Accuprint AP42CL 8000 Service Manual Download Page 72

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11-2

94MS42 Rev.B1 S/W Ver 2.06

Center/Drive Assembly Diagram (cont.)

41BF2BHX.75

5/16 - 18 X 3/4 HEX BOLT BLK.

THREADED ROD

12D1751A00

3/8-`6 NYLON LOCK NUT, OV45

41 F3NLN

12D1750A62

SLIDE

SWITCH MOUNT, OV45

11D2111B62

62D3798A00

MOTOR, DRIVE ASS'Y

191"

81TAP17

12D2150A99

11D3750A00

TAPE GLIDE (BLACK UHMW)

WELDMENT OV45 TOP,RAIL & LOW

SHAFT, ACCUTRACK

IDLER SPROCKET

SLIDER

IDLER BUSHING

12D1752A62

12D1753A00

12D1754A00

SPRING, CHAIN TENSIONER

43SPR14

12D1996A00

TENSIONER SPROCKET

CHAIN YOKE

12D1757A62

52RCP28

NSI #10-31HEX KEP NUT

DEFLECTOR, AIR

11D3395A17

43CHA05

CHAIN, #35 RLR- 10 FT

12D1635A62

16D2319A00

55SW02

BLOCK, MOUNT AC-TRACK

SWITCH, TIMING-ROLLER

HARNESS, MOTOR- POS SWT

OVERTORQUE SAFETY DEVICE

43OSD01

41 04PFO.62

4/40 X 5/8 PHIL FLAT MS

NSI 6-32 X 5/8 PPMS ZINC

41 06PPS.62

41 04NKP

NSI 4-40 KEP NUT

41 04NLM

NSI 4-40 FLEXLOCK METAL

1/4-20 X 3/4 HEX HEAD BOLT

NSI 6-32 X 3/4 PPMS ZINC

WASHER, SPLIT LOC 1/4"

41 06PPS.75

41 FOBHX.75

41 40WFR

NSI 1/4 SAE FLAT WASHER

41 FOWLS

41B40NLN

NSI 1/4-20 LOCKNUT NYLON INS.

NSI 8-32 X 1/2 SOC. HD CAP SCR

41B08SHC.50

TENSIONER BUSHING

12D1755A00

41B40BHX1.75

NSI 1/4-20 X 1 3/4 HEX BOLT BLK.

41B08PF2.62

41B10WFR

41 08WLS

NSI 8-32 5/8 FLAT HEAD 82

NSI #8 LOCK WASHER SPLIT

NSI #10 FLAT WASHER BLACK

ITEM

QTY

DESCRIPTION

PART NO.

NSI 3/8 X A3/4 SOC. SHLD.

41BF3SHC1.7

41 06PFO.37

NSI 6-32 X 3/8 PHIL FLAT

COVER, DRIVE CHAIN-UPPER

11D2799A08

COVER, DRIVE CHAIN-LOWERLD.

11D2799B08

INSULATION PAD AL13/14

15D725

41BF2SHF.62

SOCKET HEAD FLAT #5/16-18 X .62

5/16 SPLIT LOCK WASHER

41F2WLS

41BO8WFR

NSI #8 FLAT WASHER

Summary of Contents for AP42CL 8000

Page 1: ...P P AP42CL 8000 Closed Loop High Resolution Printer Service Manual 94MS42 Rev B1 S W 2 06 O ...

Page 2: ... 2 06 This manual is designed for technical personnel and should only be used by authorized Dealer service personnel This manual is written to provide an understanding of the equipment as well as a plan for troubleshooting ...

Page 3: ...tor 3 1 Feature Quick Reference 3 3 Operator Control Panel 3 4 Table Showing the 12 Calibration Positions 3 4 Calibration Procedures 3 5 Changing the Calibration Number 3 6 Matching Exposure Surfaces 3 7 Splitting Steps 3 8 Matching with a meter 3 8 4 Integrator Program Set Up To Enter the Select Mode 4 1 Lock Level Feature 4 1 Lock Level Description and Operation 4 2 Setting or Changing your Lock...

Page 4: ...tions Lamp Changing Instructions 6 1 7 Preventive Maintenance Preventive Maintenance Daily 7 1 Preventive Maintenance Monthly 7 1 Preventive Maintenance Semi Annually 7 1 8 Vacuum System Vacuum Pumps 8 1 Flushing the Pump 8 1 Pump Disassembly 8 2 Pump Check 8 2 Pump Replacement 8 3 Tubing Fitting Replacement 8 4 Vacuum Gauge Replacement 8 4 Vacuum Seal Replacement 8 5 Phototool Wiring Diagram opti...

Page 5: ...ent 11 3 Tray Speed Adjustment 11 4 Light Block Assembly 11 6 Lower Light Block insert section Assembly Drawing 11 7 Replacing Light Block Springs 11 8 12 Diagrams Control Box Front View Typical 12 1 Control Box Wiring Diagram 12 2 Base Assembly Diagram 12 4 Unit Cabling Diagram new style 12 7 Unit Cabling Diagram old style 12 8 13 Light Source Component Layout 13 1 Ballast Tap Switch Wiring 13 3 ...

Page 6: ...7 60Hz 13 22 Lamphead for all Lights 13 23 AL 84 Power Supply 60Hz 13 24 AL 84 480 Power Supply 60Hz 13 25 AL 94 Power Supply 50Hz 13 26 Interconnect Cable 13 27 14 Printing Light Check List Check List for Printing Light Troubleshooting and Service 14 1 15 Fault Trees No Strike Fault Tree 15 1 Shutter Rotation Fault Tree 15 2 Drive Motor Fault Tree 15 3 16 Parts List Parts List 16 1 17 Warranty Li...

Page 7: ...t Crated 2 400 lbs 1089kg Uncrated 2 000 lbs 907kg Actual Dimensions Cabinet welded heavy gauge steel construction with access doors on both sides Length Width Height 110 61 99 279cm 155cm 251cm Note The AP42CL can be disassembled see Base Assembly Diagram into 4 pieces if required to pass through most doorways or hallways Please make sure there is adequate room for its passage ...

Page 8: ...cal Room Requirements TOP VIEW Rear Front 36 Circuit Breaker 36 36 Electrical specifications and connections 3 phase Wye See Figure A 3 wires neutral ground 380 415V 50 Hz 24 amp 3 phase Delta See Figure B 3 wires ground 208 240V 60 Hz 44 amp 3 phase Delta See Figure C 3 wires ground 480V 60 Hz 18 amp Single phase See Figure D 2 wires ground 480V 60Hz 35 amp ...

Page 9: ...pply 1 Blowers Vacuum Pumps Electronics Drives Etc L3 208V OLITE Power Supply 1 Earth Ground L1 L2 L1 L2 L3 Figure C 480V 60Hz Connection DELTA 3 Wires Ground Terminal Block 480V OLITE Power Supply 1 Blowers Vacuum Pumps Electronics Drives Etc L3 X1 X2 X3 480V OLITE Power Supply 2 X1 X2 X3 X4 H1 H2 H3 H4 L1 L2 L3 Blowers Vacuum Pumps Electronics Drives Etc X1 X2 X3 X1 X2 X3 X4 H1 H2 H3 H4 480V OLI...

Page 10: ...elow Connect the main leads to the 4 position or 6 position terminal block and connect the ground lead to the single ground terminal see Figures A B C D Reinstall the lower side door Z Feed power through here Energize the main power circuit You should hear the lamp head and power supply cooling fans go into a cool down cycle Ensure that the voltage select switch on the hinged control panel is swit...

Page 11: ... water flow do not meet the following specifications the unit will overheat one or both light sources will shut themselves off randomly under heavy usage and damage to the unit could be the result AP42CL 8000 Cooling Requirements 24 000 BTU hr at idle 65 000 BTU hr at full load Water Pressure 26 PSI 20 GPM minimum at 50 F 10 C 10 PSI 10 GPM minimum at 45 F 7 C ...

Page 12: ...1 6 94MS42 Rev B1 S W Ver 2 06 ...

Page 13: ...tor P63 marked Evaporator provided inside the unit Note The evaporator is ON when the machine is ON If the fan in the evaporator does not come ON when the machine is turned ON unplug the electrical connector P8 on the evaporator and check with a voltage meter the P8 connector between pins 1 2 for 240V If voltage is present and the blower is not running replace the blower If voltage is not present ...

Page 14: ...he Flow Meter will not function properly Connect the hose from the Water in from Chiller to the flow meter Temp guage Flow meter From chiller for 1 ID hose Mount Assembly on wall Overflow Bucket Bleed Valve 1 2 NPT internal taper thread Return to chiller 1 ID Connect another hose from the temperature gauge to the Closed Loop In Connect the hose from the Closed Loop Out to the Water out to Chiller ...

Page 15: ...TEFLON TAPE ITEM 26 TO ALL PIPE THREAD CONNECTION 4 DO NOT OVERTORQUE FITTINGS 4 20 19 Bleed Valve 9 12 3 14 5 1 2 43CLM13 11D3382A62 43FIT66 43FIT58 49DCT34 43FIT60 43FIT65 43FIT52 43FIT51 43FIT49 12D3466A07 43FIT46 43FIT57 43FIT44 43FIT43 43FIT42 43FIT41 31S0V09 C240 31S0V09 OLEC PART NOTE 3 49THERM01 49FLOW01 4 4 14 13 6 5 ASSEMBLE THE SOLENOID VALVE BRANCHES FIRST BEFORE CONNECTING THEM TO CRO...

Page 16: ...e bleed valve handle Checking the chiller if the Closed Loop System is getting to hot or shut ting itself down Make sure temperature and pressure in the system meets those in section Cooling Requirements Make sure the air in the system is properly bled as described in Filling the Closed Loop System Make sure the four blowers in the back of the unit are all spinning Turn the unit off and wait for t...

Page 17: ...flowing through the unit Turn the unit off and disconnect the coil Repeat for each of the other two coils If water does not flow with any of the coils connected and you have the new style go to the J1 connector on the 64AX501V01 PCB and measure for 240V from pin 6 white to pin 3 black for valve 1 pin 6 white to pin 2 green for valve 2 and pin 6 white to pin 1 red for valve 3 If you have the old st...

Page 18: ...Closed Loop Cooling Assembly 30 33 33 2 PL 33 2 PL 8 41 9 A C D D 5 6 4 PL 4 2 PL 3 2 PL J 6 11 29 28 8 3 L 9 9 G 4 PL 10 7 J 1 2 H B 35 36 2 PL 23 24 7 J 45 K C 4 PL E H F 3 43 42 1 7 11 10 N 4 REF REF REF REF Continued on next page ...

Page 19: ...SHER SPLIT LOCK 12 46 10 WASHER FLAT 41 10WFR 21 41 08PPS 37 8 32x 38 PHIL PAN HD 6 22 6 8 32 HEX KEP NUT 41 08NKP 43BXC01 COVER ELECT HANDY BOX 1 23 24 1 BOX ELECT HANDY 43HBX02 44GKT01 GASKET 1 16 THK 8 ft 25 26 REF 5 REF REF REF REF REF 1 CLAMP CABLE 1 2 43CLM01 27 6 ft FOAM TAPE 5 x 12 THK 81TAP18 15D509 LABEL BLACK 1 28 29 1 DUCT INTAKE UPPR 11D3685B17 REF 2 PL 2 PL REF 2 PL REF 30 1 ASSY UPP...

Page 20: ...2 8 94MS42 Rev B1 S W Ver 2 06 ...

Page 21: ...about two minutes to cool the lamp Y MEMORY Pressing the memory key will advance the memory location The display will show which memory is selected V VACUUM Press the vacuum key and use the numerical keypad to enter a vacuum delay time The window shows the delay in seconds 0 2 4 6 8 9 7 5 3 1 P 0000 e 0000 V 00 Y T I U D m F 1 4 7 2 5 8 3 6 9 0 e EXPOSURE Press the exposure key and use the numeric...

Page 22: ...auto step function ON or OFF Press the e key the memory window will read AC and the exposure window will read CUAC Press the V key to turn continuous vacuum function ON or OFF m MEASURE This key is used to check the lamp intensity 0 9 NUMERICAL KEYPAD These keys are used to enter the vacuum time exposure units and to access a particular memory location 0 9 INSTANT MEMORY KEYPAD The OV 45 33HD has ...

Page 23: ...features you must first be in the setup mode LocK Lock Level Feature codE Lock Code Feature 2UAL 2 two Value Exposure Feature SPgt Motorized Filter Feature SSur Single Surface Exposure Feature bcnt Exposure Count Feature FrCl Frame Control Switch Feature AUAC Automatic Vacuum Feature AStP Auto Step Feature dUAC Vacuum Delay Feature trAY Frame Speed Feature tYPE System Type Setting Feature ...

Page 24: ...osure G GO Button Press the G button once to initiate vacuum drawdown on the exposure frame Press the G button a second time to move the frame into the unit and start an exposure If frame switch FrCl and auto vacuum AUAC are turned on press the G button once to move the frame into the unit and start an exposure If frame switch FrCl and auto vac AUAC are turned on press the G button once without op...

Page 25: ...ress the integrator I key to select the desired light level to be calibrated always start at Low Intensity For 8kW Low 2000 W Medium 5000 W High 8000 W In order to prevent possible damage to the high resolution printers Mylar while calibrating we recommend you set the no vacuum feature Press the V key on the keypad the Memory and Exposure windows will dim Press the 9 key three times Press the V ke...

Page 26: ...e 500 3 Perform this procedure on the remaining three surfaces _SEL Press 1 2 3t4on the numerical keypad The Vacuum window will read _SEL This places you in select mode Press the V key once and press the0 key to clear then V key then the 0 key to activate the vacuum after being turned off earlier in this procedure Changing the Calibration Number Press the m key on the integrator The Memory window ...

Page 27: ...75 1 22 2 00 1 26 _SEL Press 1 2 3t4on the numerical keypad The Vacuum window will read _SEL This places you in select mode Then press the m key and the exposure window will show previous calibration number There is a separate number for each intensity Select the intensity to be adjusted with the I key Read the current calibration number and multiply it times the correction For example if you doub...

Page 28: ...scale that straddle the first In the example the reference is 30 step A is 24 and step B is 40 Ref A B A 06 16 375 The example step is 375 steps under the reference Matching with a meter If an integrating meter is available that has a photocell that matches the film it can be used to match the surfaces We recommend that the results be verified on film Make a reading on the reference surface and th...

Page 29: ... on individual memories may be turned ON and OFF without the need to enter a code Level 2 3 Locks functions per memory similar to lock level 1 except once lock is turned ON for a particular memory it may not be turned OFF again without entering the lock code Also locks the parameters on the set up menu so they cannot be changed without entering the lock code Level 4 Locks all functions A code is r...

Page 30: ...a decimal point will be displayed after each digit in the Memory window 0002 Lock Level 2 3 The Vacuum window will read 0002 or 0003 Locks functions for seconds enter vacuum and intensity per memory and Integrator Program Set Up Features Before this mode is turned ON enter all needed information into a memory location Then press the U key the Memory window will read Ac the Vacuum window will read ...

Page 31: ...t this mode To Clear Lamp Statistics C This step clears all lamp statistics explained in sections Lamp Statistics Note You can abort clearing the lamp statistics by pressing the 0 key before the display counts down to SEL_ and you will not change any memory and exposure statistics Note Lock Level must be set to 0 to program this step and reset when finished see Lock Level feature Press the P key o...

Page 32: ...window will read SEL_ This places you in the select mode Press the Y key once The Memory window will read Su 2UAL Press and release the e key until 2UAL is displayed in the Exposure window Press the V key to cycle mode ON or OFF Press the 0 key twice to exit this mode Split Exposure Mode The split exposure mode works in conjunction with the previously mentioned two value mode It enables the user t...

Page 33: ...single surface option ON or OFF Press the 0 key twice to exit this mode Note Press the U key to activate feature in operating mode so that the Memory display reads Ac and the Exposure display reads SUrF Press the V key to select bottom bot_ top toP_ or both both Now press the U key If you have selected both lamps the left memory digit is complete and means upper and lower lamps are selected If you...

Page 34: ...itches and the exposure unit s computer system SEL_ Press 1 2 3t4 in sequence The Vacuum window will read SEL_ This places you in the select mode Press the Y key once The Memory window will read Su FrCL Press and release the e key until FrCL appears in the Exposure window This places you in the frame control interface mode Press the V key to cycle the frame control interface mode ON or OFF Press t...

Page 35: ... OFF Press the 0 key twice to exit this mode Set Default Vacuum Delay Note This feature is used to provide sufficient vacuum drawdown time before exposure The time begins when the frame lid is closed with the AUAC turned ON or when you press the G button for the first time If you press the G button again before the vacuum delay counts down the frame will move into the cabinet but the exposure will...

Page 36: ...me press 5 0 and then press the V key again the Memory window and Exposure window will return to normal brightness Press the 0 key twice to exit this mode Type Mode C The type has been set at the factory and should not be changed Proper operation of the unit will be affected if changed Press the P key on the integrator to power up the light the front remote switches and the exposure unit s compute...

Page 37: ...e unit has been ON will be displayed in the Exposure window tCr_ Press the 1 key a third time The letters tCr_ will appear in the Vacuum window The elapsed time in hours that the lamp has been used at medium power will show in the Exposure window tLo_ Press the 1 key a fourth time The letters tLo_ will appear in at the Vacuum window The elapsed time in hours that the lamp has been used at low powe...

Page 38: ...xit this mode Selecting a Memory Location Press and release the Y key on the operator control panel to cycle through the 40 memory locations 0 39 You may go to a particular memory by entering the desired memory number on the numerical keypad on the integrator EXAMPLE Enter a desired memory number e g 12 Press the corresponding keys 1 then 2 on the numerical keypad then press the Y key Quick Keypad...

Page 39: ... gauge will indicate the vacuum level for the appropriate frame Examine both sides of the frame to check the vacuum drawdown visually When good vacuum contact is assured press the G button to move the frame into the cabinet and start exposure If second frame has been examined press the G button and the frame will go into the cabinet The frames will not move if the previous exposure is still in pro...

Page 40: ...alues being entered What was the last button pressed How long ago 0004 Frames not in position at start of exposure Solution Put the frames in position by cycling the power switch If the frames don t move check the wiring to the frame motor and the frame position sensing switches If everything is OK and this error still occurs call your service representative See also the I O test mode description ...

Page 41: ...SEL_ Press 1 2 3 then 4 in sequence The Vacuum window will read SEL_ This places you in select mode Press the 6 key to enter the Diagnostics mode The number in the Vacuum window will be the sum of all values for peripherals that are turned On o000 Press the 9 key to reset the Diagnostics mode This turns Off all peripherals Therefore the Vacuum window will indicate o000 Refer to the Functions Table...

Page 42: ...ower Vacuum Pump On Off 0008 5 Work Light and Nose Section Fans On Off 0016 6 Motor Direction Control 0032 7 Frame Motor On Off 0064 8 Motor Fast Slow 0128 9 All controls off 0000 0 Return to Select mode SEL_ Viewing Lights Motor Direction Blowers Motor Power Motor Speed Top Vacuum Pump Bottom Vacuum Pump 6 2 3 4 5 7 8 Heat Exchanger 1 Heat Exchanger 1 ...

Page 43: ... and the G key pressed on the nose section the lower integrator display should read 0165 With the lower frame in the display should read 0172 G DOOR FRAME SWITCH FRAME NUMBER DISPLAYED 128 32 4 1 0165 Upper Frame In 128 32 4 8 0172 Lower Frame In Switch Table Switch Value Function 1 Upper frame in labeled frame 4 Frame switch 8 Lower frame in labeled frame 16 S key nose section 32 Door emergency z...

Page 44: ...ither the door switches or emergency z button 0005 Indicates upper frame in position magnetic frame switches closed and does not have the correct reading from either the door switches or emergency z button 0012 Indicates lower frame in position magnetic frame switches closed and does not have the correct reading from either the door switches or emergency z button Whatever the switch value display ...

Page 45: ...xposure time has become too long Support the safety glass on the lamp head and loosen the two thumbscrews to release the glass Carefully slide the holding brackets up or down The safety glass will slide from either side of the lamp head Loosen the thumbscrews for both lamp wire spade lugs Disconnect and remove the lamp by removing the spade lugs and wires from under the thumscrews Carefully lift e...

Page 46: ... or the reflector and cooling tube Insert the safety glass into the holders and push against the housing Ensure the safety interlock lever is positioned firmly underneath the glass towards the lamp and not squeezed to the side Also ensure the safety glass is loose enough to allow for heat expansion during an exposure The light will not operate unless the safety glass is installed properly When the...

Page 47: ...xposure frame tracks every month Wet a small piece of cloth or paper towel with a lightweight machine oil and rub it on the linear bearing surface Keeping the linear bearings oiled will ensure smooth and quiet operation C Do not use silicone spray lubricants in the printer Lubricate gas strut mounts Apply a light coat of oil on the retaining ball mountings for the gas struts that support the upper...

Page 48: ...25 mm flex between the drive motor and the adjuster wheel C Do not use silicone spray lubricants in the printer Lubricate upper and lower light block mechanisms Apply a light coat of machine oil to the piano style hinges on the on the upper and lower light blocks Apply a light coat only otherwise excess oil will drip on the exposure frames during operation Clean vacuum pump filters Remove and clea...

Page 49: ...arbon vanes and grease packed motor bearings require no oil Filtration Be certain that dirt chips and other foreign material often found in new plumbing is not allowed to enter the pump Liquid moisture vapor or oil based contaminants will affect pump performance and must be prevented from entering the pump Dirty filters restrict air flow and if not corrected could lead to motor overload poor perfo...

Page 50: ...ples into the same holes With the pump running allow about 2 tbsp of flushing solvent to be ingested into the vacuum side of the unit Pump Disassembly Pump disassembly is required if flushing does not remove the foreign materials Disconnect the power to the pump motor Remove the six bolts holding the end plate to the body Remove the end plate and the four vanes do not remove the rotor or loosen an...

Page 51: ...ing on the connector and pull the vacuum tubing out BRACKET VAC3 PS1 XMR1 PS2 VAC2 VAC1 FRONT GTOOL VACUUM PUMP LOWER VACUUM PUMP UPPER VACUUM PUMP TRANS FORMER 5KVA 480V LOWER POWER SUPPLY LOWER LAMPHEAD UPPER POWER SUPPLY Disconnect the in line electrical pump connection located approx 6 from the motor end of the pump Remove the four 1 4 20 nuts that secure the pump mounting plate to the isolati...

Page 52: ...n will greatly increase the vacuum drawdown time required if not eliminate full vacuum altogether All vacuum lines are separated from the connectors by pressing down and holding the connection outer ring while pulling the vacuum line out To replace the vacuum line into the connections simply push the line all the way into the connection Vacuum Gauge Replacement See section Nose Assembly ...

Page 53: ...nto the frame glass PART NO DESCRIPTION QTY 1 GLASS AP30D 18D3728A00 VACUUM BLOCK 12D1738A71 2 2 5ft TUBING CLEAR VINYL 49DCT24 12D1728A62 INTAKE PORT 2 1 TAPE TEFLON SEALANT 81TAP12 17 00 17 00 11 5 7 9 8 6 CUT SEAL ENDS FLUSH AND BOND ENDS TOGETHER USING A THIN COAT OF GASKET ADHESIVE CLEAN ANY EXCESS FROM SEAL SURFACE NO GAP ALL0WED REF TEXTURE NEARSIDE TYP 10 12 10 1 14ft SEAL WAVE SHAPE 44GKT...

Page 54: ...dge of glass C Do not stretch seal Cut 90º notch see Detail B Use a seal miter cutting tool Continue pealing off paper from seal bend 90º and press seal onto transfer tape while aligning seal with outside edge of the glass C Do not stretch seal Press ABS strip items 9 10 onto transfer tape align with seal Clean any excess transfer tape along inside edge Press transfer tape onto back of short ABS s...

Page 55: ...essed to turn ON the vacuum pump Once the pump has been turned ON the button for the upper tool or lower tool can be pressed to activate the respective solenoid in order to hold the art work to the glass tool 3 3 1 2 1 2 J4 P4 1 2 1 2 P3 J3 J2 P2 1 2 2 1 6 1 2 8 7 6 1 2 5 P1 J1 5 6 3 2 4 1 P18 CONTROL PUMP GRN YEL BLUE BROWN RED BLACK GRN YEL ORANGE BLACK RED WHITE NEUTRAL 220VAC RELAY DC COM 12VD...

Page 56: ...8 8 94MS42 Rev B1 S W Ver 2 06 ...

Page 57: ... PC Board Remove the right rail cover and place it on carpet or any surface that will not damage the keypad overlay or the paint see Nose Assembly Left and Right Covers Remove the 6 nuts holding the Display Keypad and the 4 nuts from the Quick Memory Keypad along with all the plug in connectors Cut any tie straps holding wiring harnesses soldered to the boards in order to remove them Install the n...

Page 58: ...e to separate the switch in two pieces and remove it from the rail cover Install the new switch in reverse order Replacing the Vacuum Gauges Remove the right rail cover and place it on carpet or any surface that will not damage the keypad overlay or the paint see Nose Assembly Drawings Remove the vacuum tubing from the gauge Remove the gauge retaining bracket and the faulty vacuum gauge Install in...

Page 59: ...ays start moving Just before the trays reach the center turn the power OFF Lift the diffusion cover off of the light assembly Twist the lamp to disengage it from the socket and remove it Install in reverse order Nose Fans Note The nose fans are controlled by a rocker switch on the underside of the right front corner of the rail cover Note If the nose fans are not turning ON check the rocker switch...

Page 60: ...2 1 1 1 1 1 2 2 2 1 1 SWITCH CW NSI 8 32 X 3 8 PPMS ZINC NSI 6 32 X 3 8 PHIL PAN MS BLK 1 4 20 X 5 8 SOCKET BTN HD BLK NSI 8 32 X3 8 PFMS 100 ZINC NSI 6 32 X 1 2 BLK SELF TAP NSI 10 32 X 1 2 PPMS ZINC NSI 8 32 X 3 4 PPMS ZINC NSI 10 32 KEP NUT ZINC NSI 8 32 KEP NUT ZINC NSI WASHER SPLIT LOCK 1 4 NSI 8 SPLIT LOCK WASHER NSI 6 SPLIT LOCK WASHER NSI 1 4 SAE FLAT WASHER NSI 8 FLAT WASHER SAE NSI 6 FLA...

Page 61: ...gs cont 18 2 PL 45 44 3 PL 3 PL 4 PL 2 PL 35 5 PL 47 41 44 41 33 47 33 41 44 38 55 54 42 45 16 14 16 51 39 37 4 PL 4 PL 40 48 49 3 PL 2 PL 17 15 35 5 PL 4 PL 46 43 36 46 36 43 4 PL REF 34 6 PL 35 34 14 PL TOP VIEW 1 2 7 6 3 4 5 8 Continued on next page ...

Page 62: ...7 TUBING NYLON 1 4 OD O 126 44 17 8 81TAP12 16 TAPE TEFLON SAELANT 1 2 15 CONNECTOR TUBE 3 8 TO 1 4 OD VACUUM GAUGE 0 30 HG 1 1 2 13 14 49VAG02 43FIT14 2 2 15D2270A00 OVERLAY CONTROL PANEL 1 12 1 HARNESS MERGENCY SWITCH 16D2412A00 16D2196A00 HARNESS SW OPERATOR OV45 1 11 1 1 1 55SW48 1 55SW53 55SW45 2 10 CONTACT BLOCK 9 8 7 BUTTON YELLOW STOP EMERGENCY PUSHBOTTON COVER RAIL LEFT 45 COVER RAIL RIGH...

Page 63: ...lap on all sides so that it comes up between the inner and outer frames Mark on the Mylar where the cam latches are and cut a small slit in the mylar to allow the cam latches to lock down Then trimmed off once the inner frame has all the cam latches in the closed position Make sure the inner and outer frames are not bent or damaged if so replace them Outer Frame Replacement Remove the inner frame ...

Page 64: ...hout the Mylar and close all cams End View Bar Hinge Outer Frame Allen Screw 1 32 to 1 16 Loosen all the Allen head screws in the corners of the inner and outer frames shown in the diagram Tighten the outer frame Allen head screws in the order shown in the diagram 2 per corner Tighten the inner frame Allen head screws in the order shown in the diagram 2 per corner 1 2 3 4 6 7 5 8 Lift the frame an...

Page 65: ...L 2 PL 28 30 27 48 3 2 1 38 37 39 3 PL 12 9 PL 3 3 A A VIEW 34 21 18 35 34 23 36 43 42 34 22 32 33 31 31 33 32 2 PL 2 PL 2 PL 2 PL 2 PL 17 2 PL 14 2 PL 2 PL 1 45 32 33 31 33 32 32 34 5 2 PL 40 10 PL 2 PL 31 33 32 34 47 4 PL 45 32 47 7 2 PL 4 PL 38 37 30 38 16 2 PL 4 REF 2 37 41 15 16 2 PL 24 44 A A 10 PL 6 PL 13 6 2 PL 50 16 2 PL 4 PL 2 46 Continued on next page ...

Page 66: ...2 43SDB03 19D3825A76 HINGE BLOCK 4 19 18 3 END PIVOT BLOCK 12D1895A99 12D1731A71 FRONT WHEEL BLOCK 1 17 16 1 REAR WHEEL BLOCK 12D1733A00 12D1730A71 FRONT BEARING BLOCK 1 15 14 1 REAR BEARING BLOCK 12D1732A71 13 12 1 TIE WRAP ADHESIVE MOUNT BASE 44PAD03 10 GLASS FRAME ASSEMBLY 7 8 9 HANDLE 6 ALUM BLACK 91GLFRM 42 44HDL05 1 2 PART NO WELDMENT TRAY OV42 DESCRIPTION 1 2 QTY 3 4 19D3826A02 1 5 4 SOCKET...

Page 67: ...SSEMBLY SIDE VIEW 19 2 PL 23 2 PL 1 3 20 15 REF 2 REF 17 6 2 PL 21 6 PL 7 2 PL 12 8 2 PL 14 2 PL KNURRLED SURFACE 2 OUTER FRAME ASSEMBLY TOP VIEW 3 GLASS TRAY ASSEMBLY 24 2 PL 9 23 3A 30 2 PL 31 2 PL 32 38 PL 8 PL REF ADD WASHERS IF NEEDED TO ADJUST CATCH TO LATCH Continued on next page ...

Page 68: ...I S T ITEM NO DESCRIPTION 1 FRAME MYLAR OUTER REAR 19D3817B76 1 2 3 4 5 6 FRAME MYLAR OUTER FRONT FRAME MYL OUTER LH SIDE FRAME MYLAR INNER SIDES FRAME MYLAR INNER F R BASE HANDLE LATCH 19D3817B17 19D3819B76 19D3824A76 19D3823A76 12D2389A76 1 2 2 2 1 12 SEE B O M NSI 8 X 5 SLOTTED BNDG 81TAP21 GASKET 1 16 W X 1 2 SWITCH MAGNETIC INTE 13 55SW50 B 1 2 43SPR12 SPRING 7 16 X 9 16 COMP 16 15 14 18 NSI ...

Page 69: ... slide it forward about 3 to 4 76mm to 102mm Remove both linear bearing retainer block screws using a 5 32 Allen wrench Lift up the frame assembly about 2 51 mm and slide the bearing block assembly forward off the shaft support the frame to prevent contact with the shaft Remove the bearing from the retainer block see Tray Assembly Drawing Detail B Install in reverse order To replace the upper fron...

Page 70: ...bearing from the retainer block Install in reverse order Frame Glass Replacement Note Wear leather gloves and safety glasses when performing this procedure Open the frame to be changed Cl The glass frame could suddenly move up as soon as the glass weight is removed Secure the glass frame to the tray cable ties or heavy duty tape Remove the black silicone fillers in each corner on the front edge of...

Page 71: ...3 PL 6 PL 3 PL 10 PL CHAIN TENSIONER ASSY DETAIL B 4 PL 2 PL 34 34 32 35 1 74 37 36 3 2 36 37 15 39 40 9 8 68 33 70 69 71 72 73 42 38 17 18 5 PL 3 PL 2 PL D 2 PL 2 PL 2 PL RED BLK BLK RED BOT POS TOP POS UPPER LOWER LOWER UPPER C A B 4 PL 1 2 3 2 PL 2 PL 1 2 25 6 7 11 41 28 14 5 27 13 26 27 30 29 21 10 43 44 31 4 12 16 67 DETAIL DETAIL DETAIL DETAIL Continued on next page ...

Page 72: ...X 5 8 PHIL FLAT MS 4 2 NSI 6 32 X 5 8 PPMS ZINC 41 06PPS 62 41 04NKP NSI 4 40 KEP NUT 2 6 41 04NLM NSI 4 40 FLEXLOCK METAL 1 4 20 X 3 4 HEX HEAD BOLT NSI 6 32 X 3 4 PPMS ZINC WASHER SPLIT LOC 1 4 41 06PPS 75 41 FOBHX 75 41 40WFR 4 4 3 8 NSI 1 4 SAE FLAT WASHER 41 FOWLS 41B40NLN NSI 1 4 20 LOCKNUT NYLON INS 4 24 NSI 8 32 X 1 2 SOC HD CAP SCR 41B08SHC 50 1 TENSIONER BUSHING 12D1755A00 41B40BHX1 75 N...

Page 73: ...he cabinet stops frame movement when it is actuated by the frame moving into the exposure position If the system switch fails the frame contacts a second switch that turns off power to the frame drive motor Tray Drive Motor Replacement The drive motor is in the left rear corner of the cabinet It is a 1 8 hp PMDC design with a slip clutch on the output shaft The clutch is intended to prevent frame ...

Page 74: ...art 31MSC02 is replaced This adjustment is critical failure to do so can damage the board and or hardware Locate the FAST and SLOW potentiometers in the upper left hand corner of the Control Box The frame speed adjustments will be made from these pots VACUUM PUMPS ACCESSORY A C COMMUNICATION SET SELECT SWITCH TO LINE UP WITH LED INDICATOR LIGHT LINE VOLTAGE SELECTION SWITCH HF1 BLOWER POWER SUPPLY...

Page 75: ... AUX Exit the diagnostic mode by pressing the 9 key then the 0 key Adjust the FAST pot on the control box Press and hold the STOP key then press the GO key and then release both keys to start a blank frame cycle no vacuum or exposure Measure across pins 5 6 on motor speed connector Adjust the FAST pot on the control box to read between 70 and 84 VDC The frame should travel at high speed for about ...

Page 76: ...16 NSI 6 FLAT WASHER BLACK ZINC 41B06WFR 1 SPACER HINGE OV45 11D2202B02 12D1653B62 HINGE LIGHT BLOCK OV45 1 1 LIGHT BLOCK UPPER OV45 11D2148A17 11D1659A99 BRACKET WHEEL MOUNT OV45 2 2 NYLON IDLER PULLY 49PUL01 11D1660A99 MOUNT SPRING LT BLK AP30 2 2 SWITCH INTERLOCK 55SW46 11D2240A62 MOUNT DOOR SWITCH OV45 2 1 SPRING TORS LH 43SPR17 43SPR18 SPRING TORS RH 1 2 6 BRASS 6 32 RND THD SPACER 42HHS8779 ...

Page 77: ...38 52 2 41 06PPS 50 48 1 12D1653B62 41 12NKP 8 49 51 5 41 06WLS 50 13 41B06WFR 11D2202B02 1 53 31 30 29 28 32 33 36 35 34 58 2 41 F5WFT 62D2719A00 2 57 11D1659A99 2 59 BRACKET WHEEL MOUNT OV45 ASS Y CONTROL DELAY BOX 1 2 THIN FLAT WASHER SPACER HINGE OV45 NSI 6 FLAT WASHER BLACK ZINC NSI 6 SPLIT WASHER NSI 10 32 KEP NUT ZINC HINGE LIGHTBLOCK OV45 NSI 6 32 X1 4 PPMS ZINC NSI 6 32 X 312 HEX THD SPAC...

Page 78: ...ht side panels Remove the left mounting bracket first Use the new mounting bracket Insert two 8 32 x 0 62 screws and secure to mounting bracket with two 8 32 kep nuts Use the 1 2 13 x 2 0 shoulder screw and large 1 2 washer and insert through the hole in the mounting bracket Place the mandrel over the shoulder screw Place left spring over mandrel Secure washer and nut over shoulder screw Reinstall...

Page 79: ...LECT SWITCH TO LINE UP WITH LED INDICATOR LIGHT LINE VOLTAGE SELECTION SWITCH R1 MOTOR L SWT STOP IN SLOW OUT FAST MOTOR SLOW SPEED 208 240 E C L U 1 4 2 5 3 12 VDC 1 Blk Red 4 1 4 1 4 1 1 4 3 6 Blk Red Wht Red Blk Wht Org Wht Blk Blk Red Blk Red Blk Red J21 1 1 4 3 6 R5 R3 R4 R6 R2 On 480VAC printers only GTOOL 12VDC AUX ...

Page 80: ... VSEL BLACK TFAN J17 120V 220V BFAN 12VDC RELAY WHITE BLUE BLUE BROWN J18 CONTROL PUMP 1 2ASB WHITE WHITE BLACK BLACK RED XFMR PS B A IN WHITE BLACK BLUE VIOLET B 208 C 120 D COM A 240 RED VOLTAGE SELECTION ASSEMBLY POWER SUPPLY 12VDC WIRE FOR 120V OPERATION 15ASB X4 L 3ASB K J H YELLOW VIOLET ORANGE WHITE F10 F5 F6 F7 F8 F5 OUT OUT 1 4 F9 BLACK RED E D F G BROWN BLUE RP S LP S L3 L2 DBLK GND N L1...

Page 81: ...LACK WHITE IN A B BLACK PS VSEL XFMR BLACK MOTOR SPEED CONTROLLER L1 L2 S3 COMPRESSOR EVAPORATOR T3 12VDC INTEG PWR A C VACUUM PUMPS J14 64CT464V00 T5 ACC T4 P10 T1 T2 T6 T7 SCR MOTOR LIMIT SWITCHES BLACK RED BLACK BLACK WHITE BLACK RED 1 4 2 3 6 1 2 3 4 L1 L2 L3 TERM AC INPUT WIRING 480V 3 PHASE DELTA F H1 G D E H4 X1 X4 X2 H K M J L N P H K M J L N P D F H1 E G H4 NOT USED 480V SINGLE PHASE 480V...

Page 82: ...2 4 94MS42 Rev B1 S W Ver 2 06 Base Assembly Diagram 4 PL 12 PL 24 PL 2 25 31 TYP 24 PL 7 7 7 A 12 7 8 C D 3 B B 13 25 6 G 10 2 E A 27 A A A C 30 F 9 1 5 4 31 C 3 PL H A 12 PL H 7 Continued on next page ...

Page 83: ...S 24 24 WASHER SPLIT LOCK 10 41 10WLS 41B10WFR WASHER FLAT 10 24 25 1 PALLET SHIPPING 19D2896A00 26 PART NO WELDMENT RAIL CENTER WELDMENT LOWER DESCRIPTION ITEM 1 2 QTY 3 WELDMENT TOP 4 11D3690A00 11D3750A00 11D3748A00 1 1 1 5 1 COVER RAIL L H 11D2163A00 11D2163B00 COVER RAIL R H 1 1 6 WELDMENT INSERT SECTION 11D3754A00 27 4 LEVEL LEG 12D2904A00 48TRM02 GASKET TRIM LOCK 18 ft 28 29 12 SCREW 10 32 ...

Page 84: ...12 6 94MS42 Rev B1 S W Ver 2 06 ...

Page 85: ...GA BLACK 18 GA RED 18 GA GREEN 18 GA BLR2 BLR1 16D4171A14 RED 22 GA BLACK 22 GA SOL1 SOL2 SOL3 16D4249A12 BLACK 18 GA RED 18 GA BLACK 18 GA BLACK 18 GA RED 18 GA BLACK 18 GA RED 18 GA CTRL TEMP SENSOR BOARD 64AX508V00 BLACK 5 COND 16D1003A10 TEMPERATURE MONITOR BASIC OPTION VACUUM AND TEMPERATURE MONITOR XMR L1 L2 L3 L4 SW8 SW9 GRN YEL 18 GA 16D3804A00 BLACK 18 GA RED 18 GA RED 18 GA BLACK 18 GA W...

Page 86: ...18 GA BLACK 18 GA BLACK 18 GA RED 18 GA BLACK 18 GA RED 18 GA BLACK 18 GA RED 18 GA RED 18 GA BLACK 18 GA RED 18 GA BLACK 18 GA RED 18 GA BLACK 18 GA RED 18 GA BLACK 18 GA 16D2319A00 CM NC NO NC NO CM CM NC CM NC 16 128 4 1 8 16D2656A00 16D3811A00 RED 16 GA BLACK 16 GA BLACK 16 GA SW6 SW5 SW4 NO CM NO CM CM NO RED 18GA BLACK 18 GA CM NO RED 18GA SW3 BLACK 18 GA 32 RED 18GA 62D3476A00 56TMP01 BLACK...

Page 87: ... Support Assembly 90RF83 C Reflector for AL 84 AL 94 45KOB05 Knob Interconnect Cable To Power Supply 62SA83 Shutter Assembly PA91 Photocell 39BLO14 Power Supply for AL 84 60Hz L1 T1 T2 L2 Power Output Power Input 120 VAC Coil Voltage 33RLY04 Sealed Relays 33RLY02 Power Relay 32TRC08 Autoformer 32BAL01 Ballast 52FUH04 Fuse Holder 39BLO03 Blower 64MV407 83 Control Board 53JKP01 Safety Interlock 62D2...

Page 88: ...use Sealed Relays Power Relay Capacitor Assembly Safety Interlock Control Board Blower Fuse Holder Ballast Power Supply for AL 94 50Hz Power Power 120 VAC 32TRC08 32BAL01 52FUH04 39BLO03 64MV407 95 53JKP01 62D2723A00 56FUS15 L1 T1 T2 L2 33RLY04 Sealed Relays 33RLY02 Power Relay 18 Terminal Strip 1 Output Input Coil Voltage 3Amp 250V 3AG Slow Blow Fuse Autoformer Capacitor Assembly Interlock Jack C...

Page 89: ...PACK AC IN 6 GA BLK BLK RED 16 18 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CONTACTOR AL 84 Ballast Tap Switch Wiring AUTOFORMER 240 VOLT RED TO FUSE YELLOW TO AUTOFORMER VOLTAGE SELECTOR SWITCH 12 11 10 6 5 4 3 2 1 BALLAST 3 CAP 240 208 COM BALLAST 4 COM 208 240 CAP TERMINAL STRIP RED T2 T1 L2 ORANGE TO CAP PACK L1 BALLAST 2 BALLAST 1 COM 208 CAP 240 CAP 240 208 COM 16 18 17 15 14 13 12 11 10 9 8 7 ...

Page 90: ...nnected to a voltage selector switch then is connected to taps on a step down autotransformer This transformer is located under the terminal strip on the component bracket near the dividing wall The transformer tap marked 120V becomes the unit common and returns to the terminal strip The other line wire is connected to the transformer common and becomes the hot 120V lead to the PC Board and also r...

Page 91: ...ices in the air tubes Lamp Voltage The lamp voltage measurement can provide useful information for lamp striking lamp output and level switching information The meter used to measure can cause different results We use traditional needle movement meters in our factory due to the trigger pulses on the lamp before striking The waveforms are not sinusoidal so different meters may produce different res...

Page 92: ...s 1 and 3 and causing an arc from terminal 3 to terminal 1 This arc should be 015 or greater Lamp Current 1 Violet Wire Lead to Lamp 3 High Temp Wire Other Lamp Lead 2 Yellow Wire M2 M1 M3 TRIGGER BOARD 64MV414 FOR AL 84 AL 84 480 and AL 94 Capacitors and Level Switching The capacitors pass all the current that flows through the lamp They are also used to switch power levels The capacitors for the...

Page 93: ...ual exposure then switch between the power levels noting the change in intensity When switching down in power allow the unit three seconds to respond AL 84 Capacitor Assembly 5 WIRE COLORS 1 YELLOW 2 BROWN 3 BLUE 4 BLUE WITH WHITE STRIPE 5 ORANGE CAPACITOR ASSEMBLY PART 62D2652A00 12µƒ 12µƒ 10µƒ 16µƒ 2 1 4 3 5 5 AL 84 480 Capacitor Assembly 5 WIRE COLORS 1 YELLOW 2 BROWN 3 BLUE 4 BLUE WITH WHITE S...

Page 94: ... WIRES FROM HARNESS WIRES TO CAPACITOR TOP FRONT VIEW OF PC BOARD 1 2 3 1 2 3 4 WIRE COLORS 1 YELLOW 2 BROWN 3 BLUE 4 BLUE WITH WHITE STRIPE 5 ORANGE CAPACITOR ASSEMBLY PART 62D2723A00 SWITCH ON CAPACITOR MOUNTING BRACKET 4 3 2 1 REAR VIEW OF PC BOARD 6 1 4µƒ 12µƒ 16µƒ 12µƒ 16µƒ 5 1 4 3 5 5 5 2 SWA SWB SWC ...

Page 95: ...t the opposite end from the shutter motor under the air plenum plate Side View Shutter The shutter is controlled by the PC board with information from a switch in the lamp head to provide position information During cool down and exposure the shutter is open and during warm up and idle the shutter is closed The PC board compares the shutter position with the requested position The shutter motor wi...

Page 96: ...r Brake The motor that drives the shutter has a brake that is magnetically operated When the motor core magnetizes it pulls a lever to release the brake If the shutter coasts or rotates continuously look at the shutter LED on the PC board On early boards where there are three LEDs in a row near the front of the power supply it is the third from the front of the power supply On the newer models the...

Page 97: ...move the four motor screws Installing the Motor Mount the motor with four screws Install the sprocket in line with the shutter sprocket and tighten Install the chain on the sprockets Set the chain to where it has 3 8 side travel and tighten the two accessible motor screws lightly C Turn the shutter only counterclockwise looking from the motor end or you may damage the shutter switch on the other e...

Page 98: ...ubes and remove the reflector and lamp from the lamp head C DO NOT TOUCH THE REFLECTOR SURFACE WITH YOUR HANDS Bottom View Remove the three screws from the blower mounting plate to the cooling tubes on both sides Compress the cooling tubes into the shutter assembly remove the chain from the motor sprocket then remove the shutter assembly End View Reassemble in reverse order C DO NOT TOUCH THE REFL...

Page 99: ... 25 SCREW 100 FLAT HD 2 3 6 WASHER LOCK INTERNAL 41 06WLI 63D0142B03 LAMP SUPPORT ASSEMBLY 2 IDLER ARM SHUTTER 63D3530A62 4 SHUTTER END PHOTOCELL SLOT QTY 11D3974A71 2 1 11D0210A62 TIMING DISC LT 1 12D1873A62 AIR TUBE DRIVE 1 SPRING SHUTTER AL83 2 12D2060A07 12D1874A62 1 AIR TUBE FRONT LT8 SHUTTER REFLECTOR ASS Y 11D2216 1 1 REFLECTOR INNER RF83 SW G 11D1876B99 42HHS8500 6 X 187 ROUND SPACER 23 20...

Page 100: ... left for a period of time Successive rapid exposures would not fail since it takes many minutes for the unit to over cool This over cooling situation could also be due to a bad idle capacitor which would not allow sufficient energy to the lamp to keep it warm After checking the capacitors mark the factory setting of the trimpot that is located on the back side of the PC board The trimpot sets the...

Page 101: ...Fuse on PC Board If the fuse blows on the printed circuit board check if the fuse is a 5 amp fuse The printed circuit board drives five or six circuits the lamp head blowers shutter motor power supply blower and the relays To find the cause unplug the unit and replace the fuse then disconnect the wires to the lamp head on terminals 5 and 6 and disconnect one of the wire nuts connecting the blower ...

Page 102: ...er 14 Incoming voltage 1 The ground terminal is for safety purposes and carries no current 2 3 Lamp terminals 2 and 3 carry the power to the lamp If the lamp is hot or fails to start the voltage should be 600 to 950V During this time there are voltage pulses that may damage a sensitive voltmeter Immediately after the lamp strikes the voltage will drop as low as 20V then rise as the lamp warms to t...

Page 103: ...ently used 9 The shutter position switch reports the position of the shutter to the printed circuit board This switch is open when the shutter is closed and closes when the shutter opens This signal is low voltage DC and can be measured on terminal 9 on terminal 7 The meter will read 12 VDC when the shutter is closed and 0 VDC when the shutter is opened 10 Interlock and thermostat switching During...

Page 104: ... period the lamp fans vary in speed to maintain the proper lamp temperature This allows the unit to consume less power on idle and provides a wider range of exposure capabilities since this same low power level is available for exposures The lower idle saves power generates less heat and extends the lamp life Expose The units allow exposures at three levels At high power the high and medium relays...

Page 105: ...Shutter Motor K1 TR101 TR102 TR103 TR104 P1 Power Connector 6 5 4 3 2 1 AC Hot AC Common Lamp Fans Shutter Motor High Relay Medium Relay 11 7 8 9 10 12 Unit Fan Power Relay Not Connected Aux Terminal DC Common Position P2 Switch Connector 6 5 4 3 2 1 AC Hot AC Common Not Connected Aux Terminal DC Com Ground Power Switch 7 8 9 10 12 11 High Switch Manual Expose Interlock Not Connected 12 VDC Low Me...

Page 106: ... to drive the main relay This provides power to the lamp circuit P9 Not currently used P10 Aux Terminal connects to the signal connector for accessories Not used in most equipment P11 DC Common Circuit common for low voltage signals from the lamp this may not be the same potential as V Common connection and should never be interchanged P12 Position Shutter switch active signal from the lamp head L...

Page 107: ... 12V Output for internal accessories Not used in most equipment DIN Connection D1 Expose High expose when connected to a compatible integrator High Medium Low expose depending on the unit switches when connected to an older style integrator or other manufacturer s equipment D2 DC Common Common for all signals D3 Low Exp Low expose input D4 Power Signal from integrator to turn on the power D5 Mediu...

Page 108: ...ux Terminal High Relay Shutter Position DC Common 110 VAC AC Common Lamp Fans Shutter Motor Connector P1 12 V Power Supply Output for Lamp Blowers D18 U4 U5 Output for High Relay D15 Q4 K3 Output for Medium Relay D16 Q5 K4 Output for Shutter Motor D17 Q6 K5 Output for Power Relay D14 Q3 K2 Output for Power Supply fan D13 Q2 K1 Shutter and Intensity Logic AUX AUX A A A A Ouput Type A K__ Q__ AC Sou...

Page 109: ...94MS42 Rev B1 S W Ver 2 06 13 23 Lamphead for all Lights 12 10 8 6 4 2 Shutter Position Switch 11 9 7 5 3 1 Shutter Motor Lamp Trigger Board Blowers Thermostat Thermostat Safety Glass Switch ...

Page 110: ... clear 8 brn 7 org 6 red 5 blu 4 wht 3 pur 2 yel 1 grn yel Power Relay P O W E R S U P P L Y T E R M I N A L S T R I P Voltage Selection Board 240 208 208 120 0 Ballast High Relay 220 VAC 50HZ INPUT 3 Amp Slow Blow Fuse P O W E R C O N T R O L B O A R D 12µƒ 12µƒ 16µƒ 10µƒ Power Supply Blower Ballast 11 9 7 5 3 1 12 10 8 6 4 2 Interconnecting Beau Plug Connector Medium Relay COM COM Toward front o...

Page 111: ... 14 blk 13 wht 12 red 11 10 blk 9 clear 8 brn 7 org 6 red 5 blu 4 wht 3 pur 2 yel 1 grn yel Power Relay P O W E R S U P P L Y T E R M I N A L S T R I P 277 277 Ballast High Relay 480 VAC 60HZ INPUT P O W E R C O N T R O L B O A R D 12µƒ 12µƒ 10µƒ 10µƒ Power Supply Blower Ballast 11 9 7 5 3 1 12 10 8 6 4 2 Interconnecting Beau Plug Connector Medium Relay Toward front of unit Toward center of unit P...

Page 112: ...10 blk 9 clear 8 brn 7 org 6 red 5 blu 4 wht 3 pur 2 yel 1 grn yel Power Relay P O W E R S U P P L Y T E R M I N A L S T R I P 240 240 240 120 0 Ballast High Relay 220 VAC 50HZ INPUT 3 Amp Slow Blow Fuse P O W E R C O N T R O L B O A R D 16µƒ 12µƒ 4µƒ 12µƒ Power Supply Blower Ballast 11 9 7 5 3 1 12 10 8 6 4 2 Interconnecting Beau Plug Connector Position 2 Position 1 Medium Relay COM COM Toward fr...

Page 113: ...Ver 2 06 13 27 Interconnect Cable 1 2 4 3 6 5 8 7 10 9 12 11 WHITE GREEN VIOLET BLUE ORANGE BLACK YELLOW RED BROWN HEAT SHRINK 1 2 4 3 6 5 8 7 10 9 12 11 WHITE GREEN VIOLET BLUE ORANGE BLACK YELLOW RED BROWN HEAT SHRINK ...

Page 114: ...13 28 94MS42 Rev B1 S W Ver 2 06 ...

Page 115: ...r supply you notice right off burnt wires or connectors one of the most likely causes is the tap switch in the wrong position This condition usually take months and sometimes years depending upon the degree of voltage discrepancy to show up When the burnt wire is on the tap switch itself or on the bottom side of the power relay it is very difficult to see the burnt wires without some disassembly o...

Page 116: ...at the safety interlock circuit is shorting to ground On older light sources this condition would burn up the autoformer On newer light sources this condition will blow the 3A slow blow fuse on the dividing wall below the wiring harness 6 Check input voltage with the power off at terminals 12 14 Then with power on intensity level on high and manual expose set on check the voltage again If the volt...

Page 117: ... power relay is most likely the problem There is a possibility that if there is zero V that you might have a grounded safety interlock circuit At idle check voltage from terminal 3 to the capacitor outputs yellow brown and blue wires on top of the capacitors On the following charts find the Wattage of the unit you are working on and then for the lamp installed into the unit these are the general v...

Page 118: ...reading remains high 700V or more see note and it should be low less than 600V see note the capacitor is not being pulled into the circuit Check the respective relay resistor and wiring for an open 11 If a reading remains low less than 600V see note and it should be high 700V or more see note the capacitor is locked into the circuit Check the respective relay wiring and PC board for a short 12 If ...

Page 119: ...e unit to do an exposure the only time the shutter will rotate if this circuit is open is when the power is turned on or off If you suspect this circuit is faulty turn the manual expose switch on then short the blue and white wires on the jack together with a screwdriver make sure you do not short to ground and see if the shutter opens if it opens the circuit is at fault 17 Check for smooth shutte...

Page 120: ...mble everything it is a real good idea to Check the manual operations of the light source Just to make sure everything is back together 27 Reconnect all wires to the integrator and then Check the remote operations of the light source from the integrator ...

Page 121: ...200 245 VAC to top of power relay Replace lamp Go to test 3 Good All O K Still no strike Check for 0 VAC between 4 white 10 black on terminal strip Test 3 500 VAC on 2 yellow 3 pruple Thermostats safety switch or associated wiring could be faulty Check for 120 VAC on PCB power connector pins 2 white 8 red Replace fuse No good Good Replace PC Board Go to test 2 after checking wires on voltage set s...

Page 122: ...s on PC Board Is LED D17 lit No Yes Is the lamp lit shutter motor Possible faulty and air tubes replace bearings motor and or Adjust shutter No Yes switch shutter position gear and the on shutter motor Check set screw worn sufficiently bearing surface likely too tight or Chain most No Yes rotation to bind during Does shutter seem Yes No time rotate at any Does shutter Triacs Relay TR105 Lamp head ...

Page 123: ...9 on back of control box PCB 64CT464 Also check the fuse Motor speed controller wires A1 A2 reversed check against wiring diagram Yes Perform a diagnostic test to ensure frame movement Refer to Diagnostic section in the service manual No No Check wiring from switch to control box Probable bad relay on 64CT464 Replace board Do the In Out LEDs change on control box Yes No Yes Check for 120 VAC input...

Page 124: ...15 4 94MS42 Rev B1 S W Ver 2 06 ...

Page 125: ...1D1660A99 Mount Spring Lt Blk 2 11D2111B62 Switch Mount 2 11D2148A17 Light Block Upper 1 11D2202B02 Spacer hinge 1 11D2240A62 Mount Door Switch 2 11D3395A17 Deflector Air 1 11D4326A07 Strip right rail 2 12D1635A00 Block Mount Accu Trac 10 12D1653B62 Hinge Light Block 1 12D1750A62 Slide 1 12D1751A00 Threaded Rod 1 12D1752A62 Slider 1 12D1753A00 Idler Sprocket 1 12D1754A00 Idler Bushing 1 12D1755A00...

Page 126: ...A62 Bracket Mount Heat Exchanger 4 11D3374A17 Panel side Clsd Loop 2 11D3381A17 Plate Rear Blower Clsd Loop 1 11D3382A62 Mounting plate Plumbing 2 11D3685A17 Duct Intake 1 11D3685B17 Duct Intake 1 11D3687A08 Cover Rear Lower 1 11D3857A17 Bracket molex connector 1 11D4079A17 Ass y upper collector 1 12D3466A07 Nipple flow meter 1 16D3808A00 Harness valves 1 16D3810A00 Harness blowers 1 31SOV09 Two w...

Page 127: ... NPT x 20 L 3 49DCT39 Hose braided 1 2 NPT x 12 L 3 49DCT41 Hose insulation 30 49THERM01 Thermometer 1 68D3765A00 Assy inst plumb cool mdl 0 72FOM42 Foam close loop 1 thk 4 72FOM43 Foam closed cell polyethe 4 11D4326A07 Strip right rail 2 81TAP17 Transfer tape 3 4 18 90KITSTRIP OV45 Retrofit kit for drawer rail tape 1 62AP42CL INSERT Ass y insert sectiion 1 11D2051A62 Mount Spring Low Lt Blk R 1 1...

Page 128: ...tor 15Kohm 2W 5 1 32TRC08 Autoformer 208 225 240 V 1 35LMF06 Lamp Yellow Viewing 20 w 4 39BLO11 Blower 2 39CLF02 Light Fixture Undercabine 4 43FIT13 Reducer Tube 3 8 to 1 4 2 43FIT14 Connector 1 4 Tube to 1 2 49DCT27 Tubing Nylon 1 4 OD 0 51SI18E Spade Ins 22 18Ga 8 4 52SKL13 Lampholder Bi Pin 0 52TS05 5 Position Terminal Strip 1 55SW01 Switch CW 2 62AP42CL TOP Assy Top Section AP42 1 11D2222A17 S...

Page 129: ...11 2 DIA 3 44RUB03 Grommet Continuous 06 0 44TIE03 NSI Cable Tie 71 2 50 Max 10 52FUH04 Fuse Holder 3AG 3AB 4 52FUH08 Fuseholder 3AG 25 Tab 2 52LUG01 Lug Connector 2 8 Wire 1 52RCP21 Receptacle 250V 15A 6 1 2 52RCP24 Receptacle 250V 50A 6 5 2 52TS20 Pwr Dist Block 2 pole 2 56FUS15 Fuse 3A 250V 3AG Slow Bl 1 56FUS16 Fuse 1 2A 250V 3AG Slow 1 56FUS28 Fuse 10A 250V Slow Blow 4 62D2483A00 Blower 220V ...

Page 130: ...w Blow 1 56FUS16 Fuse 1 2A 250V 3AG Slow 1 56FUS28 Fuse 10A 250V Slow Blow 4 62D2483A00 Blower 220V 1 62D331A Voltage Selector Assembly 1 64CT464 PCB Assembly AccuPrint 1 62AL85 L2 Printing Light with L 1282 208 240 60Hz 2 62CL85 8K CL85 Power Supply 208 240 60Hz 1 16D1045A00 Harness Beau Plug OEM 1 16D1585 Interlock Harness 1 16D2617B00 Power Cable AL85 AP42 PS 1 16D2629A00 Harness 8K B P S Main ...

Page 131: ...crimp nut 6 52FUH04 Fuse Holder 3AG 3AB 1 54PWR05 Pwr Crd 18 3 SJT 12 5 15 1 56FUS15 Fuse 3A 250V 3AG Slow Blow 1 62D3533A00 Assy Capacitor 60H 480V 1 64MV407V04 Assy UV Lt Ctrl 8K 60Hz 1 62LH83SE SW Lamp Head 8K Stdrd Rev SE 1 62LH83SE SW Lamp Head 8K Stdrd Rev SE 1 62LHK02 83 Roller Assembly AL 83 1 62SA83SE BASE AL 83 Shutter 1 63D0142B03 8K Lamp Support Bracket 2 L1282 Lamp 1 PA91 photocell as...

Page 132: ... Rev B1 S W Ver 2 06 Part Number Description Qty per unit 55SW03 Switch Glass 2 Pos Blk 1 56THM01 Thermostat model K 2 62LHK01 Switch Assembly 1 63D3669A00 Idler Arms Assy LT8 1 64MV414 T Trigger Board Tested 8K 1 ...

Page 133: ...e the equipment It is the Buyer s responsibility to ascertain the suitability of the equipment for the application The Buyer assumes all risk and responsibility for the proper installation for reading the Instruction Manual and retaining it with the equipment for the safe use of the OLEC product All operators must be made familiar with the proper use and safe operation upon installation and period...

Page 134: ...O Corporation 17112 Armstrong Avenue Irvine Ca U S A 92614 U S A 949 399 6500 Fax 949 399 6501 ...

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