting several 8- by 10-inch test

films into the processor and observing the film movement through the processing
section, squeegee, and dryer. The test films check the transport system for
tracking of the film through the racks and crossovers, check the dryer for
proper drying temperature, and remove any dirt that may be on the rollers.

d. The processor is now ready to operate in a definite series of steps.

Study these seven steps so that you can recall them without difficulty.

(1) Turn on the main power switch and outside water source.

(2) Turn on the dryer fan, main drive, and developer recirculating pump
switches. Press the replenisher pump switch to the desired operating mode AUTO
or MANUAL.

(3) Consult processing data sheets to determine the processor speed,

water temperature, dryer temperature, developer temperature and replenishing
rate for the particular film you are using.

(4) Set the developer and fixer flow meters to the recommended flow rate
by adjusting the replenishment control valves.

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 (5) Allow the developer and dryer to rise to the desired temperature
before beginning to process.

(6) Make sure the film edges are square with the edges of the film feed
tray; then advance the film until it is drawn in by the detector rollers.

CAUTION: Do NOT feed film of less than 5 inches in length. Figure

2-11 shows the proper film feeding procedure for cut sheet film.
Always feed the film into the processor with the emulsion up.

Figure 2-11. Film feeding procedures

(7) Whenever possible, feed all narrow films side by side to avoid over-
replenishment of the solutions.

CAUTION: To ensure proper transport of roll film, use a stiffening

tab, such as a sheet of clear acetate or a piece of heavy leader.
For 16mm or 35mm films the tab should be 7 inches long and 2 inches
wide. With 70mm or 90mm films, the tab should be 7 inches long and
cut as wide as the film. Use 1-inch wide pressure-sensitive tape to
fasten the tab to the film. Use a butt splice and make sure the
adhesive side of the tape is not exposed.

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 e. When you process roll film, be sure to place it on the roll feed
adapter (or in the magazine) so it will feed through the processor emulsion up.
If you plan on multi-strand processing, allow a 5-minute interval between the
strands to keep them properly positioned in the in the processor so they won't
overlap. Thread the film strands through the roll film takeup so that they
wind onto the takeup spools evenly without damaging the edges of the film.

f. When the operation ends, turn off the replenisher switch, remove the
cover, and wipe any "splashed" chemicals from the crossover assemblies and
other exposed surfaces.

g. Always feed film into the processor emulsion side up. The center
microswitch also actuates replenisher pumps into the auto mode of operation as
the leading edge of the film enters the detector roller assembly.

2. Versamat SOP Checklist:

a. Preoperational Inspection.

(1) Check for obstructions in gears, chains, belts, etc.

(2) Check racks and crossovers for proper seating and clean them.

(3) Check all dry rollers.

(4) Check dryer compartment for cleanliness.

(5) Check silver recovery cartridge for proper operation and silver
content.

(6) Check solution levels in processor and replenisher tanks.

(7) Make sure all switches on the control panel are in the "OFF"
position, the speed control is at "0" (full counterclockwise), and the wash
tank drain valves are closed.

b. Daily Startup

(1) Ensure all switches on the control panel are in the "OFF" position,
the speed control is at "0" and the wash tank drain valves are closed.

(2) Turn on the water and adjust the flow rate to approximately 0.5
gallons per minute at a temperature 5° F less than the developer temperature
being used.

(3) Turn on MAIN POWER.

NOTE: The MAIN DRIVE switch activates the water pump for the wash
tanks. As a precaution, to keep this pump from "running dry," never
turn the main power on unless the water

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 is on and the on and the last wash tank is half full.

(4) Turn on DEVELOPER RECIRCULATION switch. (If the developer

temperature is to be raised a considerable amount, the remaining steps may be
delayed until that temperature is reached.) Check DEVELOPER THERMOSTAT control
for proper temperature setting, adjust only if necessary.

(5) Turn REPLENISHER PUMP switch to "manual" and adjust flow rate of
replenisher to required setting. (Flowmeters are set at eye level from the
bottom of the float.) Turn switch to "automatic."

(6) After the number 2 wash tank (last tank) is half filled, turn on the
MAIN DRIVE.

(7) Adjust SPEED CONTROL to 5 fpm, and make sure that all moving parts
are moving freely.

(8) Turn DRYER FAN on and adjust DRYER THERMOSTAT to desired setting.

CAUTION: Always turn dryer fan on before setting dryer thermostat.

(9) When DEVELOPER HEATER GLOW LAMP goes out, check developer
temperature with a thermometer of known accuracy. Make minor corrections to
DEVELOPER THERMOSTAT as necessary.

CAUTION: Use a dial thermometer for this purpose. NEVER use a

mercury thermometer to check temperature in a processor. If the
thermometer should break, serious contamination will result and the
entire tank may have to be replaced.

c. Daily Shutdown.

(1) Ensure that speed is at 5 fpm.

(2) Turn DRYER THERMOSTAT off and remove top and side covers from dryer.
To speed dryer cooling, remove dryer entrance air tube.

(3) Turn REPLENISHER PUMP switch off.

(4) Turn DEVELOPER RECIRCULATION switch off.

(5) While dryer is cooling, remove all crossovers and rinse in water not
over 120°F. Wipe down top rollers on racks.

(6) When dryer temperature has reached 100°F or less, turn DRYER FAN
off.

CAUTION: Turning dryer fan off while dryer temperature is over 100°F
may damage dryer transport rollers by warpage.

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 (7) Reduce speed to 0 fpm and turn off MAIN DRIVE. NEVER turn the water
off before turning the main drive off. Doing so will damage the water pump.

(8) Turn off MAIN POWER.

(9) Turn water off.

(10) Open wash tank drain valves if processor is to be shut down for
overnight or longer.

(11) Wipe down all surfaces of machine and replace crossovers.

(12) Replace Versamat side covers and dryer top cover. Always leave top
cover slightly ajar to allow fumes to escape and prevent condensation and
crystallization of chemicals on those rollers above the solutions.

CAUTION: Observe all safety precautions.

PRACTICE EXERCISE

1. The Versamat 11C-MW is designed to process B&W film as well as color

negative film and positive transparency film.

a. True b. False

2. The Versamat 11C-MW uses a leader to transport the film through the
processor.

a. True b. False

3. What are the major systems of the Versamat 11C-MW? There are a total of
9. _______________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

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Match the control or indicator with the proper function.

______ 4. Speed indicator light switch a. Applies power to the blower

motor and heater circuit

______ 5. Dryer lamp switch b. Applies power to the drive

motor

______ 6. Dryer thermometer c. Selects the mode for

replenishing the solutions.

______ 7. Replenisher pump switch d. Controls the recirculation

of the developer solution

______ 8. Speed control knob e. Controls the illumination of

the speed indicator.

______ 9. Dryer thermostat f. Varies the speed transport

______10. Dryer fan switch g. Allows the use of a

safelight

______11. Developer recirculation switch h. Controls the illumination of

the dryer cabinet.

______12. Accessory outlet i. Indicates the dryer

temperature

______13. Developer temperature control j. Controls the dryer

temperature

______14. Damper control k. Controls the developer

temperature

______15. Main drive switch l. Controls air flow in dryer

The following statements are either true or false. If the statement is

correct, mark it true; if the statement is incorrect, mark it false.

______16. The detector rollers on the Versamat sound a buzzer if damaged film
is fed into the processor.

______17. The center microswitch activates the replenishing pumps when in the
manual mode of operation as film feeds through the processor.

______18. Running cut film through the processor allows you to check the
system for proper tracking of film.

______19. You consult the processing data sheets to find the processor speed
recommended for a given film.

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 ANSWERS TO PRACTICE EXERCISE

1. False

2. False

3. Main drive system, developer recirculation system, water circulation

system, developer and fixer replenishment system, air circulation system,
drainage system, roller transport system, dryer transport system and the
electrical system.

4. E

5. H

6. I

7. C

8. F

9. J

10. A

11. D

12. G

13. K

14. L

15. B

16. T

17. F

18. T

19. T

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