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Olec Accuprint AP30-5000 Service Manual Download Page 4

0-2

94MS36 Rev. F2 S/W Ver 2.06

Selecting a Memory Location .................................................... 3-10
Quick Keypad ............................................................................ 3-10
Entering an Exposure Time ....................................................... 3-10
Setting the Light Intensity ......................................................... 3-11
Making an exposure................................................................... 3-11
Blank frame cycle ...................................................................... 3-11
Error Handling System .............................................................. 3-12

4.

Diagnostics

Output Diagnostics ...................................................................... 4-1
Output Functions Check .............................................................. 4-1
Functions Table ........................................................................... 4-2
Input Diagnostics ......................................................................... 4-3
Typical values that you will see when all switches are good. ..... 4-3
Typical values that you will see when a fault occurs. ................. 4-4

5.

Lamp Changing Instructions

Lamp Changing Instructions ....................................................... 5-1

6.

Preventive Maintenance

Preventive Maintenance Daily..................................................... 6-1
Preventive Maintenance Monthly................................................ 6-1
Preventive Maintenance Semi-Annually ..................................... 6-1

7.

Vacuum System

Vacuum Pumps ............................................................................ 7-1
Flushing the Pump ....................................................................... 7-1
Pump Disassembly ...................................................................... 7-2
Pump Checkout ........................................................................... 7-2
Pump Replacement ...................................................................... 7-3
Tubing/Fitting Replacement ........................................................ 7-3
Vacuum Gauge Replacement ...................................................... 7-3
Vacuum Seal Replacement .......................................................... 7-4
Glass Photo Tool (Optional) ........................................................ 7-6

8.

Nose Assembly

Removing the Nose ..................................................................... 8-1
Replacing the Display and Keypad P.C.Board ............................ 8-1
Replacing the Emergency kz Button ........................................... 8-1
Replacing the 

S

 and 

G

 Buttons .......................................... 8-2

Replacing the Glass Tool Vacuum Buttons ................................. 8-2
Replacing the Vacuum Gauges .................................................... 8-2
Nose Section Autoformer ............................................................ 8-2
Work Lights ................................................................................. 8-3
Nose Fans .................................................................................... 8-3
Cleaning or Replacing Nose Filters ............................................. 8-3
Nose Assembly Drawings ........................................................... 8-4

Summary of Contents for Accuprint AP30-5000

Page 1: ...P P AP30 5000 AP30 8000 High Resolution Printer Service Manual 94MS36 Rev F2 S W Ver 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: ... Procedures 2 4 Changing the Calibration Number 2 6 Matching Exposure Surfaces 2 7 Splitting Steps 2 8 Matching with a meter 2 8 3 Integrator Program Set Up To Enter the Select Mode 3 1 Lock Level Feature 3 1 Lock Level Description and Operation 3 2 Setting or Changing your Lock Code feature 3 3 To Clear Lamp Statistics 3 3 To Clear Memory and Exposure Statistics 3 3 Two Value Exposure Mode 3 4 Sp...

Page 4: ...ntive Maintenance Preventive Maintenance Daily 6 1 Preventive Maintenance Monthly 6 1 Preventive Maintenance Semi Annually 6 1 7 Vacuum System Vacuum Pumps 7 1 Flushing the Pump 7 1 Pump Disassembly 7 2 Pump Checkout 7 2 Pump Replacement 7 3 Tubing Fitting Replacement 7 3 Vacuum Gauge Replacement 7 3 Vacuum Seal Replacement 7 4 Glass Photo Tool Optional 7 6 8 Nose Assembly Removing the Nose 8 1 Re...

Page 5: ...Assembly 10 6 Replacing Lower Light Block Springs 10 7 11 Air Conditioning System Compressor 11 1 Inlet Filter 11 1 12 Diagrams Control Box Front View 12 1 Control Box Wiring Diagram Standard with 5kW 12 3 Control Box Wiring Diagram Standard with 8kW 12 4 Control Box Wiring Diagram 480V all 12 5 Control Box Wiring Diagram CE all 12 6 Unit Cabling Diagram old nose 12 7 Unit Cabling Diagram new nose...

Page 6: ...cription 13 28 Circuit Diagram 64MV407 60Hz 13 30 Lamphead for all Lights 13 31 AL 54 Power Supply 60Hz 13 32 AL 54 480 Power Supply 60Hz 13 33 AL 64 Power Supply 50Hz 13 34 AL 84 Power Supply 60Hz 13 35 AL 84 480 Power Supply 60Hz 13 36 AL 94 Power Supply 50Hz 13 37 Interconnect Cable 13 38 14 Printing Light Check List Check List for Printing Light Troubleshooting and Service 14 1 15 Fault Trees ...

Page 7: ... lbs 727 kg Uncrated 1375 lbs 625 kg Actual dimensions Cabinet welded heavy gauge steel construction with access doors on both sides Length Width Height 89 48 5 81 226cm 123cm 206cm Note The AP 30 5000 cannot be disassembled to pass through any doorways or hallways Please make sure there is adequate room for its passage Effective exposure frame area Width 30 76 cm Depth 25 64 cm ...

Page 8: ...To minimize the impact on the working environment the exhaust must be vented to the outside a heat exchanger or up through a dropped ceiling A C Filter Rear Front 36 Power 36 36 Top View Room Air Supply The exposure lamp cooling air is drawn from the exposure room The ventilation system must be sized to maintain positive pressure in the exposure room for cleanliness and to avoid drawing chemical f...

Page 9: ...N 208V OLITE Power Supply 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...

Page 10: ...te on the lower rear center of the printer Connect the main leads to the 4 position terminal block and connect the ground lead to the single ground terminal 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 switched to the lit LED Reinstall the lower rear panel M...

Page 11: ...r 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 numer...

Page 12: ...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 13: ...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 14: ...ch 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 opening the upper or lower frame will start a blank frame cycle no vacuum or exposure Note If a vacuum delay dUAC is used the exposure will not begin until the vacuum delay time has counted down...

Page 15: ...ure Press the V key on the keypad the Memory and Exposure windows will dim Press the 9 key three times Press the V key once This will prevent vacuum while calibrating The Vacuum window will read _ The high resolution printer s calibration has been set at the factory Ut Upper frame top surface Ub Upper frame bottom surface Lt Lower frame top surface Lb Lower frame bottom surface Note Preset all 12 ...

Page 16: ...L 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 will read Ut the Exposure window will show the existing calibration number for the top surface of the upper frame at the selected intens...

Page 17: ...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 18: ...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 19: ... 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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ... 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 26: ...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 27: ...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 28: ...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 29: ...ton to start vacuum The upper or lower vacuum 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 ...

Page 30: ...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 31: ...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 32: ...004 4 Lower 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 A C Blowers Motor Power Motor Speed A C Compressor Top Vacuum Pump Bottom Vacuum Pump 6 1 2 3 4 5 7 8 ...

Page 33: ... 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 34: ...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 35: ...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 36: ... 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 37: ...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 38: ...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 39: ...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 40: ...shing 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 any electric motor through bolts The vanes could be worn or only require further cleaning The top clearance between rotor and body may be adjusted by Loosening the body bolts Lightly tappi...

Page 41: ...it Remove the mounting plate from the defective pump and install it on the new pump Note the wire positions and remove the electrical harness from the defective pump and install it on the new pump Install the new pump in reverse order of removal and verify the correct operation and rotation Tubing Fitting Replacement If a vacuum line or connection is cracked loose leaking or broken replace it as s...

Page 42: ... as it is being placed onto the frame glass 11 5 7 9 8 6 CUT SEAL ENDS FLUSH AND BOND ENDS TOGETHER USING A THIN COAT OF GASKET ADHESIVE CLEAN ANY EXCESS NO GAP ALL0WED FROM SEAL SURFACE REF TEXTURE NEARSIDE TYP 9 10 12 10 1 5 REF REF 12 50 11 50 ITEM 1 2 3 4 5 6 7 ITEM 8 9 10 11 12 13 QTY 1 2 2 4 11 2 1 QTY 1 2 2 1 11 2 DESCRIPTION GLASS AP30D VACUUM BLOCK INTAKE PORT O RING Ø 50 I D SEAL WAVE SH...

Page 43: ...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 44: ...o hold the art work to the glass tool Several different glass tools are available according to customer needs so each tool itself is going to be different however the electrical wiring and operation is the same Wiring Diagram for Glass Photo Tool Option J22 PUMP UPPER TOOL LOWER TOOL P70 P71 P72 BLACK 18 GA BROWN 18 GA BLUE 18 GA GRN YEL 18 GA GRN YEL 18 GA 16D2741A00 RED 18 GA RED 22 GA BLACK 22 ...

Page 45: ...ructure Reassemble in reverse order Replacing the Display and Keypad P C Board Remove the nose see section Removing the Nose and place it on carpet or any surface that will not damage the keypad overlay or the paint Remove the 6 nuts holding the Keypad and the 4 nuts from the Quick Keypad along with all the plug in connectors Cut any tie straps holing wiring harnesses soldered to the boards in ord...

Page 46: ...ce that will not damage the keypad overlay or the paint Disconnect and mark the wires on the back of the switch base Remove the two screws from the bottom of the switch base While holding the top of the button unscrew the switch base to separate the switch into two pieces and remove it from the nose Install the new switch in reverse order Replacing the Vacuum Gauges Remove the nose see section Rem...

Page 47: ...ust 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 nose If the nose fans are not turning on check the rocker switch and power to the switch Remo...

Page 48: ... 2 1 14 15 16 8 9 10 11 12 13 7 22 21 20 19 18 23 1 1 4 1 1 2 1 1 2 1 80 QTY 1 2 2 2 1 1 1 1 1 1 1 2 2 2 1 1 2 NSI 6 32 KEP NUT ZINC 6 32 X 312 HEX THD SPACER SWITCH CW TRIMLOCK NSI 8 32 X 3 8 PPMS ZINC CONNECTOR TUBE 3 8 TO 1 4 OD ADHESIVE SQUARE 4026 HARNESS EMERGENCY SWITCH 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 ...

Page 49: ...cont B B A A 18 2 PL 45 1 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 4 3 16 14 16 51 39 37 4 PL 4 PL 40 48 49 3 PL 2 PL 17 15 2 5 6 7 35 5 PL 4 PL 46 43 36 46 36 43 4 PL REF 34 6 PL 35 34 14 PL TOP VIEW Continued on next page ...

Page 50: ...Drawings cont STOP GO BOT POS TOP POS VIEW C C REF 4 PL 4 PL 1 30 DETAIL B 10 PL 58 22 10 PL 10 PL DETAIL A 8 32 8 32 29 57 53 13 21 VIEW B B VIEW A A 2 PL 2 PL 26 23 25 24 2 PL 2 PL 31 19 20 52 DETAIL A 2 PLACES RED BLK BLK RED REF 27 30 DETAIL B ...

Page 51: ...Mylar must overlap on all sides so that it comes up between the inner and outer frames and 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 they are replace them Outer Frame Replacement Remove the inner frame Open the frame then remove the safety clips from the gas shocks While holding the frame up ...

Page 52: ...len 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 4 per corner 3 7 8 4 1 5 6 2 Lift the frame and push the gas shocks back onto the ball joints Reinstall the safet...

Page 53: ...R SEE DETAIL D REAR WHEEL ASSY 4 PL 9 4 PL 2 PL 2 PL 2 PL 4 PL 20 6 40 37 38 36 2 PL 39 24 2 PL 3 2 PL 27 24 40 29 2 44 45 39 28 37 38 36 36 38 37 2 PL 2 PL 1 46 8 PL 39 5 2 PL 2 PL 36 38 37 49 4 PL 49 12 39 23 37 38 36 2 PL BOTH SIDES 2 PL 41 22 21 2 PL BOTH SIDES 13 13 52 11 50 8 4 10 BOTH SIDES 8 PL 38 37 47 37 36 38 2 PL REF 2 PL 7 2 PL 2 PL VIEW AA VIEW AA VIEW AA Continued on next page ...

Page 54: ...X 50 122 11D2971A71 RAMP SWITCHES AP30 OV33 1 42HHS8500 NSI 6 X 125 ROUND SPACER 2 4 41B12PFO 50 NSI 10 32 C 1 2 PHIL FLAT MS 92 TAPE OV24 1 8 THK 1 4 W 81TAP06 1 TIE WRAP ADHESIVE MOUNT BASE 44PAD03 PIVOT BAR AP30 OV33 11D1696A02 BRACKET VACUUM HOSE OV45 1 1 12D1727A99 2 NSI SOCKET SHOULDER BOLT 41BF3SHC 50 41HHS2679 WASHER NYLON 3 8 X3 4 X1 16 2 1 WASHER 380 ID 625 41WFR03 11D1894B62 GUIDE LT BL...

Page 55: ...S NEEDED TO ADJUST CATCH TO LATCH LATCH HANDLE ASSEMBLY SIDE VIEW 19 2 PL 32 2 PL 1 3 2 PL 20 8 PL 15 REF 2 REF 17 6 2 PL 21 6 PL 7 2 PL 12 8 2 PL 14 2 PL 15 APPLY GASKET ALL AROUND FRAME ASSEMBLY AS SHOWN 2 2 OUTER FRAME ASSEMBLY TOP VIEW 3 18 2 PL GLASS TRAY ASSEMBLY 24 2 PL 9 32 Continued on next page ...

Page 56: ...E HANDLE LATCH 12D2380B76 12D2381A76 12D2382A76 12D2382B76 12D2389A76 1 2 2 2 2 6 41B08PPS 50 NSI 8X1 2 PPMS BLACK 44GKT11 GASKET 33W X 06THK SWITCH MAGNETIC INTE 13 55SW50 B 1 2 43SPR12 SPRING 7 16 X 9 16 COMP 16 15 14 18 KEP NUT 10 32 41B12NKP 2 20 SHCS 8 32 X 3 8 41B08SHC 37 24 WAVE WASHER 25 ID 22 23 24 NSI 6 32 X 3 8 FLT BLK 41B06PFO 37 2 6 41B12SHC 75 21 SHCS 10 32 X 3 4 NSI 6 FLAT WASHER BL...

Page 57: ...se Disconnect the molex plug at the tray motor and move the frame to be worked on to the front Remove the Phillips screw attaching the front of the light block guide to the frame upper frame only Remove both linear bearing retainer block screws using a 5 32 Allen wrench Lift the frame and slide the linear bearing and linear bearing retainer block forward and off Remove the Phillips screw attaching...

Page 58: ...rom under the frame Hold it up about 12 inches 305 mm off of the frame Disconnect both vacuum hoses and lift out the glass Install new glass in the reverse order Gas Strut Replacement Each frame assembly has two gas struts to support the top coversheet frame when it is opened Open the frame with the strut to be replaced Remove the retainer from both ends of the strut Pull the strut from the retain...

Page 59: ...G SWITCH ASSY DETAIL C 18 PL 12 PL 1 32 34 3 40 33 9 8 34 35 47 42 2 15 39 37 36 46 33 8 9 40 37 36 38 62D3566A00 3 PL 2 PL 2 PL 2 PL 2 PL RED BLK BLK RED BOT POS TOP POS 2 PL 2 PL BLK WHT BLK 1 2 2 PL 1 2 3 2 PLACES 28 14 5 27 13 26 27 30 29 23 26 19 21 24 20 18 17 4 22 DETAIL A DETAIL C UPPER LOWER LOWER UPPER 4 PL 2 PL 31 12 16 45 DETAIL D 25 6 7 11 41 10 43 44 DETAIL B Continued on next page ...

Page 60: ...PHIL FLAT MS 41 04PFO 62 51TML05 TERMINAL FEMALE MINIFIT 2 10 WIRE 22 GAUGE BLK 2 CON 54M22BLK2 49DCT05 1 4 HEAT SHRINK TUBBING 8 1 1 2 43OSD01 51TML04 51TML02 OVERTORGUE SAFETY DEVICE TERMINAL FEMALE 18 22 AWG TERMINAL FEMALE 14 20 AWG HARNESS MOTOR POS SWT SWITCH TIMING ROLLER BLOCK MOUNT AC TRACK 55SW02 16D2319A00 12D1635A00 4 1 8 1 CHAIN 35 RLR 10 FT 43CHA05 52CTP08 PLUG 3 PIN MOLEX 093 PIN 1 ...

Page 61: ...nto the exposure position If the system switch fails the frame contacts a second switch that turns off power to the frame drive motor Frame Drive Motor Replacement The drive motor is in the left rear corner of the cabinet It is a 1 8 hp PMDC Permanent Magnet Direct Current design with a slip clutch on the output shaft The clutch is intended to prevent frame damage in the event of a jam or if an ob...

Page 62: ...s critical failure to do so can damage the board and or hardware Locate the FAST and SLOW potentiometers in the upper lefthand corner of the Control Box The frame speed adjustments will be made from these pots VACUUM PUMPS ACCESSORY A C COMMUNICATION LINE VOLTAGE SELECTION SWITCH HF1 BLOWER POWER SUPPLY HF1 BLOWER POWER SUPPLY MOTOR L SWT STOP IN SLOW OUT FAST MOTOR SPEED SLOW 12 VDC Activate the ...

Page 63: ...y pressing the 9 key then the 0 key Adjust the FAST pot on the control box Depress 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 4 5 seconds then shift to a s...

Page 64: ...38 28 33 33 26 2 37 34 37 34 26 33 WHEEL ASSY BOTH SIDES SEE DETAIL C 4 PL 8 PL TORSION SPRING ASSY BOTH SIDES SEE DETAIL B REF 5 PL 5 PL 26 33 2 9 33 26 21 37 4 33 26 WHEEL ASSY BOTH SIDES SEE DETAIL C 4 PL TORSION SPRING ASSY BOTH SIDES SEE DETAIL A 5 PL 4 PL 5 PL Continued on next page ...

Page 65: ...EP NUT ZINC 1 2 13 HEX NUT 1 2 THICK FLAT WASHER MOUNT SPRING LOW LT BLOK RT SPACER HINGE MANDREL SPRING LOW LT BLOK 6 BRASS RND THD SPACER SPRING TORSION LH CABINET WELDMENT AP30 HINGE 6 FT LONG LIGHT BLOCK LOWER AP30 LIGHT BLOCK TOP BRACKET HINGE OFFSET AP30 MOUNT SPRING LOW LT BLK AP30 NYLON IDLER PULLY BRACKET WHEEL MOUNT SPRING TORSION LH LOW SPRING TORSION RH LOW SPRING TORSION RH NSI 10 32 ...

Page 66: ...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 to 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 ...

Page 67: ...perating temperature will increase above normal if the inlet filter is dirty or clogged or if the condenser coil is plugged This is caused by a reduction in cooling air flow across the surface of the compressor and condenser coil The air conditioner compressor will shut down if the thermal overload cutout switch located on the compressor housing is actuated When the compressor temperature has drop...

Page 68: ...ter bottom into lower retainer Intake Filter Cleaning Cl Do not run the air conditioner for extended periods of time with the inlet filter removed A buildup of dirt can plug the fins of the condenser coil which will give the same reaction as a plugged filter The condenser coil is not visible through the filter opening therefore we recommend that you protect it with a clean filter Aluminum washable...

Page 69: ...l it is not necessary to remove the air conditioner from the cabinet or enclosure to replace the blower The condenser blower is mounted on its own and is easily accessible by removing the front access panel Refrigerant Loss Your air conditioner was thoroughly tested to ensure against refrigeration leaks Shipping damage or microscopic leaks not found with sensitive electronic refrigerant leak detec...

Page 70: ...11 4 94MS36 Rev F2 S W Ver 2 06 ...

Page 71: ...O LINE UP WITH LED INDICATOR LIGHT LINE VOLTAGE SELECTION SWITCH HF1 BLOWER POWER SUPPLY HF1 BLOWER POWER SUPPLY 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 220 120 Blk Red Blk Red Blk Red Blk Red GTOOL optional 5 6 4 3 2 1 ...

Page 72: ...12 2 94MS36 Rev F2 S W Ver 2 06 ...

Page 73: ...SOR 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 240V 240V F2 F1 F3 F4 BLUE BROWN BLACK RED G F E D 30ASB X4 R1 R2 COOLING FAN BLACK BLUE BLACK YELLOW WHITE RED 16GA YELLOW VIOLET J21 1 2 3 4 J9 3 4 1 2 P9 J12 J13 WHITE RED BLACK GRAY YELLOW ORANGE BLUE S2 S1 A2 A1 INHIB INHI...

Page 74: ... 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 240V 240V BLUE BROWN BLACK RED G F E D R1 R2 COOLING FAN BLACK BLUE BLACK YELLOW WHITE RED 16GA YELLOW VIOLET J21 1 2 3 4 J9 3 4 1 2 P9 J12 J13 WHITE RED BLACK GRAY YELLOW ORANGE BLUE S2 S1 A2 A1 INHIB INHIB J15 2 3 ...

Page 75: ...T BLUE BLACK 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 PH...

Page 76: ...A BLACK 16GA BLUE 16GA BLACK 16GA YELLOW 16GA BLUE 16GA BLACK 16GA MOTOR SPEED CONTROLLER L1 L2 P3 S3 P2 S2 P1 S1 A A2 A A1 I1 INHIB I2 INHIB POWER SUPPLY 12VDC WIRE FOR 240V OPERATION 15ASB X4 3ASB 1 2ASB J COMPRESSOR EVAPORATOR T3 VACUUM PUMPS J9 64CT464V00 T5 T4 MOTOR LIMIT SWITCHES P10 COOLING FAN VIOLET 16GA T1 T2 T6 T7 YELLOW 14GA A 240 D COM C 120 B 208 YELLOW 16GA F6 F5 PS XFMR F1 F2 F3 F4...

Page 77: ...ENSORS BOARD DISPLAY BOARD REMOTE BOARD LOWER CONTROL BOX LOWER UPPER AIR CONDITIONER EVAPORATOR COMPRESSOR HF1 UPPER LAMPHEAD UPPER DOOR SWITCH RIGHT DOOR SWITCH LEFT HF1 LOWER LAMPHEAD LOWER POWER SUPPLY UPPER 62D2369A00 62D2369A00 MAG TRAY SW LOWER UPPER 16D2251A00 16D2251C00 16D2251C00 16D2251A00 16D1830A00 SWITCH CONNECTIONS 16D2495B00 EMER SW POS SW 16D2412A00 62D2411A00 12 22 11 21 COM NO N...

Page 78: ... COND BLACK 15 COND BLACK 5 COND 16D1003A06 GRAY 5 COND 16D2621B00 BLACK 5 COND 16D1003A06 BLACK 5 COND 16D1003A09 BLACK 5 COND 16D1003A08 BLACK 5 COND 16D1003A09 BLACK 5 COND 16D1003A06 NO C C NO RED 18 GA BLACK 18 GA GRN YEL 18 GA RED 18 GA BLACK 18 GA 16D2740A00 16D2741A00 16D0957 5 16D2741A00 16D0957 10 BLACK 14 GA WHITE 14 GA RED 14 GA ORANGE 14 GA 56TMP01 BLACK 14 GA GREEN 14 GA BLACK 18 GA ...

Page 79: ...EYCO ADHESIVE MNT 3 SEE B O M 29 2 VAC PUMP FITTING SEE B O M 28 SEE B O M 27 WIREWAY SELF ADHESIVE SEE B O M 25 1 ASSEMBLY CONTROL BOX 42HHS8914 TUBING 3 8 O D INTERCONNECT CABEL 5 FT 2 20 4 PL 19 NSI 6 32 X 1 1 4 PPMS ZINC 26 2 44TIE10 NSI CLAMP 3 8 O D 1 2 NSI 6 KEP NUT ZINC ELBOW UNION 3 8 TUBING TEE UNION 3 8 TUBING NSI NYLON TIE UV RESISTANT 43FIT09 25 3 43FIT07 4 11 41 06NKP 41 06PPS1 25 4 ...

Page 80: ...168A02 11D2104B02 11D2141A02 2 1 14 15 16 8 9 10 11 12 13 7 21 20 19 18 ITEM QTY DESCRIPTION PART NO 11D2362B00 4 65 41B06PPS 37 EXT REFL SIDE G EXTENSION SIDE R H PLATE FRONT PANEL COVER DEFLECTOR AIR REAR AP30 OV33 BRACKET DOOR SWITCH INTAKE LOW LAMPHEAD FLANGEPLATE HF1 AP30 OV33 34 EXHAUST BLOWER 230V 60 LAMPHEAD ASSEMBLY VACUUM PUMP POWER SUPPLY ASSEMBLY CABINET WELDMENT EXTENSION SIDE L H BOX...

Page 81: ...r 45KOB05 Knob 55SW03 Safety Interlock Switch 39BLO03 Blower PA91 Photocell 55SW02 Shutter Position Switch Power Supply for AL 54 60Hz L1 T1 T2 L2 Power Power 120 VAC 33RLY04 33RLY02 32TRC01 32BAL01 52FUH04 39BLO03 64MV407 53JKP01 62D104 56FUS15 62D1047 Voltage 18 Terminal Strip 1 Output Input Coil Voltage Sealed Relays Power Relay 3Amp 250V 3AG Slow Blow Fuse Autoformer Capacitor Assembly Safety ...

Page 82: ...3Amp 250V 3AG Slow Blow Fuse Assembly Capacitor Safety Interlock Control Board Blower Fuse Holder Ballast Power Supply for AL 64 50Hz Power Output Power Input 120 VAC Coil Voltage 32TRC01 Autoformer 32BAL01 Ballast 52FUH04 Fuse Holder 39BLO03 Blower 64MV407 50 Control Board 53JKP01 Safety Interlock Jack 62D1046 64 Capacitor Assembly 56FUS15 3Amp 250V 3AG Slow Blow Fuse L1 T1 T2 L2 33RLY04 Sealed R...

Page 83: ... 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 62D2652A00 Capacitor ...

Page 84: ...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 85: ... 4 5 6 10 11 12 VOLTAGE SELECTOR SWITCH YELLOW TO AUTOFORMER RED TO FUSE AUTOFORMER 240 VOLT AC IN 10 GA 16 18 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 TERMINAL STRIP CONTACTOR AL 54 480 Ballast Wiring COM 120 CAP 120 CAP COM BALLAST 1 BALLAST 2 L1 L2 T1 T2 RED BLK TERMINAL STRIP CAP 120 COM BALLAST 4 COM 120 CAP BALLAST 3 29 VIOLET NO 20 ORANGE TO CAP PACK AC IN 6 GA BLK BLK RED 16 18 17 15 14 13 1...

Page 86: ...T 4 COM 240 CAP BLK RED 50 Hz BALLAST 50 Hz BALLAST 50 Hz BALLAST 50 Hz BALLAST 16 18 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CONTACTOR AL 94 Ballast Wiring COM 120 CAP 120 CAP COM BALLAST 1 BALLAST 2 L1 L2 T1 T2 RED BLK TERMINAL STRIP CAP 120 COM BALLAST 4 COM 120 CAP BALLAST 3 NO 29 VIOLET NO 20 ORANGE TO CAP 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 ...

Page 87: ... 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 6 5 4 3 2 1 AC IN 6 GA BLK CONTACTOR AL 84 480 Ballast Wiring COM 277 CAP 277 CAP COM BALLAST 1 BALLAST 2 L1 L2 T1 T2 RED BLK TERMINAL STRIP CAP 277 COM BALLAST 4 COM 277 CAP BALLAST 3 NO 29 VIOLET NO 20 ORANGE TO CAP PACK AC IN 6 GA BLK RED 16 18 17 15 14 13 12 11 10 9 8 ...

Page 88: ...lass filters short UV radiation and covers the high voltage lamp terminals This interlock also protects from overheating by traveling through two thermostats in the lamp head There is also an outlet on some equipment marked interlock and is not used in this equipment The internal interlock is a loop that travels through the light head passing through the glass switch and two thermostats This inter...

Page 89: ...5 125 115 125 AL64 w L1250 200 200 230 270 500 55 75 90 120 115 125 115 125 AL64 w L1261 210 210 230 270 500 65 90 90 120 115 125 115 125 AL64 w L1252 200 200 230 270 500 65 90 90 120 115 125 115 125 AL84 w L1280 360 380 360 380 380 410 415 445 500 75 95 90 120 115 125 115 125 AL84 w L1281 400 430 400 430 425 500 460 530 500 75 95 90 120 115 125 115 125 AL84 w L1282 400 430 400 430 425 500 460 530...

Page 90: ...n without cooling The trigger board is located in the lamp head in the end where the cable enters It is located in the cool air path inside the air plenum One lamp lead is in series with the trigger transformer 1 input 3 output the other lamp lead 2 is used to sense the lamp voltage Outside the unit the board can be tested by putting 350 750VAC between terminals 1 and 3 and causing an arc from ter...

Page 91: ...s pull in for high power exposures The capacitors set the operating current of the lamp If the lamp output has changed rapidly inspect the capacitors for swelling The design of capacitor we use will burn open if it begins to short A swollen capacitor should be replaced and the unit should be tested to see that the capacitor did not damage the high or medium relay To test the unit s ability to swit...

Page 92: ...TOR ASSEMBLY PART 62D3654A00 SWITCH ON CAPACITOR MOUNTING BRACKET 4 3 2 1 REAR VIEW OF PC BOARD 6 3 1 12µƒ 10µƒ 12µƒ AL 64 Capacitor Assembly DO NOT SWITCH WHILE UNIT IS ON CAUTION 2 1 5 4 3 2 5 5 1 1 1 2 3 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 6 BLACK CAPACITOR ASSEMBLY PART 62D1046 64 S...

Page 93: ... 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 STRIPE 5 ORANGE CAPACITOR ASSEMBLY PART 62D3533A00 12µƒ 12µƒ 10µƒ 10µƒ 2 1 4 3 5 5 5 ...

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: ...the lighthead Bottom View Top View Remove the 6 screws from each side of the lamphead and remove the two endcaps On 8kW lampheads you can now access the trigger board and shutter position switch that are located at the opposite end from the shutter motor under the air plenum plate Side View On 5kW lampheads remove the 5 screws from the air plenum plate to remove it The trigger board and shutter po...

Page 96: ...l strip from terminal 9 to terminal 7 The level is 12 VDC when the shutter is closed and 0 V when the shutter opens The switch is in the lamp head on the end where the cable enters inside the air manifold on older units On newer units we use the normally open contacts COM contact and the center contact We use the normally closed contacts the two outside leads not the center contact This switch is ...

Page 97: ...the other end of the light Remove the chain from the sprocket with care to keep tension The chain has shortened links and will separate if slackened If the chain opens attach an end to the sprocket with tape or wire and revolve the shutter Remove the motor sprocket by loosening the set screw Remove the two wire nuts from the motor coil wires Remove the four motor screws Installing the Motor Mount ...

Page 98: ...m the lamp support assembly makes this easier END VIEW Remove the 4 screws holding the rear reflector to the air tubes and remove the reflector and lamp from the lamphead C DO NOT TOUCH THE REFLECTOR SURFACE WITH YOUR HANDS BOTTOM VIEW Remove the top screw from the cooling tube on both sides Compress the air tubes into the shutter assembly remove the chain from the motor sprocket then remove the s...

Page 99: ...REW PHIL PN HD 8 WASHER SPLIT LOCK 2 6 WASHER SPLIT LOCK ITM 9 1 2 3 4 5 6 7 8 PART NO DESCRIPTION D3214B 6 X 180 ROUND SPACER 42HHS8500 11D886 REFLECTOR INNER RF53 1 1 11D2206 SHUTTER ASSEMBLY LT1 12D2060A07 2 SPRING SHUTTER AL83 2 AIR TUBE LT 1 AL25 53 12D0217A62 TIMING DISC LT 1 11D210A62 1 2 11D1949A71 QTY SHUTTER END 4 2 LAMP SUPPORT ASSEMBLY 63D0142B00 41 06WLI 6 WASHER LOCK INTERNAL 3 2 4 4...

Page 100: ... 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 REFLECTOR SU...

Page 101: ... 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 102: ... 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 103: ...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 104: ...nd 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 the operating voltage between 180 ...

Page 105: ...l 4 V common An V voltage present would indicate the glass switch or one of the two thermostat switches open 11 Not presently used 12 14 Incoming voltage To get load voltage meter between terminals 12 14 while power is on On 208 240V equipment set voltage selection switch accordingly low 219V or below high 220V or above 13 a Autoformer Light Function States Model Warm Up Idle Low Exp Med Exp High ...

Page 106: ...edium power the medium relay is activated Cool Down When the unit is switched off all fans are turned on to cool the equipment After the cooling period the unit disables all of its functions until it is started again Trigger If the lamp is turned on before the unit has fully cooled the fans will run at full power and a trigger pulse is created This mode will release itself when the lamp strikes Th...

Page 107: ...it Power Main Contactor High Relay Medium Relay 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 Man...

Page 108: ... 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 109: ...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 Medium Exp Medium...

Page 110: ...ot Connected Aux 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 ...

Page 111: ...94MS36 Rev F2 S W Ver 2 06 13 31 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 112: ...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 240 208 240 208 240 208 120 0 Tap Switch Ballast High Relay 208 240 VAC INPUT 3 Amp Slow Blow Fuse P O W E R C O N T R O L B O A R D 12µƒ 16µƒ 12µƒ 16µƒ Power Supply Blower Ballast 11 9 7 5 3 1 12 10 8 6 4 2 Interconnecting Beau Plug Connector Position 1 Position 2 Medi...

Page 113: ...5 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 Ballast High Relay 480 VAC 60Hz INPUT P O W E R C O N T R O L B O A R D 16µƒ 16µƒ 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 277 277 ...

Page 114: ...ar 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 240 240 240 120 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 12µƒ 16µƒ 16µƒ 8µƒ Power Supply Blower Ballast 11 9 7 5 3 1 12 10 8 6 4 2 Interconnecting Beau Plug Connector Position 1 Position 2 Medium Relay COM C...

Page 115: ... 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 116: ... 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 117: ...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 118: ...2 S W Ver 2 06 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 119: ...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 120: ...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 121: ...at the power relay or a bad 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 u...

Page 122: ...0 270 270 270 270 8kW with L1280 LAMP ORANGE YELLOW BROWN BLUE 1 BLUE 2 a IDLE 700 360 700 700 700 b LOW 700 360 700 700 700 c MEDIUM 700 390 390 700 700 d HIGH 700 425 425 425 425 8kW with L1281 LAMP ORANGE YELLOW BROWN BLUE 1 BLUE 2 a IDLE 700 395 700 700 700 b LOW 700 395 700 700 700 c MEDIUM 700 425 425 700 700 d HIGH 700 485 485 485 485 8kW with L 1282 LAMP ORANGE YELLOW BROWN BLUE 1 BLUE 2 a...

Page 123: ... for cooling obstructions on intakes and exhausts If any are found remove them 15 Check lamp idle voltage at terminals 2 3 This voltage should match the voltage chart above if not YOU MUST install a new lamp and recheck see Idle Setting if adjustment is necessary C DO NOT ADJUST idle voltage with a used lamp Lamp voltage can be effected by all the checks in the check list to this point So if this ...

Page 124: ... in the correct position 23 If the shutter stops immediately but in the wrong position check the shutter position switch 24 If the shutter coasts to a stop in the wrong position check the shutter brake 25 If you run into a situation were you are not getting voltage at the terminal strip relay blower etc make sure you go to the PC board itself and Double check the PC board outputs before replacing ...

Page 125: ...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 126: ...the the lamp being exposure w o not open for an The shutter will shutter motor terminal strip to wiring from Repair or replace motor shutter Replace No Yes shutter motor 120VAC at Check for No Yes shutter should be rotating on the terminal strip when 120VAC on 4 white and 6 red When LED D17 is lit check for No Yes on PC Board Is LED D17 lit No Yes Is the lamp lit shutter motor Possible faulty and ...

Page 127: ...e glass 1 EA 11D2392A62 Catch Latch Handle 1 EA 11D2422A62 Top Hinge Glass Tray 2 EA 41 10WLS NSI 10 washer split lock 4 EA 41 12PPMS 50 10 32 X 1 2 PPMS Zinc 4 EA 41B12NKP 10 Kep Nut 4 EA 41B12PF0 50 NSI 10 32x1 2 Phil Flt MS 4 EA 44GKT07 Seal Solid D 2 83 EA 44HDL03 Handle 2 EA 81TAP06 Tape 1 8 Thk 1 4 W 7 670 FT 81TAP07 Tape OV24 1 8 x 1 x 50 12 FT 62D1759A00 Glass Seal Assy Grade B 2 EA 12D172...

Page 128: ...e 1 EA 11D3255A07 Reflector Work Lt 2 Lamp 1 EA 16D2196A00 Harness SW Operator OV 1 EA 16D2412A00 Harness Emergency Switch 1 EA 16D3249A00 Harness 1 EA 18D2430A00 Bezel Worklight 3 Lamp 1 EA 19D1942A99 Filter Top AP30 2 EA 26CF4 15 4 Resistor 15Kohm 2W 5 1 EA 32TRC08 Autoformer 208 225 240 V 1 EA 39BLO11 Blower 2 EA 39CLF02 C Coated lamp yellow w fix 2 EA 43FIT13 Reducer Tube 3 8 to 1 4 2 EA 43FIT...

Page 129: ...ssis 1 EA 44CPG08 Plug plastic black 1 5 3 EA 44RUB03 Grommet Continuous 06 FT 52FUH04 Fuse Holder 3AG 3AB 4 EA 52FUH07 Fuse Block 13 32 x 1 5 4 1 EA 52FUH08 Fuseholder 3AG 25 Tab 2 EA 52RCP15 Receptacle 250V 30A 2 EA 52RCP21 Receptacle 250V 15A 2 EA 52TS20 Pwr Dist Block 2 pole 2 EA 56FUS14 Fuse 15A 250V 2 EA 56FUS15 Fuse 3A 250V 3AG Slow Blow 1 EA 56FUS16 Fuse 1 2A 250V 3AG Slow Bl 1 EA 56FUS20 ...

Page 130: ...DT 250V 10A 1 EA 64VS409 Assembled Voltage Sel 1 EA 62D3558A00 Assy Ctl Bx 8K 480VCLS GT 1 EA 16D3074A00 Harness Control Box 1 EA 16D3208A00 Harness Cntrl Bx GTools 1 EA 16D3455A00 Harness CT Box Closed 1 EA 16D3878A00 Harness cntrl bx suppl 1 EA 31MSC02 Motor speed control KB 1 EA 32PSF01 Power Supply Open Frame 1 1 EA 32TRC01 Autoformer 208 240V 1 EA 33RLY20 Relay 12VDC Chassis 1 EA 44RUB03 Grom...

Page 131: ...ylar frame inner 1 EA 11D4302A62 Latch 12 EA 41 08WSP NSI Spring Washer 24 EA 41B04PPS 37 NSI 4 40 x 3 8 Phil Pan Ms 12 EA 41B04WFR 4 Flat Black Washer 12 EA 44WFN01 NSI Nylon Washer 24 EA 62MFIA01 Mylar frame inner assembly 1 EA 11D4307A07 Bracket right angle 02 4 EA 12D4471A76 Frame mylar inner fr rr 2 EA 12D4472A76 Frame mylar inner side 2 EA 81TAP16 Tape Glide Black UHMW 1 RL 81TAP25 Tape blue...

Page 132: ...r 2 pole NO 30Amp 1 EA 33RLY04 Relay Sealed 2 EA 39BLO23 Blower mdl ball bearing 1 EA 52FUH04 Fuse Holder 3AG 3AB 1 EA 54PWR01 Power Cable for AL53 1 EA 56FUS15 Fuse 3A 250V 3AG Slow Blow 1 EA 62D1047 Voltage Selector 60Hz 1 EA 55SW26 Switch 3PDT 250V 10A 1 EA 64VS409 HA Voltage Selection Board 1 EA 62D1048 Capacitor Assembly 60 Hz 1 EA 64MV407V03 Assy UV Lt Ctrl 5K 60Hz 1 EA 62CL54 480 5kW 480V 6...

Page 133: ...04 Fuse Holder 3AG 3AB 1 EA 54CAB10 Cable 3x 4 0MM2 black rubb 8 FT 56FUS15 Fuse 3A 250V 3AG Slow Blow 1 EA 62D1046 64 Capacitor Assembly 50Hz 1 EA 64MV407V01 Assy UV Lt Ctrl 5K 50Hz 1 EA 62LHSE SW Lamphead 5kW SE SW 1 EA L1261 Lamp L1261 1 EA PA91 PA91 photocell assembly 1 EA 90RF53 SW Reflector 2 EA 63D0142B00 Lamp Support Assy 2 EA 12D1361 Shutter Chain 1 EA 12D1577 Spring Idler 5K Shutter 1 EA...

Page 134: ... 33RLY04 Relay Sealed 2 EA 39BLO23 Blower mdl ball bearing 1 EA 44RUB11 Grommet Continuous 085 1 25 FT 52FUH04 Fuse Holder 3AG 3AB 1 EA 56FUS15 Fuse 3A 250V 3AG Slow Blow 1 EA 62D1047 Voltage Selector 60 Hz AL 1 EA 55SW26 Switch 3PDT 250V 10A 1 EA 64VS409 HA Voltage Selection Board 1 EA 62D2652A00 Assembly Capacitor 1 EA 64MV407V24 Prnt Light Ctrl PCB w Min 1 EA 62CL84 480 8kW 60Hz 480V Power Supp...

Page 135: ...ug OEM 1 EA 16D1585 Interlock Harness 1 EA 16D2617A00 Power Cable 8K P S 1 EA 16D2629A00 Harness 8K B P S MAIN 1 EA 32BAL01 Ballast 4 EA 32TRC08 Autoformer 208 225 240V 1 EA 33RLY02 Contactor 2 pole NO 30 1 EA 33RLY04 Relay Sealed 2 EA 39BLO23 Blower mdl ball bearing 1 EA 44RUB11 Grommet Continuous 085 1 25 FT 52FUH04 Fuse Holder 3AG 3AB 1 EA 56FUS23 Fuse 4 Amp 250V Slo BLo 1 EA 62D2723A00 Assembl...

Page 136: ...16 10 94MS36 Rev F2 S W Ver 2 06 ...

Page 137: ...quipment 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 periodically ...

Page 138: ...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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