BGK AutoCure 5000 Assembly And Operating Manual Download Page 3

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Warnings

DANGEROUS VOLTAGES ARE

PRESENT IN THIS EQUIPMENT!

CONTACT WITH LIVE PARTS

COULD CAUSE

SERIOUS INJURY OR DEATH!

CONNECTION, INSTALLATION, MAINTENANCE,

ADJUSTMENT, SERVICING AND OPERATION TO BE DONE BY

QUALIFIED PERSONNEL ONLY.

ENSURE THAT EQUIPMENT IS COMPLETELY

AND PROPERLY GROUNDED BEFORE APPLYING

SUPPLY POWER AND BEFORE EQUIPMENT

OPERATION.

Summary of Contents for AutoCure 5000

Page 1: ...January 2016 AutoCure 5000 Portable Repair Arm Assembly and Operating Manual AC5 2116 380...

Page 2: ...Pyrometer Lens 12 Trouble Shooting Guide 13 Heater Power Problems 13 Temperature Controller Problems 13 Temperature Problems 14 Temperature Controller Error Codes 15 Ramp Soak Errors 15 Service Instru...

Page 3: ...IVE PARTS COULD CAUSE SERIOUS INJURY OR DEATH CONNECTION INSTALLATION MAINTENANCE ADJUSTMENT SERVICING AND OPERATION TO BE DONE BY QUALIFIED PERSONNEL ONLY ENSURE THAT EQUIPMENT IS COMPLETELY AND PROP...

Page 4: ...handling heater head Do not move heater when in operation Heater contains high voltage Do not insert metallic objects into cooling louver openings Ensure that equipment is properly grounded before app...

Page 5: ...y indicates the mode of the heating cycle and the process temperature During the Ramp mode the upper display will toggle between the process temperature and ramping Once the cure temperature set point...

Page 6: ...ress the to exit setup menu 6 Set auxiliary heater off or on 7 Press the cycle start Double Ramp 1 Turn power on 2 Turn positioning beam on and position heater 3 Set controller parameters 4 Hold the b...

Page 7: ...r assembly and prevent the possibility of arcing or shorting Lamp Installation Replacement Procedure 1 Make sure main system circuit breaker is OFF 2 Rotate heater so lamps are horizontal 3 Remove end...

Page 8: ...ic terminal in heater head Ensure all bare wire is contained up to terminal trim lead if necessary Heater Power Cord Make sure lamp sleeving is pushed all the way into ceramic end of lamp Lamp Support...

Page 9: ...re any types of reinforcements or extra thicknesses of metal in the area to be cured These areas will heat at different rates and not achieve the same temperature as the single thickness metals withou...

Page 10: ...heat sensor aim with the positioning beam 6 Set the temperature and time settings 7 Start heat cycle 8 Approximately 3 5 minutes after start check that the temperature is at set point and the timer h...

Page 11: ...the next repair Positioning Set Up of an arm on rocker panels heavy reinforcements multiple metal thickness 1 Follow any of the instructions previously mentioned in the precautions and instructions se...

Page 12: ...monthly 2 Dual head units have seven 7 castle nut spring combinations and two 2 shoulder bolts with Nylock nuts If pivot points become loose heater positioning will not be maintained Check these poin...

Page 13: ...ontactors change the temperature controller Check that the set point bottom display is higher than the process temperature top display Are the line fuses FU 101 104 in front of the contactors good che...

Page 14: ...rcuit board or SCR by exchanging the firing circuit board with one from a known good control Does the problem follow the firing circuit board or does it stay with the SCR replace the defective compone...

Page 15: ...y is functioning and there is no voltage at the heat sink assembly open the Raytek pyrometer and test for the voltage the 2 wire nuts replace the Positioning Beam Temperature Controller Error Codes Di...

Page 16: ...ctions 7 Loosen and remove standoffs 8 Remove Insulating plate 9 Remove heat sink then remove Pyrometer 10 Install new pyrometer into heat sink making sure to adjust fit using varnish tape wrapped on...

Page 17: ...ocouple side Loosen and remove nut and all washers on AC arm side 5 Unmount housing and replace with new housing 6 Install nut grommet and 2 washers onto Thermocouple leads as shown below 7 Once insta...

Page 18: ...18 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 19: ...19 Mechanical Drawings and Parts Lists Pyrometer...

Page 20: ...20 CAUTION...

Page 21: ...AC 61228 INSULATOR PYROMETER 11 1 AC 61227 MOUNT INSULATOR PYROMETER 12 1 AC 611232 HOUSING PYROMETER 13 1 AC 61230 COVER PYROMETER 14 2 AC 200099 3 SCREW MACH FL HD SLOT 8 32 X 2 750 15 2 AC 200032 S...

Page 22: ...22...

Page 23: ...tion 4 2 X 2 TR SSEM 283 SHRINK TUBING 19 2 AC 200031 FEMALE CONNECTOR 20 2 AC 200030 MALE WIRE CONNECTOR 21 2 AC 200033 CABLE SLEEVE 22 28 AC 200052 1 MESH 23 35 AC 200077 BROWN WIRE 24 35 AC 200078...

Page 24: ...24...

Page 25: ...2 CUT 1 8 X 1 8 V NOTCH TO SRINK TUBE 23 INSTALL GROMMET ONTO SHRINK TUBE USING BULLET TOOL OR PLIERS 24 INSTALL 2 WASHER AS SHOWN 25 INSTALL NUT ASSEMBLY Parts Listing Pyrometer Item No QTY Part No D...

Page 26: ...26 Heater Head Assembly ACH5 2116...

Page 27: ...19 2 AC 50869 WASHER 1 5 OD X 531 X 125 THK 22 1 AC 63940 J BOX HEATER 24 2 AC 64237 MOD HEX BOLT 1 2 13 X 2 00 25 2 AC 54585 PIN COTTER 1 8 X 750 26 2 AC 54583 SPRING COMPRESSION 27 2 AC 39487 NUT HE...

Page 28: ...0097 RIVET BLACK ALUMINUM 43 10 1 AC 59449 REFLECTOR OUTER 2 LAMP 1600 11 3 AC 58833 TERMINAL 3 POLE CERAMIC 600V 12 4 AC 50686 3 SCREW CAP SOCKET HD 8 32 X 1 13 5 AC 3903 1 NUT HEX FLG SERRATED NONLO...

Page 29: ...RCEMENT HANDLE 7 2 AC 4012 3 8 16 AVK 1ST GRIP 8 2 AC 61923 INSULATOR END COVER 2 LAMP 3 CTR 9 4 AC 200097 RIVET BLACK ALUMINUM 43 10 1 AC 59449 REFLECTOR OUTER 2 LAMP 1600 11 3 AC 58833 TERMINAL 3 PO...

Page 30: ...30 AC5 Stand 92 93 93 92 92 41 48 57 8 96 63 70 8 71 77 59 2 52 30 30 80 79 2 36 58 25 15 9 76 18 72 10 49 42 51 6 73 32 5 31 87 81 4 9 60...

Page 31: ...ATE CASTER MOUNTING 49 1 TABLE AAA COLUMN AA POST MOUNT CONTROLS 51 1 TABLE C COLUMN CA ARM UPPER EXTENDED 52 1 AC 65844 PLATE TAPPING GAS SPRING 57 TABLE B COLUMN BD AC 3903 3 NUT HEX SERRATED 5 16 1...

Page 32: ...SO CORD CONTROL CABLE MUST BE TO THE OUTSIDE OF THE SO CORD SPACER NOT BETWEEN THEM 43 34 50 20 21 58 65 90 37 62 62 48 62 66 75 74 59 25 N N SECTION N N SCALE 1 8 59 25 1 67 2 22 89 7 P DETAIL P SCAL...

Page 33: ...S 43 1 AC 61220 COVER ACCESS CONTROLS 46 1 TABLE C COLUMN CC BRACKET 48 1 AC 61241 WELD BASE 50 1 TABLE C COLUMN CB ARM LOWER EXTENDED 52 1 AC 65844 PLATE TAPPING GAS SPRING 54 2 AC 68268 TUBE SPACER...

Page 34: ...TANT READ AND UNDERSTAND OPERATORS MANUAL BEFORE INSTALLING OR OPERATING THIS EQUIPMENT XXX VOLTS AUX HEATER OFF ON SEE DETAIL F J J 3 43 50 91 35 44 53 84 85 4 9 49 33 55 53 66 38 62 47 45 62 39 62 4...

Page 35: ...RATION LABEL 38 4 AC 52841 SPACER ARM TUBE 39 1 AC 57416 HOOK CABLE 43 1 AC 61220 COVER ACCESS CONTROLS 44 1 AC 61221 1 BRACKET GAS SPRING 45 1 AC 61221 2 BRACKET GAS SPRING 47 1 TABLE C COLUMN CD BRA...

Page 36: ...36 F DETAIL F POSITION LEVER CAUTION REF ABOVE ITEM CENTERED AC 59981 68 62 44 47 38 62 51 49 42 19...

Page 37: ...AC 52841 SPACER ARM TUBE 42 1 AC 61219 BAFFLE ELECTRICAL CORD 44 1 AC 61221 1 BRACKET GAS SPRING 47 1 TABLE C COLUMN CD BRACKET POST 49 1 TABLE AAA COLUMN AA POST MOUNT CONTROLS 51 1 TABLE C COLUMN C...

Page 38: ...38 BG K FINISHING SYSTEM S DANGER CAUTION CAUTION DANGER LETHAL SHOCK 78 L L SECTION L L SCALE 1 8 M DETAIL M SCALE 1 4 49 33 82 56 88 19 19 19 19 CAUTION 27 23 29...

Page 39: ...5 1 4 X 5 8 FLAT HEAD 27 12 AC 3775 WASHER FLAT 1 2 ID SST 29 1 AC 49155 NUT METRIC GAS SHOCK 33 1 AC 59981 KIT ACTUATOR RELEASE 49 1 AC 59981 KIT ACTUATOR RELEASE 56 13 AC 4090 WASHER FLAT 10 SST 78...

Page 40: ...40 SECTION J J SCALE 1 8 K DETAIL K SCALE 1 4 88 53 89 64 63 83 86 16 17...

Page 41: ...ULDER SCREW 9 2 AC 3772 1 4 FLAT WASHER 10 2 78405 06 WASHER FLAT USS 312Z 11 7 AC 3773 3 8 FLAT WASHER 12 4 AC 3903 NUT HEX SERRATED 1 4 20 14 4 AC 3831 3 8 HEX NYLOCK NUT 15 10 AC 3887 10 LOCK WASHE...

Page 42: ...AC 4090 WASHER FLAT 10 SST 57 TABLE B COLUMN BD AC 3903 3 NUT HEX SERRATED 5 16 18 58 TABLE B COLUMN BD AC 200161 CLIP SAFETY TO GAS SPRING 59 6 AC 200091 2 SCREW TRUSS HD 8 32X3 4 SST 65 6 AC 200098...

Page 43: ...20827 00 PANDUIT TYWRAP MOUNT 95 4 27141 044 TYWRAP A A SECTION A A B DETAIL B SO CORD TERMINATION DETAIL TYP 3 HEATER HEADS ATTACH 8 RING TERMINAL TO GROUND WIRE AND USE THIS SCREW TO MOUNT TO LAMP...

Page 44: ...44 Parts List DESCRIPTION PART NUMBER QTY ITEM ASSY AC5 CRS CRL CTE STE 101861 1 1 ASSY HEATER 2306 103622 1 2 OPTICAL PYROMETER AND SIGHTING DEVICE...

Page 45: ...45 ACH5 2116 Lamp Wiring Schematic...

Page 46: ...ll replacement materials THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES INCLUDING BUT NOT LIMITED TO ALL WARRANTIES OR MERCHANTGABILITY AND FITNESS FOR PURPOSE This warranty shall not...

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