AP-800A Service Manual PDF

SERVICE MANUAL
ONLINE PROCESSOR
AP-800A
First Edition
INTRODUCTION
This manual contains installation and setup procedures specific to the AP-800A, the dedicated online processor
for the Luxel F-6000.
2 AP-800A
MANUAL ORGANIZATION
CHAPTER 1 PRECAUTION
Describes safety, environmental, and other important precautions regarding the operation of the AP-
800A. Be sure to read this chapter carefully. 1
CHAPTER 2 INSTALLATION PROCEDURE
Describes how to install the Ap-800A. Describes plumbing and electrical work.
2
CHAPTER 3 MAINTENANCE
Describes how to use the maintenance services such as revising the data. Describes how to reset
the safety thermostats and replace the lithium battery. 3
CHAPTER 4 ERRORSHOOTING
Describes how to solve various problems that may occur.
4
CHAPTER 5 REPLACEMENT of PARTS
Describes how to replace various parts such as heaters or pumps.
5
CHAPTER 6 APPENDIX
AP-800A Specification
6
AP-800A 3
WARNING’s, CAUTION’s, IMPORTANT’s, and NOTE’s
This manual includes WARNING’s, CAUTION’s, IMPORTANT’s, and NOTE’s which are used as follows.
WARNING
Warns against a procedure which can cause injury to personnel or damage to equipment.
CAUTION
Warns against a procedure which negatively affects the performance or produces an undesir-
able result.
IMPORTANT
Contains information vital to proper operation and optimal use.
NOTE
Contains information helpful to operations and other supplemental information.
4 AP-800A
CONTENTS
INTRODUCTION ......................................................................................... 2
MANUAL ORGANIZATION ........................................................................ 3

1
WARNING’s, CAUTION’s, IMPORTANT’s, and NOTE’s .......................... 4
CONTENTS ................................................................................................ 5
Chapter 1 Precautions ............................................................................. 7

1.1 General ............................................................................................................... 8
1.2 Chemicals ........................................................................................................... 9
1.3 Operation Environment .................................................................................... 10
1.4 Power ............................................................................................................... 12
1.5 Safety ............................................................................................................... 13
Chapter 2 Installation Procedure .......................................................... 15

2.1 External measurement ..................................................................................... 16
2.1.1 Caution at the Carry of the AP-800A .............................................................................. 16
2.1.2 External Measurement ................................................................................................... 16
2.1.3 AP-800A Measurement .................................................................................................. 17
2.2 LAYOUT ........................................................................................................... 18
2.2.1 Space ............................................................................................................................. 18
2.2.2 Place for the Replenisher Tanks ..................................................................................... 18
2.3 The Procedure of Unpacking ............................................................................ 19
2.4 Docking ............................................................................................................ 21
2.5 Release the Inner Fixture ................................................................................. 23
2.6 Plumbing .......................................................................................................... 25
2.6.1 Chemical Collection ........................................................................................................ 25
2.6.2 Water Connection (Supply and Drain) ............................................................................ 27
2.6.3 External Connection ....................................................................................................... 28
2.6.4 Connecting the Exhaust Duct Hose ................................................................................ 28
2.7 Power Connection ............................................................................................ 29
2.7.1 Power Specification ........................................................................................................ 29
2.7.2 Power Electrical Work .................................................................................................... 29
2.8 Pouring the Chemicals ..................................................................................... 31
2.9 Replenisher Tanks ............................................................................................ 33
Chapter 3 Maintenance .......................................................................... 35

3.1 Maintenance Mode (Flow Chart) ...................................................................... 36
3.2 Resetting and Confirmation .............................................................................. 37
3.2.1 Error History Display ....................................................................................................... 37
AP-800A 5
Contents
3.2.2 I/O Check ....................................................................................................................... 38

3.2.3 Sensor Status Display .................................................................................................... 40
3.2.4 Sensor OFF Setting ........................................................................................................ 41
3.2.5 Component Test ............................................................................................................. 42
3.2.6 Temperature Calibration ................................................................................................. 43
3.2.7 Replenishing Pump Calibration ...................................................................................... 44
3.2.8 DipSW Information Display ............................................................................................. 45
3.3 Maintenance ..................................................................................................... 47
3.3.1 Extracting the Air from the Filter Case ............................................................................ 47
3.3.2 Setting and Exchanging Filter ......................................................................................... 48
3.3.3 Resetting the Safety Thermostats .................................................................................. 49
3.3.4 Replacing the Lithium Battery ......................................................................................... 50
3.3.5 Regular Replacing Parts List .......................................................................................... 51
Chapter 4 Error Shooting ...................................................................... 53

4.1 Error Shooting .................................................................................................. 54
4.2 I/O Check of the Processor .............................................................................. 62
Chapter 5 Replacement ......................................................................... 83

5.1 Developer Circulator Pump .............................................................................. 85
5.2 The Fixer Circulator Pump ............................................................................... 86
5.3 The Developer Replenishment Pump .............................................................. 87
5.4 The Fixer Replenishment Pump ....................................................................... 88
5.5 The Drive Motor ................................................................................................ 89
5.6 The Developer Temperature Control Heater .................................................... 90
5.7 The Fixer Temperature Control Heater ............................................................. 91
5.8 The Dryer Heater .............................................................................................. 92
5.9 Dryer Fan Motor ............................................................................................... 93
5.10 Electromagnetic Valve ...................................................................................... 94
5.11 The Developer Thermistor ................................................................................ 95
5.12 The Fixer Thermistor ........................................................................................ 96
5.13 The Dryer Thermistor ....................................................................................... 97
5.14 Operation Panel ............................................................................................... 98
5.15 The Control PCB .............................................................................................. 99
5.16 DC Power Source ........................................................................................... 100
5.17 SSR ................................................................................................................ 101
5.18 Lithium Battery ............................................................................................... 102
Chapter 6 Appendix ............................................................................. 103

AP-800A SPECIFICATIONS ................................................................................... 104
6 AP-800A
Chapter 1 Precautions
7
1.1 General
WARNING
Do not disassemble.
Do not remove any covers or parts secured with screws. Touching internal parts may result in
injury or electrical shock.
WARNING
Do not modify equipment.
Modifications may affect safety or other functions.
WARNING
Specified accessories, consumables, maintenance tools only.
Do you use any accessories, consumables (parts of sensitized materials), or maintenance tools
not specified or recommended by FFEI. Such products may affect safety or other functions.
WARNING
Work Clothes
When working near the equipment
• Do not wear neckties, scarves, or other loose clothing or accessories.
• Keep long hair away from moving parts.
Loose clothes or hair may get wrapped onto moving parts and result in bodily injury.
WARNING
When resetting the safety thermostats, make sure the main power is turned off to prevent
electrical shock.
8 AP-800A
1.2 Chemicals
Safety Glasses
WARNING
1
Always wear safety glasses when handling developer and fixer. Developer and fixer will cause
irritation if it contacts the eye. In such a case, rinse thoroughly with fresh water for
approximately 15 minutes. If irritation continues, contact an ophtalmologist.
WARNING
Rubber Gloves, Rubber Apron
Always wear rubber gloves and rubber apron when handling developer and fixer. Developer
and fixer may cause irritation if it contacts the skin. Always wash your hands after handling
chemistry.
WARNING
Never ingest processing chemicals. Otherwise injury may result. Keep processing chemicals
out of reach of children.
WARNING
Waste Chemicals and Water
Disposal of waste chemicals and water must be carried out in strict compliance with local laws
and regulations regarding such disposal.
AP-800A 9
1.3 Operation Environment
CAUTION
Ventilation
Avoid locations with the following:
• High moisture content in the air
• Corrosive gases production
• Dust
• Cigarette smoke
The above may cause malfunction or affect machine life.
If necessary, install a ventilation fan in the same room with the equipment to protect operator
health.
CAUTION
Dust and Dirt
Avoid locations with excessive dust and dirt. Keep the area around the equipment clean in
order to maintain quality.
IMPORTANT
Direct Sunlight, Bright Room Lighting
Avoid locations in direct sunlight or under bright room lights. Otherwise, film fogging may result.
If necessary, block the light from the problem window with curtains or other means.
IMPORTANT
Air Conditioning
Air conditioning may be necessary to maintain proper environmental conditions for optimal
quality. These conditions are:
Temperature: ...... 18 - 29 °C (Must not be lower than 7 °C from developer set temperature)
Humidity: ............ 20 - 70% RH
10 AP-800A
1.3 Operation Environment
Floor Strength
IMPORTANT
1
Make sure the floor can withstand the weight of the equipment.
AP-800A : ....... 240kg, 310kg when full
IMPORTANT
Work Space
Provide enough space around the installation so that basic maintenance and inspection can be
easily performed.
IMPORTANT
Water-proofing the Floor
Water-proofing the floor around the equipment is recommended to prevent damage from water
and chemistry spilled when changing chemistry or during other maintenance. Always clean up
spills immediately to prevent adverse effects on the equipment.
IMPORTANT
Rinse Water Temperature
If the temperature of the rinse water is too low, residual color or color changes may result.
Maintain the water temperature within the range 10 °C - 30 °C. If necessary, provide water
heating equipment.
IMPORTANT 9
Rinse Water Flow
Maintain a flow of about 3 liters per minute.
AP-800A 11
1.4 Power
WARNING
Earth Connection
To prevent electrical shock and malfunctions, make sure the equipment is properly connected
to earth.
CAUTION
Power Specifications
Voltage 208V/240VAC 60HZ Single phase (UL)
220V/230V/240VAC 50HZ Single phase (TUV)
Frequency ±10%
Power Consumption Single phase 21A
VOLTAGEDROPS
Connect equipment only to power with a voltage fluctuation that is within specified limits. Large
capacity equipment with large load fluctuations on the same line may result in power drops.
12 AP-800A
1.5 Safety
WARNING
When performing maintenance and inspection, always turn OFF the power except for proce-
1
dures that require power.
WARNING
Lubrication
Always turn the power OFF when performing lubrication to prevent get caught in moving parts.
When lubricating around hot areas, let the processor cool for about 30 minutes before starting
lubrication.
CAUTION
Tank Cleaner
Never let undiluted tank cleaner in the tanks. Always dilute according to the manufacturer’s
instructions before using in the tank. Limit use to once a month, fifteen minutes each time.
CAUTION
Empty Tank
Never leave on tank empty and the one next to it full for long periods. This may cause the tank
wall to warp. Short periods are allowable.
CAUTION
Algae Prevention Agents
Some algae prevention agents contain elements that are harmful to the tank or metal parts. Be
careful to select only agents that will not do any damage to processor components.
9
CAUTION
Algae
Algae tend to grow in areas with poor water quality. If this is the case, change the water in the
rinse tank everyday at the end of operations.
AP-800A 13
1.5 Safety
Regulations and Standards

This instrument fits or confirms to the regulations and standards shown below.
EMC
Japan VCCI, Class A (Conformance)
USA FCC Rules, Part 15, Class A
Europe EMI EN55022 (1998)
EMS EN55024 (1998)
Safety
USA UL1950 (Third Edition)
Europe EN60950/A11 (1998)
TUV Approval (TUV PS)
CE
LV Instruction (73/23/EEC)
EMC Instruction (89/336/EEC)
14 AP-800A
Chapter 2 Installation Procedure
15
2.1 External measurement
2.1.1 Caution at the Carry of the AP-800A
Clear the place for the AP-800A to be carried easily. More than 4 persons are needed to carry the equipment.
Make sure that the floor can withstand at least 400kg/m.
Figure 1 Foot print Measurement: mm
15 15
130
827
1,086
AP-800A
86
2.1.2 External Measurement
Model Width (mm) Depth (mm) Height (mm) Weight (kg)

AP-800A 1190 924.5 1167 310 (with chemicals)
16 AP-800A
2.1 External measurement
2.1.3 AP-800A Measurement
1,116
890
898
71
370 857 68
65
1,180
1,115
1,000
1,295
AP-800A 17
2.2 LAYOUT
2.2.1 Space
Secure the enough space, particularly the side space for the operation, maintenance and inspection.
Figure 3 Installation example Measurement: mm
1,000 or over
1,000 or over
AP-800A
Recorder
Main Power
1,000 or over
2.2.2 Place for the Replenisher Tanks
Place the replenisher tanks in place where they will not interfere with daily operation.
When using the automatic water supply system, water supply plumbing is needed.
18 AP-800A
2.3 The Procedure of Unpacking
Unpacking Procedure
Unpack in numerical order as follows.
Note
When removing the machine from the pallet, use a forklift from the direction of 3 only. 2
1
2
4
4
2
3
12 9
8
9
10
3
11
AP-800A 19
2.3 The Procedure of Unpacking
1 Remove the top crate.
2 Remove 2 beams.
3 Remove the two side crates.
4 Take out the attached box.
5 Remove the skid.
6 Remove the other side crates.
7 Remove the aluminum cover.
8 Take out the 3 boxes containing a rack of the

developer, fixer and dryer respectively.
9 Remove the board.
10 Remove the 8 screws which fixed the AP-800A to

the pallet. Lift the AP-800A using a forklift, and put it
on the floor.
11 Remove the fixed metal fittings.
12 Remove the protective materials from the top cover

and docking part.
20 AP-800A
2.4 Docking
1 Using the adjustment bolts, adjust the height of the

frame of the AP-800A so that the bottom of the frame
is approximately 65 mm from the floor. (If the floor is
not flat, adjust so that the lowest part is 65 mm from
the floor, and the height of the docking part will be
about 1000 mm from the floor.) Level by placing a
2
level on the stays or rollers of each rack.
65
5 2 Move the Luxel F-6000 close to the AP-800A, and

match with the height of the Luxel F-6000, marking
Mark the signs attached on the both equipment.
14
5 Dock the Luxel F-6000 with the AP-800A.
F-6000
1000 1000
AP-800A
3 The clearance on the right and left is as follow.

5 5
14
AP-800A
14
F-6000
4 Connect the interface cable from the AP-800A to the

power supply connector of the Luxel F-6000.
IMPORTANT
• Be sure to level the processor. If the chemicals level sensor is located 5 mm or more higher than
the opposite side, it cannot detect the chemicals level. This condition will activate automatic
replenishment. Eventually it could lead to a chemicals low error.
• Do not raise the recorder higher than necessary for docking.
Otherwise, the processor’s guide plate will be pushed up, or possibly deformed.
AP-800A 21
2.4 Docking
5 Connect the interface cable from the AP-800A to the

RS232C connector of the Luxel F-6000.
Communication cable
(RS-232C)
To Luxel F-6000
22 AP-800A
2.5 Release the Inner Fixture
1 Remove the rear cover.
2
2 Unscrew &
2 Tacke off the 4 screws to remove the bracket.
2
3 Screw again
3 Screw 2 positions to fix the bracket to the lower rear
cover.
1
4 4 Unscrew the chamber at the opposite side of the drive

4 motor section.
5 5
5 Remove the board (5) which is fixed for transportation
at the side of the drive motor section.
AP-800A 23
2.5 Release the Inner Fixture
6 Unscrew the dryer rack at the side of the drive motor

6 section.
7 Replace the bord (5) so that it is possible for the top

cover to open and close.
(Operation position) (Transportation position)
24 AP-800A
2.6 Plumbing
For the automatic water supply system, water supply plumbing is needed.
2.6.1 Chemical Collection

1) The AP-800A has a space underneath for 20-liter plastic tanks, supplied by users to collect chemicals.
Use the supplied hose to connect the processor to the tank.
2
Figure 4 Plastic bucket
* The bucket mouth must have the following diameters.

Outside diameter ............ 67 mm
Inside diameter ............... 38 mm
AP-800A 25
2.6 Plumbing
2) Connecting to Plumbing
When connecting the processor directly to a separate large volume drain tank, carry out as the following.
• Do not connect nozzles directly. Attach the supplied drain hoses to them. Run drain pipes up to the
processor drain and insert the drain hoses.
• The height of the drain is 500 mm. Since draining is by natural pressure difference, make sure no air
locks can form in the hoses and pipes.
Figure 5 Installation Place
Front AP-800A
Luxel
F-6000
VP25
Drain
500
100
156 135
26 AP-800A
2.6 Plumbing
2.6.2 Water Connection (Supply and Drain)
1) Water supply plumbing

• Main water valve An ON/OFF water valve for the processor must be installed between the processor
and the water supply faucet.
• Water temperature 10 °C - 30 °C
• Rinse water pressure 2kg/cm2 max. If original water pressure is greater than 2kg/cm2, install a
pressure reducing valve. (1kg/cm2 or less)
2
• Rinse supply 6 liter/min. 8 liter/min. max.
• Water filter Place a filter in the supply pipe to remove dirt from the water
2) Connecting to the water supply

Connect the water supply to the pressure resistant hose, located at the left corner of the processor.
Connect the water supply to the solenoid valve. The solenoid valve’s screw is PT3/4.
Figure 6 Water supply plumbing example
filter
valve drain
valve
water
supply
pressure
pressure resistant
reducing valve hose
AP-800A 27
2.6 Plumbing
2.6.3 External Connection
Do not connect the drain nozzles directly.

Instead, run drain pipe (VP40) up to inside the processor. Insert the supplied hose into the drain pipe.
The height of the drain nozzle is about 500mm. Since draining is by natural pressure difference, make sure
no air locks can form in the hoses and pipes.
Figure 7 External Connection
Drain
500
2.6.4 Connecting the Exhaust Duct Hose
The purpose of the exhaust duct is to prevent condensation inside the processor by expelling air. Connect
3.5m exhaust hose onto the exhaust port on the processor and direct it to outside the installation room
Use hose of the following specification.
Inside diameter ............... 75/100mm

Material ........................... Preferred flexible plastic than metals
Hose binder .................... Use proper size of hose outer diameter and
bind before deforming the port.
28 AP-800A
2.7 Power Connection
2.7.1 Power Specification
Voltage 208V/240VAC 60HZ Single phase (UL)

220V/230V/240VAC 50HZ Single phase (TUV)
Frequency ±10%
Power Consumption Single phase 21A
2
2.7.2 Power Electrical Work
1) Leakage Circuit Breaker

The leakage circuit breaker with 15A and sensitivity rating of 15mA is fitted.
2) No Fuse Breaker
No fuse breaker with 30A is equipped.
3) Connecting the Power Cable
Use the cable of AWG10 to connect.
4) Earth Connection
To prevent electrical shock and mal functions, make sure that the AP800A is properly connected to
earth (Class 3)
Use the protective earth terminal made of copper.
5) Wiring
AP800A has a bracket for conduit.
[Power Cable Connection Diagram] TB1
E
Single phase 2 wires
L1 N L2 L3
L1 N L2 L3
200-240 V
The ground cable shold be longer than the power cord.
CAUTION
Power connection should be done by an electrical engineer. It requires fully technical
knowledge.
AP-800A 29
2.7 Power Connection
6) Setting the Input Voltage

The voltage fluctuation tap terminal is connected to AC230V at the factory, connect the equipment to
the local voltage.
TB6
240V Cable for adjusting to local power specifications.
230V
240-200
220V
208V
200V
L1
200V
0V 0V (IN)
Transformer terminal Do not change connection of 0V cable
1 Remove the side cover from the control part.
2 Check the voltage connections.

Reconnect the input cable (240-200V) to fit the
voltage of the installation site.
Make sure all the other cable connections are tight.
Make sure the breaker is ON
3 Replace the side cover.
30 AP-800A
2.8 Pouring the Chemicals
NOTE
• When filling both the developer and fixer tanks at the same time, fill the fixer first and fill the
developer. When pouring the chemicals, use measuring cups and funnel.
• When filling the fixer, be careful not to splatter in the developer tank.
2
1 Drain the rinse water after washing from the fixer tank.
2 Pour the required amount of the fixer. Take great

care no fixer splashes in the developer tank
3 Reset the fixer rack to the tank. Be careful no fixer

splatters.
AP-800A 31
2.8 Pouring the Chemicals
4 Pour water to the overflow into the developer tank.
5 Drain the rinse water after washing from the

developer tank.
6 Pour the required amount of the developer and reset

the developer rack to the tank.
32 AP-800A
2.9 Replenisher Tanks
Replenisher tanks
Two tanks are necessary for replenishment of the developer and the fixer.
Two hoses with the taper which enables to connect the hose of inside diameter in the range of 8 to 15 mm
are equipped from the replenishing pumps. Each hose has a label of the developer or the fixer.
Connect the taper to the hose (inside diameter, in the range of 8 to 15 mm) from the replenisher tank
supplied by yourself. Fix with the hose cramp. 2
When you supply with tanks, pay attention to such points as follows.
The tank is preferable to be made from polyethylene or polyvinyl chloride, containing about 20 liters with an
opening for inserting a hose. If it has a wide opening, it should have a cover.
AP-800A 33
34 AP-800A
Chapter 3 Maintenance
35
3.1 Maintenance Mode (Flow Chart)
[Flow chart]
POWER OFF
Press , and for more than 3 sec.
MAINTENANCE 1
3.2.1 32 errors display and clear the errors
ERROR REPORT
Press Press
MAINTENANCE 2
3.2.2 I/O status display
I/O CHECK
Press Press
MAINTENANCE 3
3.2.3 Sensor on/off
SENSORS' STATUS
Press Press
MAINTENANCE 4
3.2.4 Setting sensor off
OFF SENSORS
Press Press
MAINTENANCE 5
3.2.5 Load test
COMPONENT TEST
Press Press
MAINTENANCE 6
3.2.6 Revise the temperature
TEMP.CALIBRATION
Press Press
MAINTENANCE 7
3.2.7 Revise the replenishment
PUMP.CALIBRATION
Press Press
MAINTENANCE 8 Display ROM version

ROM VERSION X You can see the ROM version for your
reference.
Press Press
DIPSW 01010001
3.2.8 DipSwich display
00000000
Press Press
MAINTENANCE
EXIT
Press Press
Ordinary Mode
36 AP-800A
3.2 Resetting and Confirmation
3.2.1 Error History Display
You can refer to 32 errors (error’s number/dates). You can also clear the error history.
ERROR REPORT 1
E350 11/24 10:26
History No. (1-The latest 32-The oldest)
2
The time when an error occurs
The date when an error occurs
Error number 3
MAINTENANCE 1 For this mode display, press , and
ERROR REPORT for more than 3 seconds in the ordinary mode.
Press
ERROR REPORT 1
E350 11/25 10:15
Press
Press
ERROR REPORT 2
E350 11/25 12:30
Press Press
ERROR REPORT 3
E830 11/25 14:40
Press Press
ERROR REPORT 32 * Without data, the display is as the left.

**** --/-- --:--
Press Press
Press
Press
ERROR REPORT ERROR REPORT
CLEAR CLEAR?
Press
Press Press (Error history is cleared) Press
EXIT
Press
Press
AP-800A 37
3.2.2 I/O Check
You can refer to INPUT / OUTPUT status of the developer heater, fixer heater, dryer heater 1 and 2,
dryer fan, developer circulator pump and fixer circulator pump.

I/O CHECK for more than 3 seconds in the ordinary mode.
Press .
Press
Press
INPUT1 -1--0--- The digits beginning from the left concide with the
OUTPUT2 0000-000 position number from 0 to 7 in the next page’s table.
Press Press
OUTPUT2 --000-00
OUTPUT3 ------0-
Press Press
EXIT
Press
Press
Refer to the next page’s table for the displays.
38 AP-800A
I/O Display Menu and Input & Output Device
Display Position 1 0
0
1
2
Top cover is closed. Top cover is opened.
2
INPUT 1 3
4 * CTS signal ON (untransmittable) CTS signal OFF (transmittable)
5
6
3
7
0 Developer Heater ON Developer Heater OFF
1 Fixer Heater ON Fixer Heater OFF
2 Dryer Heater 1 ON Dryer Heater 1 OFF
OUTPUT 1 3 Dryer Heater 2 ON Dryer Heater 2 OFF
4
5 Dryer Fan ON Dryer Fan OFF
6 Dev. Circulator Pump ON Dev. Circulator Pump OFF
7 Fix. Circulator Pump ON Fix. Circulator Pump OFF
0
1
2 POWER LED comes on POWER LED comes off
OUTPUT 2 3 Dev. Replenish Pump ON Dev. Replenish Pump OFF
4 Fix. Replenish Pump ON Fix. Replenish Pump OFF
5
6 Water Supply Valve OPEN Supply Water Valve CLOSE
7 Buzzer ON Buzzer OFF
0
1
2
OUTPUT 3 3
4
5
6 * RTS signal ON (impermissive) RTS signal OFF (permissive)
7
* 1 in the position 4 of INPUT 1 indicates CTS signal ON (untransmittable) which means that the
processor is not permitted to transmit the data by the image setter. 0 in the position 4 indicates that the
processor can transmit the data.
* 1 in the position 6 of OUTPUT 3 indicates RTS signal ON (impermissive) which means the processor
does not permit the image setter to transmit the data. 0 in the position indicates that the processor
permits the image setter to transmit the data.
AP-800A 39
3.2.3 Sensor Status Display
You can refer to the information detected by each the entrance, exit and chemicals detect sensors.
ENTRANCE SENSORS Indicates an item of status display.

0000 0
Input status display

SENSORS' STATUS for more than 3 seconds in the ordinary mode.
Press twice.
Press
Press
1 : With film
ENTRANCE SENSORS
0000 0 0 : Without film
* : Sensor OFF Setting - ON
Press Press
1 : With chemicals
TANK SENSORS
1100 0 : Without chemicals
Press Press
EXIT
Press
Press
Film detect: 0 0 0 0 0 Tank level detect: 1 1 0 0

From the left end: From the left end:
• Entrance sensor 1 • Dev. processing tank level sensor
• Entrance sensor 2 • Fix. processing tank level sensor
• Entrance sensor 3 • Dev. drain tank level sensor
• Entrance sensor 4 • Fix. drain tank level sensor
• Exit sensor
40 AP-800A
3.2.4 Sensor OFF Setting
You can set the sensors off.
Indicates an item of status display

ENTRANCE SENSORS
1111 1 Sensor's functions status
1 : Sensor OFF Setting - OFF
2
1 Exit sensor
4 Entrance sensors
3
OFF SENSORS for more than 3 seconds in the ordinary mode.
Press 3 times.
Press
Press
Press Procedure is mentioned below.
ENTRANCE SENSORS ENTRANCE SENSORS
1111 1 1111 1
Press Press Press (to establish)
ENTRANCE SENSORS
TANK SENSORS 1111 1
11
Press
Press Press ENTRANCE SENSORS
1111 1
EXIT
Press
Press
Press
The 5 digits indicate 5 sensors. The figure 1 flashes one by one. While it is flashing, select 1 (sensor ON)
or * (sensor OFF) by pressing or . Press to establish.
For the tank sensors, the procedure is the same as for the entrance sensors.
In the Sensor OFF Setting - ON, a film is not detected.

In the Sensor OFF Setting - OFF, the developer/fixer is not detected in the tank (or both chemicals are not
detected.)
Film detect: 1 1 1 1 1 Tank level detect: 1 1

From the left end: From the left end:
• Entrance sensor 1 • Dev. processing tank level sensor
• Entrance sensor 2 • Fix. processing tank level sensor
• Entrance sensor 3
• Entrance sensor 4
• Exit sensor
AP-800A 41
3.2.5 Component Test
You can activate each of the functions.
DRIVE MOTOR 20sec

0RPM OFF
Function Status

COMPONENT TEST for more than 3 seconds in the ordinary mode.
Press 4 times.
Press
Press
Press ON/OFF
DRIVE MOTOR 20sec
. The above digit means processing speed.
00RPM OFF
. The below digits indicate revolving speed.
Press Press
Press ON/OFF
D&F TEMP. CONTROL
. The 4 digits indicate the status of, beginning
0000 11 OFF
from the left, dev. heater, fix. heater,
dev. circulator pump and fix. circulator pump
Press Press
respectively.
. The mid. digits indicate the status of, beginning
from the left, dev. tank level sensor and fix. tank
level sensor.
. Heater activates only when the tank is full of
chemicals.
Press ON/OFF
DRY TEMP. CONTROL
000 OFF . The digits indicate the status of dryer heater 1,
dryer heater 2 and dryer fan, beginning from
Press Press the left.
Press
WATER SUPPLY SV
OFF ON/OFF
Press Press
Press ON/OFF
RECIRCULATION
PUMPS 11 OFF . The digits indicate the status of dev. tank level
and fix. tank level
Press Press
Press
POWER LED
OFF ON/OFF
Press Press
EXIT
Press
Press
42 AP-800A
3.2.6 Temperature Calibration
You can revise the temperature for developer, fixer and dryer.
DEV.TEMP. C/B Object for revise

(35.1°C) +2.0°C C/B ..... Control PCB
T/M ..... Thermistor
2
Select the setting value by pressing or while the digits are flashing.
Control temperature = Actual temperature + Revised value
3
TEMP.CALIBRATION for more than 3 seconds in the ordinary mode.
Press 5 times.
Press
While the digits are flashing,
press or to scroll the value.
Press
Press to establish.
Press
DEV.TEMP. C/B DEV.TEMP. C/B
(35.1°C) +2.0°C (35.1°C) +2.0°C
Press
Press
Press
Press
FIX.TEMP. C/B FIX.TEMP. C/B
(32.5°C) -1.0°C (32.5°C) -1.0°C
Press
Press
Press
Press
DRY.TEMP. C/B DRY.TEMP. C/B
(55.5°C) +0.5°C (55.5°C) +0.5°C
Press
Press
Press
Press
DEV.TEMP. T/M DEV.TEMP. T/M
(35.1°C) +1.0°C (35.1°C) +1.0°C
Press
Press
Press
Press
FIX.TEMP. T/M FIX.TEMP. T/M
(32.1°C) -1.0°C (32.1°C) -1.0°C
Press
Press
Press
Press
DRY.TEMP. T/M DRY.TEMP. T/M
(62.5°C) +0.5°C (62.5°C) +0.5°C
Press
Press Press
EXIT
Press
Press
AP-800A 43
3.2.7 Replenishing Pump Calibration
You can revise the calibration of replenishing pumps.

PUMP CALIBRATION for more than 3 seconds in the ordinary mode.
Press 6 times.
Press
Press
Press
DEV.PUMP. CALI- DEV.PUMP. CALI-
BRATION OFF BRATION OFF
"OFF" flashes.
To select ON or OFF, press or .
DEV.PUMP. CALI-
BRATION ON
Press Press
Press (starts activating pump)
DEV.PUMP. CALI-
BRATION ON
The display changes after 30 seconds.

Press
DEV.PUMP. RATE DEV.PUMP. RATE
464mL 464mL
Press When digits flashes,
Press Press
press or to scroll the value.
(The amount/1min.)
FIX.PUMP. CALI- Press to establish.
BRATION OFF
Press Press
FIX.PUMP. RATE
464mL
Press Press
EXIT
Press Press
44 AP-800A
3.2.8 DipSW Information Display
You can refer to the status of the DipSW.
DipSW 01010001 * Information on DipSW 1

01010001
(1: ON 0: OFF)
** Information on DipSW 2 2
* From the left end:
DipSW1- 1
DipSW1 -2
** From the left end:
DipSW2- 1
DipSW2- 2
3
DipSW1- 3 DipSW2- 3
DipSW1 -4 DipSW2- 4
DipSW1- 5 DipSW2- 5
DipSW1- 6 DipSW2- 6
DipSW1 -7 DipSW2- 7
DipSW1- 8 DipSW2- 8
It displays the status that the software recognizes. The status of DipSW is input only when
the main power is put on. Therefore, if you change the status after you put the main power on , the
display is not changed.
• For the detail, refer to the next page's DipSW Information Table.
AP-800A 45
DipSW 1 and 2 attached on the control PCB can change setting and initialize the reserved data.
1. The software can recognize the DipSW status only when the main power is put ON.
In another word, to change setting the DipSW in the software, put OFF and ON the main power after
setting.
2. DipSW has 16 bit (8 bit x 2)
Contents ON status OFF status Initial setting

DipSW 1
1 OFF (Fixed)
2 Clock display DD/MM/YYYY MM/DD/YYYY OFF
3 OFF (Fixed)
4 Change to forced Not executes Executes OFF
replenishing
5 Changing the interval 7 mins. Off/3 mins. On 14 mins. Off/1 min. On OFF
of driving motor
6 Setting the back light No back light comes Back light comes on OFF
on LCD on for READY status for READY status
7 Treatment of the [7] [8] [7] [8]
default with the main OFF-ON Uses the default. OFF-ON
8 power on. ON -ON Initializes the reserved data
ON -OFF except for the default.
OFF-OFF Initializes the reserved data.
DipSW 2
1 OFF (Fixed)
2 Setting exit sensor Connected Unconnected ON
connection
3 OFF (Fixed)
4 OFF (Fixed)
5 OFF (Fixed)
6 OFF (Fixed)
7 OFF (Fixed)
8 Speed changing 20/30 sec. processing 20/23 sec. processing OFF
46 AP-800A
3.3 Maintenance
3.3.1 Extracting the Air from the Filter Case
1) When filling the developer tank with the developer, the air may enter the filter case.
Unless foaming away in 5 minutes, extract the air from the filter case, according to the procedure.
1 Remove the operation panel side cover.

2
2
2 Loose bolt on the top of the filter case. After the

3
developer comes out a little, close the bolt tight.
1
3 Replace the cover.
AP-800A 47
3.3 Maintenance
3.3.2 Setting and Exchanging the Filter
1 Remove the operation panel side cover.
2 Take off 2-M4 screws fixed for transportation.
1
3 Move the filter case to the upper position.
4 Open the filter case.
5 Set or replace the attached filter.
2 6 Reset the filter case to the initial position.

2-M4
7 Replace the cover.
CAUTION
• Close the filter case tight. Otherwise, it may cause the leak of developer.
• Before opening the filter case, move it to the upper position. Without moving it, there may be a
leak.
• When changing a filter, be careful not to drop the developer
• When moving the filter case, do not give the stress to the hose to prevent the fold or going out
of joint.
48 AP-800A
3.3 Maintenance
3.3.3 Resetting the Safety Thermostats
Each heater has safety thermostats which can be reset by hand (manually) to prevent too high temperature.
In the case of error of high temperature, they react to cut the power to the heater. To startup again, reset the
safety thermostats following to the procedure.
2
CAUTION
To prevent the electrical chock and damage to the equipment, be sure to put the power OFF.
3
1) Reset the safety thermostats for the developer and the fixer heaters
2 Two heaters for the developer are located under the

developer tank in a line. Two heaters for the fixer are
located under the water tank in a line. The safety
thermostats are equipped to the heaters. It features
red button with a yellow cap. To reset the thermostats,
remove the yellow caps and press two red buttons
of the thermostats until to click.
3 Replace the rear cover.
2) Reset the safety thermostats for the dryer heaters
1 Remove the panel.
2 The safety thermostats are under the dryer rack.

Press the two red button of the thermostats until to
click.
3 Replace the panel.
AP-800A 49
3.3 Maintenance
3.3.4 Replacing the Lithium Battery
The lithium battery is used for memory backup. Ordinarily the lithium battery should not need replacement
for approximately 10 years. However, if SETUP DATA(error code No.E000) occurs, check, and if necessary,
replace the lithium battery. Dispose of the old battery in accordance with local laws and regulations.
1 Disconnect all cable from the control PCB.
2 Remove the control PCB from its base.
3 Cut the tie-wraps securing the battery, remove the

cable, and remove the battery.
4 Secure the new battery in place with tie-wraps and

connect the cable.
5 Re-attach the control PCB to its base.
6 Re-connect all cable (disconnected in step 1) to the

control PCB.
7 Reset the memory.
8 Reset all parameters.
CAUTION
• The battery must be disposed of in accordance with local laws and regulations.
• Danger of explosion if the battery is incorrectly replaced.
• Replace only with the same or equivalent type recommended by the manufacturer.
• Dispose of used batteries according to the manufacturer’s instructions.
50 AP-800A
3.3 Maintenance
3.3.5 Regular Replacing Parts List

User Maintenance Items
1. Cleaning tanks (at the replacing the chemicals)
2. Cleaning crossover racks (after holidays)
3. Cleaning processing racks (every month)
4. Cleaning dryer rollers (every month)
5. Cleaning dryer guides (every month)
6. Applying vaseline to worm gear (every gear (every 2 or 3 months)
2
Regarding the details, refer to the Instruction Manual.
Articles for Consumption 3

Items Code No. Note
1 Filter element 376F0175
2 Vaseline 891F8239341
Regular Replacing Parts List

Items Code No. Recom. Exc. Term
1 Washer 309F0090 At replacing roller
2 Support Shaft 322F2137 2 years
3 Support Shaft 322FA028
4 Support Shaft 322FC084
5 Support Shaft 322FC286
6 Support Shaft 322FY011
7 Spur Gear 327F0034 2 years
8 Spur Gear 327F1121601
9 Spur Gear 327F1122006
10 Spur Gear 327F1122028
11 Spur Gear 327F1122031A
14 Spur Gear 327F1122401
15 Spur Gear 327F1122404
16 Spur Gear 327F1122408
18 Spur Gear 327F1123102
21 Spur Gear 327F1125005
22 Spur Gear 327F1201510
23 Spur Gear 327F1201801
24 Spur Gear 327F1202411
25 Spur Gear 327F1202702
26 Helical gear 327F2201602
27 Helical gear 327F2201604A
28 worm 327F4202L07
29 worm 327F4202L09
30 Roller 334F2972 3 years
31 Roller 334F2973
32 Roller 334F2974
33 Rubber roller 334F3681A 2 years
34 Rubber roller 334F3685
35 Hook 343F0146 2 years
36 Spring coiled 388F2019 2 years
37 Spring coiled 388F2065
38 Spring coiled 388F2246
39 Spring coiled 388F4015 2 years
AP-800A 51
52 AP-800A
Chapter 4 Error Shooting
53
4.1 Error Shooting
ERROR MESSAGE ERROR DESCRIPTION AND HOW TO CHECK REMEDY

E000 Occurs in the case of errors when checking the default memory data
SETUP DATA area just after startup. (Battery gone, for example)
ERROR
Is 2.5v or more the voltage
between TP15 and JP1 on No
Replace the battery on PCB
the control PCB with the
Battery:ER17/33WK11(Maxell)
power off?
Code no.:125F0079
Yes
Reset the system and put the re-
vised values and set values.
E010 Occurs when the dev. temperature exceeds 42 °C.

DEV. TEMPERATURE No
The dev. temperature is re-
TOO HIGH Revise correctly.
vised correctly?
Yes * Check the revised value of DEV. TEM-
PERATURE C/B in Maintenance
Mode 6 with the value on BOARD
DATA on PCB.
* Check the revised value of DEV.
TEMP. T/M in the Maintenance Mode
6 with the value in the chart attached
on the back of a cover underside the
operation panel.
Dev. /fix. Circuit pump is ac- No

Check dev. fix. circulator pump.
tivated?
Yes * Implement RECIRCULATION PUMP
to confirm.
Implement D&F TEMP CONTROL. in Maintenance mode 5. Is

No
the difference within 0.3 °C between the actual temp. and that Check the dev. heater.
on the display (DEV. TEMP C/B)?
Yes
Implement D&F TEMP CONTROL. in Maintenance mode 5.

No
Convert the resistance value of the dev. thermistor (CN05, 1~2) Exchange the thermistor.
to the temperature.
Yes * Remove the connector from the base

to measure the resistance value.
Replace the PCB.
E030 Occurs when the dev. temperature. does not rise 1.5 °C or more in 10
DEV. HEATER minutes dev. temperature control before READY.
MALFUNCTION
The dev. circulator pump is No
Check dev. circulator pump.
activated?
Yes
Check the dev. heater.
54 AP-800A
4.1 Error Shooting

E040 Occurs when the temperature is 0 °C or lower.
DEV. THERMISTOR
Is 45kΩ or more the resis-
MALFUNCITON Yes
tance value of the thermistor Replace the thermistor.
(between CN05-1 and 2) ?
No * To measure the resistance value, re-

move the connector from the control
PCB.
3
Replace the control PCB.
E050 Occurs when the temperature is 89 °C or higher.

DEV. THERMISTOR The same as the case of E010.
SHORT CIRCUITED
E110
FIX. TEMPERATURE
Occurs when the fix. temperature exceeds 42 °C. 4
TOO HIGH Turn the main power OFF to remove connector terminal, TB4-16. 17 of
the fixer heater and turn the power ON. Then check the following mat-
ter.
The fixer temp. is revised No

Revise correctly.
correctly?
Yes * Check if the revised value of Fix.
Temp C/B with the value on the
Board Data on PCB.
* Check the revised value of Fix. Temp
T/M with the value in the chart on the
cover under the operation panel.
The fix. Circuit pump is Acti- No

Check the fixer circulator pump.
vated?
Yes
Implement D&F TEMP CONTROL in the Maintenance mode 5.

Yes
Is the difference within 1 °C between the actual temp. and the Check the fixer heater.
temp. displayed on FIX. TEM T/M?
No
Implement [D&F TEMP CONTROL] in Maintenance mode 5.

No
Convert the resistance value to the temperature between the Replace the thermistor.
pins of CN06-1 and 2 of the fixer thermister.
Yes * To measure the resistance value, re-

move the connector from the control
PCB.
Replace the PCB.
E130 Occurs when the temperature does not rise 1.5 °C or more in 10 min-
FIX. HEATER utes after dev. temperarue control before READY.
MALFUNCTION
Is the fix. circulator pump ac- No
Check the fixer circulator pump.
tivated?
Yes
Check the fixer heater.
AP-800A 55
4.1 Error Shooting

FIX. THERMISTOR
The resistance value of the
MALUFUNCTION Yes
thermistor (CN06, 1~2pin) Replace the thermistor.
is 45kΩ or more.
No * Remove the connector from PCB to

measure the resistance value.
Replace the PCB.
E150 Occurs when the temperature exceeds 89 °C.

FIX. THERMISTOR Is the same as E110.
MALFUCTION
E210 Occurs when the dryer temperature exceeds 75 °C.

DRY. HEATER
MALFUNCTION Remove the connector terminal TB4-10, 11, 12 and 13. Put on the dry-
er heater to check the following matters.
The dry. temperature is re- No

Revise correctly.
vised correctly?
Yes · Check if the revised value of DRY.
TEMPERATURE C/B in Maintenance
Mode 6 with the value in BOARD
DATA on PCB.
· Check the revised value of DRY.
TEMP. T/M in the Maintenance
Mode 6 with the value in the chart at-
tached on the dryer cover.
No
Is the dryer fan activated? Check the dryer fan.
Yes
Wait for the temperature in

the dryer zone to be parallel
to the room temperature
Yes
(about 1 hour). Is the differ- Check Dryer Heater H3-1.
ence within ±5 °C between Check Dryer Heater H3-2.
the temp. in the dryer zone
and the room temperature?
No
Convert the resistance va-

lus to the temperature be-
No
tween the pins of CN07-1 Replace the thermistor.
and 2 of thermistor in the
dryer zone.
Yes * To measure the resistance value, re
move the connector from the PCB.
Replace the PCB.
56 AP-800A
4.1 Error Shooting

E230 Occurs when the temperature does not rise 1 °C or less in 10 minutes Check the Dryer heater H3-1.
DRY. THERMISTOR after dryer temperature control before READY. Check the dryer heater H3-2.
SHORT CIRCUITED

DRY. THERMISTOR · The voltage between TP9 and JP1 on PCB is less than 42 × Vref
MALFUNCTION 1/255[V] (DC)
(when Vref 1 is 5V, it is less than 42 × 5/255=0.82V)
· Vref 1: the voltage between TP5 and JP1 on PCB.
The resistance value of the

thermistor (CN07, 1~2 pin) Yes
3
Replace the thermistor.
of the Dryer zone is more
than 45kΩ .
No * To measure the resistance value, re

4
move the connector from the PCB.
Replace the PCB.
E250 Occurs when the temperature exceeds 89 °C.
DRY. THERMISTOR · The voltage between TP9 and JP1 on PCB is more than 213 × Vref
SHORT CIRCUITED 1/255[V] (DC)
(when Vref 1 is 5V, it is more than 213 × 5/255=4.18V)
· Vref 1: the voltage between TP5 and JP1 on the PCB.
Is the same as E210.

E310 Occurs when the entrance sensor detects a film in the processor at
ENTRANCE the startup.
SENSORS
A film is at the entrance sen- Yes
MALFUNCTION Remove the film.
sor.
No
The guide caught an actua-

Yes
tor part of the entrance sen- Adjust the guide position.
sor?
No
Can the sensor detect a

film in the maintenance
No
mode 3? Besides, a film de- Replace the PCB.
tect is possible after rotat-
ing sensors. (CN16~19)
Yes
Replace the applicable sensor.
E340 Occurs when the drive motor speed decreases 30 % of the regular val-
DRIVE MOTOR ue.
MALFUNCTION
When implementing
[DRIVE MOTOR sec] in the
maintenance mode 5 after
Yes
undoing the chain of the mo- Check whether a film or a foreign
tor axis, displayed revolving substance is jammed in the pro-
speed is less than 30 % of cessor.
the regular value?
No
Check the drive motor.
AP-800A 57
4.1 Error Shooting

E350 Occurs when the upper cover is open or off during The operation or
TOP COVER startup.
OPEN
No
The top cover is closed? Close the top cover.
Yes
The top cover is closed cor- No

Close the top cover correctly.
rectly?
Yes
The connector CN01 on the No

Connect CN01 (control PCB) ex-
PCB is connected properly?
actly.
Yes
When CN01 is removed,

with the top cover closed,
the resistance value be- Yes
Replace PCB.
tween connector 1 and 4
pin on the sensor is 0Ω
short.
No
Check top cover detect switch and
Cable.
E520 Occurs when the entrance sensor is not turned on in 10 seconds after
FILM DETECT FAULT getting film exit signal of image setter.
No
Is a film at the insert roller? Check the image setter.
Yes
Is the entranse sensor in- No

Install the sensor exactly.
stalled exactly?
Yes
Are the connector No

Install the connector exactly.
CN16~CN19 on the PCB in-
stalled exactly?
Yes
Can ENTRANSE SENSOR

No
detect a film in mainte- Replace the entrance sensor.
nance mode 3?
Yes
Check the image setter.
58 AP-800A
4.1 Error Shooting

E521 Occurs in the case of bad communication between the setter and the
COMMUNICATION processor.
ERROR
Is the connector for commu-
No
nication On the control PCB Install the connector exactly.
installed exactly?
Yes
Remove the connector.

The resistance value be-
No
Replace the communications
3
tween the pins is 0Ω? cable.
Yes
Confirm of the communication data in the Maintenance mode 2.

Replace the PCB.
4
I/O check
OUTPUT2--000-00
OUTPUT3-------0-
RTS signal
AP-800A 59
4.1 Error Shooting

E810 · The dev. tank is not full with the 6 times of replenishment.
NO DEV. IN TANK · The dev. processing tank sensor detects the developer to be short
within 3 hours after replenishment before READY.
E811 · The dev. processing tank sensor detects the developer to be short
DEV. LEVEL LOW with the replenishment .
The dev. drain valve is

Yes
closed or is there any leak Close the drain valve.
or fold of hoses? Exchange the hoses.
No
The dev. processing level Yes Dev. processing tank sen- No

Install the level sensor of the De-
tank is full of dev. ? sor is installed properly?
veloper tank properly.
No Yes
In the maintenance Mode 3

[TANK SENSOR], the digit
for Dev. tank level sensor is
0?
Yes
The above display is 1 after

No
short-circuit between CN 14- Exchange PCB.
1 and 2 On PCB?
Yes
Exchange level sensor.
Check the resistance value be-
tween CN14 is 0Ω.
Check the level.
Pump is activated at the Re- No
Check the pump which is not acti-
plenishment?
vated.
Yes
The set amount of develop-

er is added? (330mL)
Yes
The revised value for replen- No

Revise correctly.
ishing pump is correct?
Yes * Check the reivesed value on the
[DEV. PUMP CALIBRATION] in the
maintenance mode 7 with the revised
value on the chart attached on the
back of the dryer cover.
Are there chemicals in the No

Replace the cartridge.
stock tanks.
Yes
Revise the value again.
60 AP-800A
4.1 Error Shooting

E820 E820
NO FIX. IN TANK Occurs when the fix. tank is not filled full with 6 times of morning re-
plenishment.
E821
FIX LEVEL LOW E821
Occurs when the fix. tank level sensors detect the fixer to be short in 3
hours after replenishment before READY.
The drain valve of fixer is

closed? Is there any bend-
ing or break of hoses?
Yes
Close the drain valve.
Exchange the hoses. 3
No
The fixer processing tank is Yes

full of the fixer?
The level sensor is installed No
correctly?
Install the fix tank level sensor
4
properly.
No Yes
The digit for fix level sensor

in maintenance mode 4
[TANK SENSOR] is 0?
Yes
The above display is 1 after

No
short-circuit between CN15 Exchange PCB.
1 and 2 on PCB?
Yes
Check the resistance value be-
tween CN15 is 0Ω.
Check the level.
The pump is activated after No
Check the pump which is not acti-
the replenishment?
vated.
Yes
The set amount of the fixer

is replenished? 390mL (set amount)
No
The revised value of the re-

No
plenishment pump is Cor- Revise correctly.
rect?
Yes * Check the revised value in the Main-

tenance mode 7 [FIX. PUMP CALI-
BRATION] with the revised value in
the chart attached on the back of a
cover under the operation panel.
Are there chemicals in the No

Replenish the chemicals.
stock tanks.
Yes
Revise the value again.
AP-800A 61
4.2 I/O Check of the Processor
WARNING
When inspecting with the power on, be careful about the electrical shock.
4.2.1 The Developer Heater (H1) Check
Check Items How to check Remedy

When it is not turned
on. Is AC200V the voltage Yes Are the developer safety Yes
Reset the safety developer thermo-
between connector TB4- thermostats(TH1) activa-
stats.
14, 15 with the developer ted?
heater turned on?
No
Inspect the short part of the cable
No * Measure the voltage
and the developer heater.
with the heater con-
(Cable ① )
nected.
* The voltage between the connec-
tor TB4-14 and 15 is normally
80Ω, while it is ∞ in the case of
the short.
Circuit protector CP4 in the control box Yes
Reset the circuit protector after
is activated?
checking the cable ① and ② , and
No the developer heater.
Is AC200V the voltage between Yes

Inspect the cable. (Cable ② )
SSR22-1 and 2 in the control box with
the power on?
No
Is DC4.0V~5.3V the voltage between Yes

Replace SSR22
SSR22-23 and 24 in the control box
with the power on?
No
Is the cable connected correctly? No

Connect the cable ③ correctly.
Yes
Replace the PCB.
When it is not turned • Remove the TB4-14 and 15 terminals because of the danger.
off.
Is DC4.0V~5.3V the voltage between No
Replace the SSR22 if the cables
SSR22-3 and 4 inside the lower con-
① and ② are connected correctly.
trol box.
Yes
Replace the PCB if the cable ③ is
connected correctly.
* The condition with the developer heater turned on
Implement [D & F TEMP. CONTROL] in the maintenance mode 5.
The LCD display for the developer heater (H1) shows 1.
* The condition with the power on
With only the breaker NFB1 turned on
62 AP-800A
The Developer Heater (H1) Control Hardware
TH2
Control box
＋5V H1
−2
CN03
U1 SSR22 Developer Heater 2
1 CP4 AC200V
3 2 TB4 TH1
U22 ＋
61 H 4 13 L 2 4 1 14 Developer heater 1
−
15 H1
−1
3 2 1
3
PCB
4
L and H in the figure come under the logic in the case of the H1-ON.
L = DC1V or less
H = DC4.0~5.3V
The logic in the case of the H1-OFF is the reverse of the H1-ON.
AP-800A 63
4.2.2 The Fixer Heater (H2) Check

on. Is AC200V the voltage Yes Are the fixer safety ther- Yes
Reset the fixer safety thermostas.
between the connector mostats (TH2) activated?
TB4-16 and 17 with the No
heater on? Check the short part of the cable
and the fixer heater. Replace if
No * Measure the voltage
necessary. (Cable ① )
with the fixer heater
turned on.
tor TB4-16 and 17 is normally
about 80Ω Awhile it is ∞ in the
case of the short.
Is the circuit protector CP5 in the con- Yes

Reset the circuit protector CP5 af-
trol box inactivated?
ter checking the cable ① and ② ,
No and the fixer heater.

Check the cable.
the power on?
No
Is DC4.0V to 5.3V the voltage be- Yes

Replace SSR23.
tween SSR23-3 and 4 in the control
box with the fixer heater turned on?
No
Is the cable ③ connected correctly? No

Connect the cable ③ correctly.
Yes
Replace PCB.
When it is not turned • Remove the connector REFIX because of the danger.
off.
Is DV4.0V to 5.3V the voltage No
If the cables of ① and ② are con-
between SSR23-3 and 4 in
nected correctly, replace SSR23.
the control box with the pow-
er on?
Yes
If the cable ③ is connected cor-

rectly, replace PCB.
* The condition with the fixer heater turned on
Implement [D & F TEMP. CONTROL] in the maintenance mode 5.
The LCD display for the fixer heater (H2) shows 1.
With only the breaker NFB1 turned on
64 AP-800A
Fixer heater (H2) Control Hardware
TH4
Control box
＋5V H2
−2
CN03
U1 SSR23 Fixer Heater 2
1 CP5 AC200V
3 2 TB4 TH3
U22 ＋
62 H 5 12 L 3 4 1 16 Fixer Heater 1
−
17 H2
−1
3 2 1 3
PCB
4
L = DC1V or less
H = DC4.0~5.3V
AP-800A 65
4.2.3 Dryer Heater (H3-2) Check

on. Is AC200V the voltage Yes
Check the short part of the cable
between the connector
and the dryer heater. If necessary,
TB4-12 and 13 with de-
replace it/them. (Cable ① )
veloper heater turned
on?
tor TB4-12 and 13 is normally 53
No * Measure the voltage Ω, while it is ∞ in the case of
with the dryer heater the short.
connected.
Are the dryer heater safety thermo- Yes

Reset the safety thermostats.
stats(TH6) activated?
No
The Leakage circuit breaker ELCB2 in Yes

Reset the leakage circuit breaker
the control box is activated?
after checking the cable ① and ② ,
No and the dryer heater.

Check the cable. (Cable ② )
the power on?
No
Is DC4.0V ~5.3V the voltage between Yes

Replace SSR21.
the dryer heater turned on?
No
Is the cable ③ connected correctly? No

Connect the cabele of ③ .
Yes
Replace PCB.
When it is not turned • Remove the dryer heater connector terminal TB4-12 and 13.
off.
Is DC4.0V~5.3V voltage between No
If the cable ① and ② are connec-
SSR21-3 and 4 in the lower control
ted correctly, replace SSR21.
box.
Yes
If the cable ③ is connected cor-

* The condition with the developer heater turned on
Implement [DRY TEMP CONTROL] in the maintenance mode 5.
The LCD display for the dryer heater (H3-2) shows 1.
With only the breaker of NFB1 turned on
66 AP-800A
Dryer Heater (H3-2) Control Hardware
Control box
＋5V
CN03 ELCB2
SSR21
1 AC200V
3 2 TH6 TB4
U1 ＋
4 1 12 Dryer Heater
U22 −
78 H 7 10 L 5
13
H2
−2
3 2 1 3
Control PCB
4
L = DC1V or less
H = DC4.0~5.3V
AP-800A 67
4.2.4 Dryer Heater (H3-1) Check

on. Is AC200V the voltage between the Yes
Check the broken down part of
connector TB4-10 and 11 with the de-
the cable and the dryer heater. If
veloper heater turned on?
necessary, replace it /them.
* Measure the voltage (Cable ① )
No with the heater con- * The voltage between the connec-
nected. tor TB4-10 and 11 is normally 53
Ω, while it is ∞ in the case of
the short.
Are the dryer heater safety thermo- Yes

Reset the dryer heater safety ther-
stats (TH5) activated?
mostats.
No
Is the leakage circuit breaker (ELCB1) Yes

Reset the leakage circuit breaker
in the control box activated?
(ELCB1) after checking the cable
No of ① and ② , and the dryer hea-
ter.
Is AC200V the voltage between the Yes
Check the cable. (Cable ② )
SSR 20-1 and 2 in the control box with
the power on?
No
Is DC4.0V~5.3V the voltage between Yes

Replace SSR20.
SSR 20-3 and 4 in the control box with
the dryer heater turned on?
No
Is the cable of ③ connected correctly? No

Connect the cable of ③ .
Yes
Replace PCB.
When it is not turned • Remove the dryer heater connector terminal TB4-10 and 11 be
off. cause of the danger.
Is DC4.0V ~5.3V the voltage between No

If the cable of ① and ② connec-
SSR20-3 and 4 in the lower control
ted correctly, replace SSR20.
box with the power on?
Yes
If the cable of ③ connected cor-

* The condition with the dryer heater turned on.
Implement [DRY TEMP CONTROL] in the maintenance mode 5.
The LCD display for the dryer heater (H3-1) shows 1.
With only the breaker of NFB1 turned on
68 AP-800A
Dryer Heater (H3-1) Hardware
Control box
＋5V
CN03 SSR20 ELCB1
1 AC200V
3 2 TH5 TB4
U1 ＋
4 1 10 Dryer Heater
U22 −
75 H 6 11 L 4
11
H3
−1
3 2 1 3
Control PCB
4
L = DC1V or less
H = DC4.0~5.3V
AP-800A 69
4.2.5 Dryer Fan (FAN1) Check

on. Are the circuit protector CP3 or CP6 in Yes
Reset the CP3, CP6 after check-
the control box activated?
ing the cable ① and FAN1.
No
Is AC100V the voltage between the No

Check the cable of ② .
connector CN53-1 and 2 on the PCB? * Measure the voltage
Yes with the CN53 connec-
ted to the PCB.
The connector CN37 on the PCB and No

Connect the connector CN37 and
the connector of the FAN1 are connec-
CN153 correctly.
ted correctly?
Yes
Implement [DRY TEMP CONTROL] in

the maintenance mode 5.

connector CN37-1 and 2 on the PCB? If the cable ① is connected cor-
rectly, replace the PCB.
Yes

Replace the fan.
connector of the dryer fan CN153-1
and 2 in the control part?
No
Replace the relay.
When it is not turned • Remove the dryer heater connector terminal TB4-10 and 11 be
off. cause of the danger.
The cable is connected correctly? No

Review the cable connection.
Yes
Replace the PCB.
70 AP-800A
AC200V
＋5V CN53 CP3
SSR10
U14
U47 3
＋
38 6 11 4 AC100V
−
CN37 CP6
SGA
FAN
3
4
AP-800A 71
4.2.6 The Drive Motor (M1) Check

on. The top cover is closed? Or the top No
Close the top cover. Close the top
cover is set correctly?
cover properly.
Yes

Reset the CP2 after checking the
trol box activated?
cable ① and cables around M1.
No

Check the cable of ② .
ted to the PCB.
The connector CN52 is connected to No

Connect the CN52 to the PCB cor-
the PCB correctly?
rectly.
Yes
Is AC100V the voltage between CN52- Yes

Replace the drive motor if the
1 and 2 when implementing [DRIVE * Measure the voltage
cable ① is connected correctly.
MOTOR xx sec ] in the maintenance with the CN52 connec-
mode 5 ? ted to the PCB.
No
Replace the PCB.

off. The cable ① is connected correctly? No
Connect the cable ① correctly.
Yes
Replace the PCB.
72 AP-800A
The Drive Motor (M1) Control Hardware
Control box
＋5V LS1
CN01 1
2
3
U1 U32
4 12 13 4
Trance (T1)
CP2 AC100V
CN43 1
2
3 1
3
＋ 2 1
60 1 U45 U46
3 3 14 4 2 CN52 1 Black
−
63 2 2 Yellow
M1 Drive motor
White
TP2
CN02 1
Taco generator
9 8
wave convert
4
2
circuit
8 Trance (T1)
U16 TP1 AC10V
CN22 1
7 Zero Cross 2
Detect Circuit
10
Control PCB
AP-800A 73
4.2.7 Water Supply Electromagnetic Valve

on. Is the water supply electromagnetic Yes
Check for the hose's bending or
valve activated when implementing * Confirm the flow of
Wear.
[WATER SUPPLY SV] in the mainte- the drain when imple-
nance mode 5? menting [WATER
WUPPLY SV] in the
No
maintenance mode 5.

trol box activated?
cables around the SV1.
No

Check the cable ① .
ted to the PCB.
Is the connector CN51 connected to No

Connect the CN51 to the PCB
the PCB correctly?
properly.
Yes

Replace the water supply electro-
connector CN51-1 and 2 on the PCB * Measure the voltage
magnetic valve.
when implementing [WATER SUPPLY with the CN51 connec-
SV] in the maintenance mode 5? ted to the PCB.
No
Replace the PCB.

off. Does the water flow with the breaker Yes
Replace the electromagnetic valve.
switched off? * Open the external
No valve and confirm the
flow.
Is the cable SV1 connected to the con- No

Connect the cable properly.
nector CN51 (not to the other connec-
tor) on the PCB?
Yes
Replace the PCB.
74 AP-800A
Water Supply Electromagnetic Valve (SV1) Control Hardware
Control box
CN43 Trance(T1)
1 L CP2 AC100V
＋5V
SSR4
U14 3 1 2 N
U46 ＋
37 H 4 13 L 4 2
− 1
CN51
3
1
Water supply
2 SV1 electromagnetic valve
PCB
4
L and H in the figure come under the logic in the case of the SV1-ON.
L = DC1V or less
H = DC4.0~5.3V
The logic in the case of the H1-OFF is the reverse of the SV1-ON.
AP-800A 75
4.2.8 The Developer Replenishing Pump (P3) Check

on. Is the circuit protector CP2 in the con- Yes
trol box activated?
cables around the P3.
No

ted to the PCB.

the PCB properly?
properly.
Yes
Is AC100V the voltage between the con- No

Replace the developer replenish-
nector CN46-1 and 2 on the PCB when * Measure the voltage
ing pump.
implementing [DEV. PUMP CALIBRA- with the CN46 connec-
TION] in the maintenance mode 5? ted to the PCB.
No
Replace the PCB.

off. Is the cable of P1 connected to the No
Connect the Cable to the CN46
CN46 on the PCB , not to the other
on the PCB.
connector?
Yes
Replace the PCB.
The Developer Replenishing Pump (P3) Hardware
Control box
CN43 Trance(T1)
1 L CP2 AC100V
＋5V
SSR9
U14 3 1 2 N
U47 ＋
42 H 4 13 L 4 2
− 1
CN46
1
Developer
2 P3 replenishing pump
PCB
L and H in the figure come under the logic in the case of the P3-ON.
L = DC1V or less
H = DC4.0~5.3V
The logic in the case of the H1-OFF is the reverse of the P3-ON.
76 AP-800A
4.2.9 The Fixer Replenishing Pump (P4) Check

Reset CP2 after checking the
trol box activated?
No

connector CN43-1 and 2 on the PCB?
Yes
* Measure the voltage
with the CN43 connec-
Check the cable of ① .
3
ted to the PCB.
Is the connector CN39 connected to

the PCB properly?
No
properly.
4
Yes

Replace the fixer replenishing
connector CN39-1 and 2 when imple- * Measure the voltage
pump.
menting [FIX. PUMP. CALIBRARION] with the CN39 connec-
in the maintenance mode 7. ted to the PCB.
No
Replace the PCB.

off. Is the connector CN39 connected to No
Connect the cable to the CN39 on
the PCB properly?
the PCB.
Yes
Replace the PCB.
The Fixer Replenishing Pump (P4) Hardware
Control box
CN43
1 L CP2
＋5V
SSR7
U14 3 1 2 N
U47 ＋
40 H 2 15 L 4 2 AC100V
− 1
CN39
1
2
P4 Fixer replenishing pump
PCB
L = DC1V or less
H = DC4.0~5.3V
AP-800A 77
4.2.10 The Developer Circulator Pump (P1) Control Hardware

trol box activated?
No

Check the cable ② .
ted to the PCB.

the PCB properly?
properly.
Yes

Replace the fixer circulator pump.
connector CN 55-1 and 2 on the PCB * Measure the voltage
in the maintenance mode 5? with the CN55 connec-
ted to the PCB.
No
Replace the PCB.

off. Is the cable ① connected correctly. No
Connect the cable ① propely.
Yes
Replace the PCB.
The Developer Circulator Pump (P1) Hardware
Control box
CN33
1 L NFB3
＋5V
SSR12
U16 3 1 2 N
U48 ＋
36 H 5 12 L 4 2 AC100V
− 2
CN55
1
2 P1 Developer Circulator Pump
1
PCB
L = DC1V or less
H = DC4.0~5.3V
78 AP-800A
4.2.11 The Fixer Circulator Pump (P2) Check

trol box activated?
No

connector CN33-1 and 2 on the PCB?
Yes
* Measure the voltage
with the CN33 connec-
3
ted to the PCB.
Is the connector CN54 connected to

the PCB properly?
No
properly.
4
Yes

Replace the fixer circulator pump.
connector CN 54-1 and 2 on the PCB * Measure the voltage
in the maintenance mode 5? with the CN54 connec-
ted to the PCB.
No
Replace the PCB.

off. Is the cable P6 connected to the con- No
Connect the cable to the CN54.
nector CN54 on the PCB, not to the
other connector?
Yes
Replace the PCB.
The Fixer Circulator Pump (P2) Hardware
Control box
CN33
1 L NFB3
＋5V
SSR13
U16 3 1 2 N
U48 ＋
12 H 4 13 L 4 2 AC100V
− 1
CN54
1
2
P2 Fixer replenishing pump
PCB
L = DC1V or less
H = DC4.0~5.3V
AP-800A 79
4.2.12 Entrance Sensor (SE1, SE2, SE3, SE4) Check

When it does not
detect a film. Are the entrance sensors at the wrong Yes
Set the sensors properly.
positions , caught by the guides for ex-
Adjust the guides.
ample?
No
Does the display of [ENTRANCE SEN-

SORS] in the maintenance mode 4
show the sensor’s status properly, 1
(sensor-ON) or 0 (sensor-OFF)?
No
After exchanging the sensor with the Yes

Replace the defective sensor.
one of other position, does the display
show the sensor’s status properly?
(CN16~19)
No
Replace the PCB.
When it does not stop

detecting a film. Is there a film at the entrance sensor? Yes
Remove the film.
No
Are the sensors at the wrong position Yes

Set the sensors properly.
or in the bad condition?
No
Does the display of [ENTRANCE SEN-

SORS] in the maintenance mode 4
show the sensor’s status properly, 1
(sensor-ON) or 0 (sensor-OFF)?
No
After exchanging the sensor with the Yes

Change the defective sensor.
one of other position, does the display
show the sensor’s status properly?
(CN16~19)
No
Replace the PCB.
80 AP-800A
The Entrance Sensors (S10, S11, S12, S13)
Control box
S10
VREF1 CN16
U44 1
13 2
3
14 ＋5V 4
15
S11
12
VREF1 CN17
Signal Switch Circuit

1
2
3
4
3
S12
U43
16
VREF1
1
2
CN18
4
3
15
4
14
S13
13 VREF1 CN19
1
LED Drive Circuit 2
3
4
Control PCB
AP-800A 81
4.2.13 The Thermistor's Temperature - Resistance Value Specific Character List
The Range of the Resistance Value / Convertibility Accuracy

Temperature (°C) Standard Resistance Value (kΩ)
The Range of the Resistance Value (kΩ) Convertibility Accuracy (%)
T R (ST) R (MIN) R (MAX) TOLERANCE (%)

0 41.76 38.20 ∼ 45.53
5 33.50 30.86 ∼ 36.28
10 27.05 25.08 ∼ 29.10
15 21.98 20.51 ∼ 23.49

20 17.96 16.86 ∼ 19.08
25 14.76 13.94 ∼ 15.59
30 12.20 11.59 ∼ 12.81 ± 5.0 (Dryer)
35 10.14 9.577 ∼ 10.70 ± 1.0 (Developer, Fixer)

40 8.467 7.956 ∼ 8.988
45 7.107 6.643 ∼ 7.584
50 5.995 5.576 ∼ 6.430

55 5.081 4.702 ∼ 5.476
60 4.326 3.985 ∼ 4.685

65 3.700 3.392 ∼ 4.025
70 3.177 2.900 ∼ 3.473

75 2.741 2.491 ∼ 3.008
80 2.373 2.148 ∼ 2.616
85 2.064 1.860 ∼ 2.284
90 1.801 1.617 ∼ 2.002

95 1.578 1.411 ∼ 1.760
100 1.397 1.236 ∼ 1.554
The values except for in the case of 30°C (Dryer thermistor) and 35°C (Dev. thermistor, Fix. thermistor) are for the reference,
not for the guarantee.
82 AP-800A
Chapter 5 Replacement
83
Replacement of Parts
WARNING
Earth Connection
To prevent electrical shock and malfunctions, make sure the equipment is properly connected
to earth.
WARNING
Electrical Shock
Do not open any covers or panels with the power ON. High voltage components inside the
processor may cause electrical shock if touched.
WARNING
Work Clothes
When working near the equipment
• Do not wear neckties, scarves, or other loose clothing or accessories.
• Keep long hair away from moving parts.
Loose clothes or hair may get wrapped onto moving parts and result in bodily injury.
WARNING
Safety Glasses
Always wear safety glasses when handling developer and fixer. Developer and fixer will cause
irritation if it contacts the eye, rinse thoroughly with fresh water for approximately 15 minutes. If
irritation continuse, contact an ophtalmologest.
WARNING
Rubber Gloves, Rubber Apron
Always wear rubber gloves and rubber apron when handling developer and fixer. Developer
and fixer may cause irritation it contacts the skin. Always wash your hands after handling
chemistry.
CAUTION
Empty Tank
Do not turn on the power when either the fixer of developer tank is empty. Otherwise the
heater may damage the tank.
84 AP-800A
5.1 Developer Circulator Pump
1 Remove the front lower cover, open the drain valve

and drain the developer.
2 Separate the recorder from the equipment, remove

the insert cover and the front upper cover.
3 Remove the hose connected to the pump and the

hose cramp from the hose nozzle.
4 Take off the 2 screws which fix the pump to the frame.
4
5 Remove the film-receive-basket and the exit cover.
5
6 Remove the connector of the pump (CN55) and earth
(E2) from the control part.
7 Cut the tie-wraps securing the cable running from

the control part to the pump. Remove the cable and
pump from the frame.
8 Replace the new pump. Insert the hose and the

connector into the nozzle and attach the hose cramp.
Lay the cable to the control part. Joint the connector
earth.
9 Replace the exit cover and the film-receive-basket.
10 Replace the front upper and lower covers.
11 Remove the top cover and the inner cover. Fill the
developer to the overflow level.
12 Replace the inner cover and the top cover. Put the
main power on and press key.
13 Press key and put the main power off after

confirming no leakage.
Reset the entrance cover and connect the recorder.
AP-800A 85
5.2 The Fixer Circulator Pump
1 Remove the front lower cover and open the drain

valve to drain the developer.
2 Separate the recorder from the equipment. Remove

the insert cover and the front upper cover.
3 Remove the hose from the pump and the hose cramp
from the pump nozzle.
4 Take off the 2 screws which fix the pump to the frame.
5 Remove the film-receive-basket and the exit cover,
6 Remove the connector of pump and earth from the

control part.
7 Cut the tie-wraps securing the cable running from

the control part to the pump. Take off the cable and
pump from the frame.
8 Replace the new pump. Insert the hose and the

cramp into the nozzle and attach the hose cramp.
Lay the cable to the control part. Connect the
connector and earth to reset.
9 Replace the exit cover and film-receive-basket.
10 Replace the front upper and lower cover.
11 Remove the top cover and inner cover to pour the

developer to the over flow level.
12 Replace the inner cover and the top cover. Put the
13 Press key and put the main power off after

confirming no leakage of the developer. Replace the
top cover and connect the recorder.
86 AP-800A
5.3 The Developer Replenishment Pump
2 Take off the 2 screws which fix the bracket for the
pump to the frame. Pull out the unit in front of you.
3 Remove the hose cramp. Take off the 4 hoses from

the nozzles. Absorb the remain of the developer
inside the hose with the cloth.
Pump Unit Fix.
Dev.
4 Take off the 4 screws which fix the pump.
4
5
Bracket for pump 6 Remove the pump connector (CN39) and earth (E5)
from the control part.
7 Cut tie-wraps securing the cable running from the

control part to the pump. Pull out the pump and the
cable.
8 Fix the new pump to the bracket with the 4 screws.

Insert the hose into the nozzle and attach the hose
cramp.
9 Put back the pump unit to the frame. Push back the
unit to the set position. Fix the bracket with the 2
screws.
10 Lay the cable to the control part. Joint the connector

and earth.
12 Put the main power on and press the key.
13 Press key to replenish the developer. Confirm of

n o l e a k a g e o f d e v l o p e r. R e p e a t m a n u a l
replenishment several times so that there is not
remain of the air in the hose.
AP-800A 87
5.4 The Fixer Replenishment Pump
2 Take off the 2 screws which fix the bracket for the
pump to the frame. Pull out the unit in front of you.
3 Remove the hose cramp. Take off the 4 hoses from

the nozzles. Absorb the remain of the fixer inside the
hose with the cloth.
Pump Unit
Fix. 4 Take off the 4 screws which fix the pump.
Dev.
Bracket for pump

6 Remove the pump connector (CN46) and earth (E3)
from the control part.
7 Cut tie-wraps securing the cable running from the

control part to the pump. Pull out the pump and the
cable.
8 Fix the new pump to the bracket with the 4 screws.

Insert the hose into the nozzle and attach the hose
cramp.
9 Put back the pump unit to the frame. Push back the
unit to the set position. Fix the bracket with the 2
screws.
10 Lay the cable to the control part. Joint the connector

and earth.
12 Put the main power on and press the key.
13 Press key to replenish the fixer. Confirm of no

leakage of the fixer. Repeat manual replenishment
several times so that there is not remain of the air in
the hose.
88 AP-800A
5.5 The Drive Motor
1 Remove the front cover and the inner cover for the
motor.
3 Remove the connector for the generator cable of the

drive motor from the control part. Cut the tie-wraps
securing the cable and pull the cable to the drive
motor.
4
4 Remove the connector of the motor cable.
5
5 Take off the 4 screws which fix the drive motor to the
motor bracket to remove the defective drive motor
from the motor bracket.
Note
The drive motor part is separated from the gear head part. Be careful when taking off the screws
and pulling the motor.
When changing only the gear head, you do not need to remove the connectors of the generator
cable and the motor.
6 Remove the old spur gear fitted the shaft and attach
it to the new gear head.
7 Place the new motor and the gear head attached the
spur gear together to the drive motor bracket.
8 Joint the connector of the drive motor cable. Lay the

generator cable to the control part and fix it. Fix the
connector to the control PCB.
9 Replace the front cover for the motor, the exit cover
and the film-receive-basket.
10 Confirm the drive motor’s running in the maintenance

mode.
AP-800A 89
5.6 The Developer Temperature Control Heater
1 Remove the lower cover and open the drain valve to

drain the developer.
2 Separate the recorder from the equipment and

remove the insert cover and the panel.
3 Take off the 2 screws to remove the heater from the

heater bracket. Remove the hose cramp and the hose
from the heater to be changed.
4 Remove the film-receiver-basket and the exit cover.
5 Remove the cable of the defective heater from the

control part terminal. Cut tie-wraps remove the cable
and heater from the frame.
6 Connect the hose removed to a new heater and

attach the hose cramp.
7 Place the heater to the bracket. Lay the cable to the

control part and connect to the terminal.
8 Reset the exit cover and the film-receive basket.
9 Remove the top cover and the inner cover to fill the
tank with developer to the overflow level.
10 Replace the inner cover and the top cover and turn
the main power on.
11 Press and turn the main power off after confirming

of no leakage of the developer. Replace the exit
cover, the rear cover and the front lower cover and
connect the recorder.
90 AP-800A
5.7 The Fixer Temperature Control Heater
1 Remove the front cover and open the drain valve to

drain the fixer.
2 Remove the recorder from the AP-800A and remove

the insert cover and the rear cover.
3 Take off the 2 screws which fix the replenishing pump

unit to the bracket. Pull the unit in front of you. Take
off 2 screws which fix the heater to the heater bracket
to remove the heater.
4 Remove the hose cramp and the hose from the

4
heater to be replaced.
5 Remove the film-receive-basket and exit cover. 5

6 Remove the cable of the heater to be changed from
the terminal. Cut the tie-wraps to release the cable.
Pull out the heater and the cable from the frame (the
cable is connected to the TB4, 11,12,13 and 14 of
the terminal in the control part.)
7 Connect the removed hose to a new heater and

8 Fix the heater to the bracket. Lay the cable to the

control part and connect the terminal.
9 Put back the replenishing pump unit to the frame.

Insert the bracket edge into the hook and fix with the
two screws.
10 Replace the exit cover and film-receive-basket.
fixer to the overflow level.
12 Replace the inner cover and the top cover. Turn the
main power on and press the operation key.
13 Press the operation key and turn the main power off
after the confirmation of the leakage of the fixer.
Replace the entrance cover, the rear cover and the
front lower cover. Reset the recorder.
AP-800A 91
5.8 The Dryer Heater
1 Remove the top cover and the board which separates

the dryer part from the processing part. Unscrew two
positions to remove the board.
2 Lift the dryer chamber to remove.
3 Disconnect the connector for the exit sensor SW at

the rear side and lift the dryer rack to remove.
4 Take off two screws which fix the heater unit to the
dryer part frame to pull the heater unit out.
5 Take off three screws to remove the heater from the

bracket.
6 Remove two thermostats and 4 cables from the

heater to replace new heaters. Reset the thermostats
and the cables.
7 Insert the heater unit into the frame and fix it with
two screws.
8 Replace the dryer rack and reset connector and

replace the dryer chamber.
9 Insert the board and fix it with the screws.
10 Replace the top cover.
92 AP-800A
5.9 Dryer Fan Motor
1 Remove the top cover and the board which separates

the dryer part from the processing part. Unscrew the
two positions to remove the board.
2 Lift the dryer chamber to remove.
3 Remove the connector for the exit sensor SW at the

rear side and lift the dryer rack to remove.
4 Remove the connector (CN153) of the fan motor and

earth (E1) from the control part. Cut the tie-wraps
4
securing the cable and pull the cable to the fan motor.
5 Take off 2 screws and loose another 2 screws fitting

in the longer hole which fix the fan motor to the frame.
5
6 Remove the fan motor unit. Shift the unit to the control
part.
7 Remove earth from the fan motor and 3 cables from

the condenser.
8 Take off 4 screws to remove the board and the shock

absorber. Place the new fan motor and replace the
shock absorber and the board.
9 Fix earth to the fan motor and insert the cable of the
fan motor to the condenser.
10 Fix the fan motor to the board at the dryer part.

Connect earth to E1 and the cable to CN153.
11 Put back the dryer rack and joint the connector to

set the chamber.
12 Insert the board and fix with the screws.
13 Replace the entrance cover and film-receive-basket.
AP-800A 93
5.10 Electromagnetic Valve
1 Close the water supply connected to the AP-800A.
2 Remove the rear cover, film-receive-basket and the

exit cover.
3 Remove the hoses connected to the electromagnetic

valve.
4 Remove the hose cramps.
5 Take off 2 screws to remove the bracket from the

frame.
6 Take off 2 screws (one of them is also for earth to fix)

to remove the electromagnetic valve from the bracket.
7 Pull out the connector (CN51) of the electromagnetic

valve and cut the tie-wraps securing the cable.
8 Remove the electromagnetic valve and the cable

from the frame.
9 Fix the new electromagnetic valve to the bracket with

earth.
10 Fix the bracket to the frame and connect the cramps

and the hoses.
11 Lay the cable to the control part and connect the cable
to the connector.
13 Open the water supply valve, turn the main power

on and the press the key.
14 Replace the rear cover after the confirmation of no

leakage of the water.
94 AP-800A
5.11 The Developer Thermistor

valve to drain the developer.
3 Remove the hose cramp and the defective thermistor

from the cramp connected from the developer heater
to the tank.
4
4 Remove the film-receive-basket.
5 Remove the connector (CN05) for the developer

5
thermistor from the control part. Cut the tie-wraps
securing the cable.
6 Pull out the defective thermistor and the cable from

the frame.
7 Insert the new thermistor into the connector and

8 Lay the cable to the control part and joint the

connector.
10 Remove the inner cover and the top cover. Fill the
tank with the developer to the overflow level.
12 Replace the rear cover and the front lower cover after
the confirmation of no leakage of the developer from
the thermistor.
AP-800A 95
5.12 The Fixer Thermistor

valve to drain the fixer.
3 Remove the hose cramp and pull the defective

thermistor out from the cramp connected the fixer
heater to the tank.
4 Remover the film-receive-basket.
5 Remove the connector (CN06) for the fixer thermistor

from the control part. Cut the tie-wraps securing the
cable.
6 Pull the thermistor and the cable from the frame.
7 Insert the new thermistor into the cramp and attach

the hose cramp.

connector.
tank with the fixer to the overflow level.
main power on and press the key.
12 Replace the rear cover and the front lower cover after
the confirmation of no leakage of the fixer from the
thermistor.
96 AP-800A
5.13 The Dryer Thermistor
1 Remove the rear cover and the inner cover.
2 Remove the thermistor unit from the box.
3 Cut the tie-wraps securing the thermistor and the

cable to the bracket to remove them from the bracket.

4
5 Pull out the connector (CN07) for the dryer thermistor
from the control part. Cut the tie-wraps securing the
cable and remove the thermistor and the cable from
5
the frame.
6 Fix the new thermistor with the tie-wraps to the

bracket. Put it into the box and fix it with the screws.

connector.
8 Replace the inner cover, the rear cover, the exit cover
and the film-receive-basket.
AP-800A 97
5.14 Operation Panel
1 Remove the front lower cover and the front cover.

Remove the film-receive-basket and the exit cover.
2 Take off the two screws to remove the operation panel

from the frame.
3 Remove the operation base and the LCD base board

from the bracket.
4 Pull out the connector (NC27) for the operation panel.

Cut the tie-wraps securing the cable to remove the
base and the cable from the frame.
5 Attach the new base to the bracket and place it to

the frame. Lay the cable to the control part and reset
the connector.
6 Replace the front upper cover, the exit cover, the front
lower cover and the film-receive-basket.
98 AP-800A
5.15 The Control PCB
2 Pull all the connectors out from the PCB.
3 Take off 8 screws to remove the defective PCB from

the chassis.
4 Fix the new PCB and joint all the connectors.

4
5
AP-800A 99
5.16 DC Power Source
2 Pull the two connectors jointed to the DC power

source.
3 Take off the four screws which fix the DC power

source to the chassis to remove the defective DV
power source.
4 Attach the new DC power source to the chassis and

joint all the connectors.
100 AP-800A
5.17 SSR
2 Remove the four cables jointed to the defective SSR.

(the four SSR are assembled to the chassis)
3 Take off 2 screws which fix the SSR to the chassis to

remove the defective SSR.
4 Attach the new SSR to the chassis and connect the

4
cables.

5
AP-800A 101
5.18 Lithium Battery
The lithium battery is used for memory backup. Ordinarily the lithium battery should not need replacement
for approximately 10 years. However, if SETUP DATA (error code No. E000) occurs, check, and if necessary,
replace the lithium battery. Dispose of the old battery in accordance with local laws and regulations.
1 Disconnect all the cables from the control PCB.
2 Remove the control PCB from its base.
3 Cut the tie-wraps securing the battery, remove the

cable, and remove the battery.
4 Secure the new battery in place with tie-wraps and

connect the cable.
5 Re-attach the control PCB to its base.
6 Re-connect all the cables (disconnected in step 1) to

the PCB.
7 Reset the memory.
8 Reset all parameters.
CAUTION
• The battery must be disposed of in accordance with local laws and regulations.
• Danger of explosion if the battery is incorrectly replaced.
• Replace only with the same or equivalent type recommended by the manufacturer.
• Dispose of used batteries according to the manufactruers instructions.
102 AP-800A
Chapter 6 Appendix
103
AP-800A SPECIFICATIONS
ITEMS SPECIFICATIONS
TYPES DEDICATED ONLINE FOR AP-800A
FILM TRANSPORT PROCESSING SECTION OPPOSED ROLLER TRANSPORT
DRYER OPPOSED ROLLER TRANSPORT
FILM SIZES WIDTH 356 - 768mm
LENGTH 350 - 630mm
THICKNESS FILM 100 175 µm
FEATURE ROLL FILM (EMULSION)-OUT
PROCESSING TIME 20sec, 23sec, 30sec
PROCESSING LENGTH 1620mm
DEVELOPMENT SEC. TEMPERATURE SET RANGE 26 ˚C - 40 ˚C changeable
REPLENISHMENT Automatic film area , Manual
TANK CAPACITY replenishment
FIXING SECTION TEMPERATURE SET RANGE 18.7 liters
REPLENISHMENT 30 ˚C -40 ˚C changeable
TANK CAPACITY Automatic film area, Manual replenishment
WASHING SECTION PROCESSING 18.2 liters
TEMPERATURE NORMAL TEMPERATURE 10˚C- 30˚C
WATER VOLUME 6 liters/min.
TANK CAPACITY 18.2 liters
* This specification satisfys the standard for EN60950 (for Europe) and UL1950 (for U.S.A)
104 AP-800A
FUJIFILM Electronic Imaging Ltd. No. Z70F0461001
Three Cherry Trees Lane 010316-02
Hemel Hempstead Printed in Japan
Herts HP2 7RH, England

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SERVICE MANUAL

MANUAL ORGANIZATION ........................................................................ 3

Chapter 1 Precautions ............................................................................. 7

Chapter 2 Installation Procedure .......................................................... 15

Chapter 3 Maintenance .......................................................................... 35

3.2.2 I/O Check ....................................................................................................................... 38

Chapter 4 Error Shooting ...................................................................... 53

Chapter 5 Replacement ......................................................................... 83

Chapter 6 Appendix ............................................................................. 103

Regulations and Standards

2.1.1 Caution at the Carry of the AP-800A

Figure 1 Foot print Measurement: mm

2.1.2 External Measurement

Model Width (mm) Depth (mm) Height (mm) Weight (kg)

2.1.3 AP-800A Measurement

Figure 3 Installation example Measurement: mm

2.2.2 Place for the Replenisher Tanks

Unpack in numerical order as follows.

1 Remove the top crate.

3 Remove the two side crates.

4 Take out the attached box.

5 Remove the skid.

6 Remove the other side crates.

7 Remove the aluminum cover.

8 Take out the 3 boxes containing a rack of the

9 Remove the board.

10 Remove the 8 screws which fixed the AP-800A to

11 Remove the fixed metal fittings.

12 Remove the protective materials from the top cover

1 Using the adjustment bolts, adjust the height of the

5 2 Move the Luxel F-6000 close to the AP-800A, and

3 The clearance on the right and left is as follow.

4 Connect the interface cable from the AP-800A to the

5 Connect the interface cable from the AP-800A to the

1 Remove the rear cover.

4 4 Unscrew the chamber at the opposite side of the drive

6 Unscrew the dryer rack at the side of the drive motor

7 Replace the bord (5) so that it is possible for the top

(Operation position) (Transportation position)

2.6.1 Chemical Collection

* The bucket mouth must have the following diameters.

Figure 5 Installation Place

2.6.2 Water Connection (Supply and Drain)

1) Water supply plumbing

2) Connecting to the water supply

Figure 6 Water supply plumbing example

2.6.3 External Connection

Do not connect the drain nozzles directly.

Figure 7 External Connection

2.6.4 Connecting the Exhaust Duct Hose

Use hose of the following specification.

Inside diameter ............... 75/100mm

2.7.1 Power Specification

Voltage 208V/240VAC 60HZ Single phase (UL)

1) Leakage Circuit Breaker

[Power Cable Connection Diagram] TB1

The ground cable shold be longer than the power cord.

6) Setting the Input Voltage

240V Cable for adjusting to local power specifications.

1 Remove the side cover from the control part.

2 Check the voltage connections.

3 Replace the side cover.

2 Pour the required amount of the fixer. Take great