Frontier 7700, Pump Output Amount Settings

[Bakul]

Hi all,

 

I am looking for the standard amounts for New pumps to be set for replenishment (F type, CP49e) that I can use as a starting point as I have replaced a pump and it seems that the p2ra and p2rb are not in balance so I am getting error messages after about 5000 prints of 4x6in. This also means that the replenisher cannot be mixed automatically and I have to do manual recovery each time.

 

I have tried various settings including manual pump output calibration but it doesn't help.

 

Any help is highly appreciated.

 

Bakul

[Dave S]

The standard pump output setting amount is normally 51 but the actual measured value is normally around 56, it should be very close to the p2rb pump amount.

What is the error message and number you are getting before you get the process amount exceeded message?

You can check in the error logs.

 

Check the p2ra tank is not blocked up with crystallised chemistry, I had this on a Frontier LP7100.

[Bakul]

Thanks for the reply Dave,

 

The message is that the P2RA replenishment management is abnormal (5907-3) and I usually never let this go to processing amount exceeded and mix manually through the Functions setting of Pump Output Setting screen according to the recovery process 2 by draining the replenisher tanks. This means that I am loosing about 800-1000 prints of 4x6 worth of chemicals each time.

 

The actual measured values from the pumps are around 66.7 mL and I have reset the amounts via the same screen.

 

I have the necessary Service Manual and enough experience to see this through if I am guided..

 

I am starting to wonder if the controller pcb for this is at fault. Diagnostics for pumps and level sensors via Input/output checks are all ok.

 

Are you referring to P2RA replenisher tank for crystalisation check or the process tank?

[Dave S]

Yes I was referring to the P2RA replenisher tank that was full of crystallisation.

Maybe the amount was 66 and not 56 I can't remember it was a while ago!

 

What happens is when you drain and refill the P2RA tank it clears enough of the crystals to make the sensors work again and the pump measure correctly.

But when more crystals form again it starts to block/ restrict the flow to the rep pump and so the pump ends up not actually pumping out the correct amount.

 

I'd be surprised if this a PCB related problem.

[Bakul]

Thanks Dave,

 

I will take out the replenisher tank and clean it properly along with all the related hoses to and from the pump.

 

Will post the results as soon as this is resolved.

[Bakul]

Hi Dave,

 

After new manual replenisher mix I was waiting for the results.

At the end I still got the 3907-03 P2RA replenisher management abonormal message.

 

I checked the replenisher tanks and found that P2RB tank had 950 cc of chemical still in the tank while other tanks were empty. I suppose that's why the message comes up..

It also indicates that the P2RB pump is not outputting same amount as P2RA. I need to increment the output amount. Any ideas how to go about it?

[Minilab service]

On minilab menu make replenishment pumps calibration for all pumps and in processor settings check replenishment rates.

[Dave S]

Yes, go to Maintenance → Extension → Processor Settings → Pump Output Amount Setting

F- functions, Pump output amount measurement, measure each pump 3 times, add the readings together then divide by 3, this will give you an average reading. Enter this figure into the setting.

 

The lower the number the more the pump will output.

[Bakul]

Thanks guys, I already did that last time but it doesn't seem to help!

I'll do that once again and post the results.

[Bakul]

BTW, what is the average number of 4x6 prints between two replenisher mixes?

[Dave S]

Thanks guys, I already did that last time but it doesn't seem to help!

I'll do that once again and post the results.

If the pumps are calibrated properly and it's still doing it, the rep rates may be set incorrectly.

From memory the P2RA and P2RB are the same rate.

 

Check with Fuji what the correct rep rates are.

[Minilab service]

Frontier 7700 replenishment rates :

CP-49E   - CD 45 mL/m² , BF 35 mL/m² 

CP-49LR - CD 40.0 mL/m² , BF 31.1 mL/m²

A and B should be used the same amount. Check levels after cartridge use. Maybe levels are different initially.

[Bakul]

Thank you.

We use cp49e.

I found that the settings were as follows:

 

CD= 50ml/m2

BF=22ml/m2

 

I've changed them as per your figures. Let us see how it goes. I will also physically check the solution levels of p2ra and p2rb after next replenisher mix.

 

I will post the results in next few days.

[Minilab service]

If replenishment rates where wrong check temperatures also :

for CP-49E ( or CP-49HVII ) CD - 43 degrees Celsius, BF - 40 , STB - 45

for CP-49LR - the same temperatures, just different replenishment rates. 

[Bakul]

Hi guys,

 

I had promised to post results after changing the parameters according to your advice.

 

Much to my regret, the situation remains the same. I did the manual replenisher mix again yesterday as it failed to mix automatically.

 

Error number remains same. I checked remaining P2RA and P2RB while draining and the difference between two is about 600 ml in favor of P2RB meaning that the pump for P2RB is outputting less chemical to the main tank.

 

What further remedy can be administered? I am thinking to change the P2RA pump but am wondering if this is the solution..

 

Hoping to hear further ideas, if any, from you.

[Dave S]

Try replacing the poppet valves on the replenisher pump.

Edited November 9, 2016 by Dave S

[Bakul]

Thanks!

I will try that and report back..

[Bakul]

Surprise guys!

 

I had automatic replenisher mixing happen yesterday. I haven't yet cleaned or replaced the poppet valves. I don't honestly know what is happening..

 

I will wait till the next replenishment mix and see from there. I will post the results of course.