BGK AutoCure Infrared Portable Curing Owner's Manual

Add to My manuals
66 Pages

advertisement

BGK AutoCure Infrared Portable Curing Owner's Manual | Manualzz

Auto C ure 8 000

Portabel Panel Heaters

Assembly and Operating Manual

AC8-4350 TABLE OF CONTENTS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

WARNINGS AND DANGER ............................................................................................................ 4

• WARNING, CAUTION & NOTE .......................................................................................... 5

EQUIPMENT SAFETY GUIDELINES

CAUTION ............................................................................................................................ 6

Lamps, Pyrometer Positioning Beam & Environment ......................................................... 7

OPERATING INSTRUCTIONS

Temperature Controllers Single or Double Ramp Operation .............................................. 8

Temperature Controller Displays ........................................................................................ 8

Cycle Start Button & Heater Position .................................................................................. 8

Setting the Temperature Controller Parameters ................................................................. 9

LAMP INSTALLATION AND REPLACEMENT INSTRUCTIONS

DANGER!!

Precautions for Handling Quartz Infrared Lamps ........................................... 10

CAUTION!! Lamp Instruction/Replacement Procedure .................................................... 10

HEATER POSITION INSTRUCTIONS

General Instructions .......................................................................................................... 11

Heat Masking .................................................................................................................... 12

Positioning/Set-up of Heater Head Instructions (2 pgs)............................................... 12-13

MAINTENANCE

Gas Spring & Pivot Points ................................................................................................. 14

Lamps, Reflectors and Heat Sensor (Pyrometer) Lens .................................................... 14

TROUBLESHOOTING GUIDE

Heater Power Problems .................................................................................................... 15

Temperature Controller Problems ..................................................................................... 16

Temperature Problems ..................................................................................................... 17

TEMPERATURE CONTROLLER ERROR CODES ...................................................................... 18

PYROMETER ASSEMBLY _DRAWING# AC-61231 (4 pgs) ................................................... 19-22

SERVICE INSTRUCTIONS FOR PYROMETER ........................................................................... 23

Old and New Raytek Units (2 pgs) ............................................................................... 24-25

Replacement of New Pyrometer Sensor (2 pgs) ......................................................... 26-27

Replacement of Pyrometer Controller (2 pgs) ............................................................. 27-28

11.

12.

• Verification / Calibration Procedure .................................................................................. 29

• Begin Verification / Calibration Cycle ..................................................................... 30

• Verify “Lock” Status of Raytek Comm Module ........................................................ 30

• Adjusting Raytek Calibration Procedure (3 pgs) ................................................ 31-33

Begin Calibration Cycle ........................................................................................... 33

Calibration Adjustment ............................................................................................ 34

“Lock” Out the Comm Box ................................................................................................ 35

AUTOCURE 8000 MODEL NUMBERS ........................................................................................ 36

• AC8-4350-480-SP ............................................................................................................. 37

Back Panel Assembly (2 pgs) ............................................................................ 38-39

Electrical Schematic ................................................................................................ 40

• Electrical Bill of Material (BOM) .............................................................................. 41

• Heater Heads (2 pgs) ......................................................................................... 42-43

• Mechanical Assembly.............................................................................................. 44

• Recommended Spare Parts .................................................................................... 45

AC8-4450-380-SP ............................................................................................................. 46

• Back Panel Assembly (2 pgs) ............................................................................ 47-48

• Electrical Schematic ................................................................................................ 49

Electrical Bill of Material (BOM) .............................................................................. 50

Heater Heads (3 pgs) ......................................................................................... 51-53

Mechanical Assembly.............................................................................................. 54

Recommended Spare Parts .................................................................................... 55

AC8-4450-480-SP ............................................................................................................. 56 •

Back Panel Assembly (2 pgs) ............................................................................ 57-58

Electrical Schematic ................................................................................................ 59

Electrical Bill of Material (BOM) .............................................................................. 60

Heater Heads (2 pgs) ......................................................................................... 61-63

Mechanical Assembly.............................................................................................. 64

Recommended Spare Parts .................................................................................... 65

AUTOCURE MODEL NUMBERS ................................................................................................. 66

1. Warnings and Danger

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.

EN

In this manual, the words WARNING , CAUTION and NOTE are used to emphasize important safety information as follows:

! CAUTION NOTE or or in in minor

! WARNING

Read the following warnings before using this equipment

READ THE MANUAL and maintenance

All

TRAINING must be before read and in the all safety, equipment.

PINCH POINT HAZARD

Moving parts can crush and cut. Pinch points are basically any areas where there are moving parts.

STATIC CHARGE

Fluid may develop a static charge that must be dissipated through proper grounding of the equipment, objects to be sprayed and all other electrically conductive objects in the dispensing area. Improper grounding or sparks can cause a hazardous condition and result in fire, explosion or electric shock and other serious injury.

EQUIPMENT HAZARD can cause the and result in injury.

to or start

WEAR RESPIRATOR

Toxic fumes can cause serious injury or death if inhaled. Wear a respirator as recommended by the fluid and solvent manufacturer’s Safety Data Sheet.

LOCK OUT / TAG OUT

Failure to de-energize, disconnect, lock out and tag-out all power sources before performing equipment maintenance could cause serious injury or death.

TOXIC FLUID & FUMES

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, injected or swallowed. LEARN and KNOW the specific hazards or the fluids you are using.

AUTOMATIC EQUIPMENT

Automatic equipment may start suddenly without warning.

PRESSURE RELIEF PROCEDURE

Always follow the pressure relief procedure in the equipment instruction manual.

KEEP EQUIPMENT GUARDS IN PLACE

Do not operate the equipment if the safety devices have been removed.

KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE

OF AN EMERGENCY

WEAR SAFETY GLASSES

Failure to wear safety glasses with side shields could result in serious eye injury or blindness.

INSPECT THE EQUIPMENT DAILY

Inspect the equipment for worn or broken parts on a daily basis. Do not operate the equipment if you are uncertain about its condition.

NEVER MODIFY THE EQUIPMENT

Do not modify the equipment unless the manufacturer provides written approval.

FIRE AND EXPLOSION HAZARD

Improper equipment grounding, poor ventilation, open flame or sparks can cause a hazardous condition and result in fire or explosion and serious injury.

MEDICAL ALERT

Any injury caused by high pressure liquid can be serious. If you are injured or even suspect an injury:

Go to an emergency room immediately.

Tell the doctor you suspect an injection injury.

Show the doctor this medical information or the medical alert card provided with your airless spray equipment.

Tell the doctor what kind of fluid you were spraying or dispensing.

GET IMMEDIATE MEDICAL ATTENTION

To prevent contact with the fluid, please note the following:

Never point the gun/valve at anyone or any part of the body.

Never put hand or fingers over the spray tip.

Never attempt to stop or deflect fluid leaks with your hand, body, glove or rag.

Always have the tip guard on the spray gun before spraying.

Always ensure that the gun trigger safety operates before spraying.

PROP 65 WARNING

WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

NOISE HAZARD

You may be injured by loud noise. Hearing protection may be required when using this equipment.

PROJECTILE HAZARD

You may be injured by venting liquids or gases that are released under pressure, or flying debris.

of the to It is the

For www.carlisleft.com this see the to the of the

AutoCure 8 000 - All Models

Operating and Assembly Manual (Revised 0 4 /2021)

2. Equipment Safety Guidelines

(Read and understand this manual before operating equipment.)

CAUTION!!

1. Turn power off at source before servicing equipment or attempting any electrical or mechanical maintenance, especially lamp replacement.

2. If the control panel main power switch is ON, voltage may exist at the lamps even though the lamps are not emitting light. AN ELECTRICAL SHOCK COULD POSSIBLY

RESULT!

3. Heater head(s) contains high voltage. Do not insert metallic objects into cooling louver openings.

4. Before applying supply power, make sure the AutoCure arm(s) are grounded properly before equipment operation.

5. Before each operation of the AutoCure arm(s), inspect the repair arm(s) heater lamp(s). If any lamps are broken or break at any time, shut the power off and discontinue use. When the damaged or broken lamp(s) are replaced by the qualified personnel, turn the power back on.

6. This is an automatic piece of equipment. Heater can very quickly come on to full intensity without warning to unaware personnel.

7. Heater surfaces can become hot when used at high power for extended periods. Use caution whenever handling heater head(s). The heater head(s) have black insulated handles to use for moving or manipulating heater head(s).

8. Do not move heater when in operation because it will move the temperature sensor viewing area and the heater head's distance to product. If the heater accidentally moves, check temperature sensor viewing area with the "Positioning Beam" and verify acceptable positioning of heater head.

9. Use care when manipulating or positioning heater head(s) and arms. Avoid possible pinch points.

10. The positioning beam/pyrometer must be aimed at the surface target to be heated.

If it is not properly aimed at the surface target, (i.e. aimed into open air) the pyrometer will read a lower temperature causing the unit to go to high lamp intensities for abnormal time lengths. If used in this condition for extended period of time, it can damage the unit.

11. When the unit is NOT in operation, the E-stop button MUST be pressed for safety of personnel, unit, and other material/equipment in vicinity of the heater head(s).

LAMPS

All lamp end covers and grills must be installed before operating and using the repair arms to avoid electrical shock.

The lamps of the repair arms have similarities to a standard incandescent light bulb. During the repair arm curing cycle, the repair arm lamps can sometimes emit bright light similar to a standard incandescent light bulb. As you would with an incandescent light bulb, we high recommend you

DO NOT STARE DIRECTLY INTO THE BRIGHT LIGHT.

DO NOT HANDLE INFRARED LAMPS WITH BARE HANDS. Remove any contamination with alcohol and a clean, soft cloth. Contamination on quartz tubes allows the quartz to overheat, which leads to premature lamp failure.

PYROMETER POSITIONING BEAM

A class 2 laser emits in the visible region (635-870mN) at 1mW of power. The blink reflex of the human eye (aversion response) will prevent eye damage, unless the person deliberately stares into the beam for an extended period.

DO NOT STARE INTO THE BEAM.

ENVIRONMENT

Heater head contains high voltage connections that are open to atmosphere. These units are not air-purged. Ensure use of unit is acceptable in the area in which it will be used.

3. Operating Instructions

Temperature Controller Single or Double Ramp Operation (See Figure 1)

Single Ramp Operation: The temperature ramps in a predetermined amount of time from ambient to a set point temperature and holds at that temperature for a required amount of time.

Double Ramp Operation: The temperature ramps in a predetermined amount of time from ambient to the first set point temperature and holds at that temperature for a required amount of time, it then ramps in a predetermined amount of time to a second set point temperature and holds at that temperature for a required amount of time.

Temperature Controller Displays

The upper display 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) has been reached the upper display will toggle between the hold time remaining (in minutes) and the process temperature. When the hold time becomes less than one minute the upper display will toggle between the hold time remaining (in seconds) and the process temperature. The lower display indicates the cure temperature (set point).

Cycle Start Button

The product will heat to the set point temperature and remain there for the time selected. The hold time will start when the temperature reaches 15°F before set point.

Heater Position

If the heater is too far from the product, the temperature will not be reached and the hold timer will not be activated.

Setting the Temperature Controller Parameters (See Figure 2)

Single Ramp

1. Turn Power On

2. Turn positioning beam on and position heater.

3. Set controller parameters

4. Hold the [Q] button for 1-2 seconds a. Set rp1 (ramp time) in minutes0[Yl

Press§] b. Set ct1 (cure temp) in degrees [K)[y)

Press §] c. Set hd1 (hold time) in minutes [K)[y)

Press� d. Set rp2 = 0 (this disables 2 nd ramp)

Press §]

5. Press the [Q] to exit setup menu

6.

C hoose the number of heaters desired.

7. Press cycle start

...

'

Au t oCu re ™ 8000

*: m<aru,

I

, .,

.....

---

Eit • Jws .. , ....... l l:-..'..jt----n ..

174'1' ........

[ A " �

.

l.

� t� ..... -·,..

-

'"::.:ae

..

_.:.,.,

.

..,

..

-w.

•jy 1

-·-

f_ i: ·

L .. t� ,,_ __ , .. 1 !!JU(.: f-•IJ8•,-.•-1YT ... ftn<

"".,..._

.:..

� • .,,� ....

...,iu, , ..._..., j.

IF

� �·

·

,.., •

Figure 2

Double Ramp

1. Turn Power On

2. Turn positioning beam on and position heater.

3. Set controller parameters

4. Hold the [Q] button for 1-2 seconds a. Set rp1 (ramp time) in minutes [K)[y)

Press� b. Set ct1 (cure temp) in degrees [K)[y)

Press� c. Set hd1 (hold time) in minutes 0[Yl

Press � d. Set rp2 (2 nd ramp time) in minutes CK) [y)

Press� e.

Set ct2 (2 nd cure temp) in degrees

Press §]

5.

Press the [Q] to exit setup menu

6.

C hoose the number of heaters desired

7.

Press cycle start

0(y] f.

Set hd2 (2 nd hold time) in minutes0[Yl

Press �

4. Lamp Installation and Replacement Instructions

Danger!!

Turn power off at source before removing end covers and servicing lamps. A fatal electrical shock could possibly result.

Precautions

for Handling Quartz Infrared Lamps

Do not handle infrared lamps with bare hands. Remove any contaminations with alcohol and a clean, soft cloth. Contaminations on quartz tubes cause the quartz to overheat, which may lead to premature lamp failure.

Caution!!

If lamps are replaced, with lamps having metal ends, metal ends must be removed to permit proper 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 covers to gain access to lamp leads.

4. Disconnect wire from the ceramic terminal block and remove lamp that is being replaced.

5. Carefully slide the lamp through the lamp support.

6. Remove electrical insulation sleeves from the old lamp on both lamp leads and install them on the new lamp leads. Push the sleeve to the ceramic end of the lamp (see drawing below).

7. Secure the lamp lead to the power wire coming into the heater at the ceramic terminal block.

8. Install end covers.

NOTE: If lamp leads are too tight, damage to lamp may result.

Make sure lamp sleeving is pushed all the way into ceramic end of lamp

Lamp Support

(outer reflector)

End Cover

Ceramic terminal in heater head

Ensure all bare wire is

contained up to terminal

(trim lead if necessary) Heater Power Co

5. Heater Position Instructions

Important: Precautions and Instructions

General Instructions (Read All)

1.

The "Positioning Beam" (red dot) is an aid for proper placement of the heat sensor. The heat sensor reads an area of 0.8 to 1.2" diameter depending on the heater's distance from the surface. The sensor takes an average temperature reading of the area and displays it on the temperature controller. Note: the red dot is not at the exact center of the sensing area. As you face the control panel the dot is 3/4" to the left of the heat sensor.

2.

Make sure the heat sensing area is reading a painted surface. If the sensing area is positioned incorrectly and is partially reading tape, masking, trim, plastic, rubber, a window, or a wheel well, it will measure an average temperature much higher or lower than the actual temperature of the painted surface. Thus, the heater will possibly overheat the area and scorch the paint, or not heat the part enough and the paint will not be cured.

3.

The heater head distance from the product is important. If the heater head is too far away, the product will not reach cure temperature and will run indefinitely trying to get to temperature. If the heater head is to close "striping" may occur. The recommended distance of the heater face to the product is 8 -12". The heater should be as parallel as possible to the product surface, which helps maintain uniform heating over the heated area.

4.

Before heating a repair, determine if there are 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 without reinforcements. Aim the heat sensor on, or near, the multiple thickness or reinforced areas so they will be fully cured.

5.

Once the cycle has started, do not move the unit. This will cause the temperature sensor to "see" a different area, which may be cooler. If the temperature drops 18°F , it will reset the timer and run another complete cycle. To help the unit's stability, be sure to lock the casters on the base of the arm after positioning the heater to lock it in place.

6.

Check the control panel 3 to 5 minutes into the cycle. See if the temperature has risen to set point and if the timer has started. If it hasn't, determine the problem and correct it. If there is a problem with the position or setup of the arm where it cannot achieve the set point temperature, the timer will not turn on. The heater will run at full intensity indefinitely.

7.

To achieve a full cure on a repair area, including overspray, the "effective cure area" of the heater must be considered. The "effective cure area" of the rectangular shaped heater heads is an oval shape that is just slightly smaller than the heater head. A general rule for the "effective cure area" dimensions are 1" in from the sides and end covers of the heater head, which creates the outer boundaries of the oval. When main and auxiliary heater heads are used together, add the two areas together.

Heat Masking

1. Any heat sensitive materials or surfaces (including plastic, rubber, trim, pin stripes, decals, light lenses, mirrors, door handles, interior materials, etc.) in the heating area must be masked or removed during the heating cycle. High temperature/reflective masking material approved for this type of application is required.

2. When curing small areas, it is not recommended to use heat masking around the area except to cover heat sensitive materials. The heat sensor "sees" an area approximately 1" in diameter, a heating area that is 1.5" or smaller could result in a false reading if the heat sensor is reading the masking.

Positioning / Set-Up of Heater Head Instructions

Positioning / Set-Up of an arm on flat surfaces (doors, hood, roofs, trunk lids, etc.)

1. Follow any of the instructions previously mentioned in the precautions and instructions section.

2. Always position heaters parallel and 8 to 12" from the surface.

3. Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive materials.

4. Engage caster locks.

5. Recheck 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 has started.

9. When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.

10. Press the E-stop button on unit when cycle has completed before moving unit to next repair or in to storage position.

4.

5.

6.

7.

8.

Positioning / Set-Up of a heater on a curved or contoured surfaces (fender, hood, roof, trunk corners)

1.

2.

3.

9.

10.

Follow any of the instructions previously mentioned in the precautions and instructions section.

Always position heaters parallel and 8 to 12" from the surface. Adjust the A and B heaters to the contour of the curve, with the most direct heat radiation in the area of the repair.

Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive materials.

Engage caster lock.

Recheck heat sensor aim with the positioning beam.

Set the temperature and time settings.

Start heat cycle.

Approximately 3-5 minutes after start, check that the temperature is at set point and the timer has started.

When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.

Press the E-stop button on unit when cycle has completed before moving unit to next repair or in to storage position.

Positioning/Set-Up of an arm on roof posts (heavy reinforcements/multiple metal thickness)

1. Follow any of the instructions previously mentioned in the precautions and instructions section.

2. Position heaters parallel to the surface, the length of the heater along the length of the roof post. Do not put the heater 90° to the post, unless the repair area is very small.

The heater should be about 8" from the surface for the heavy reinforcement in the posts.

3. Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive materials. The post is very narrow, so carefully position the heat sensor where it will "see" the post.

4. Engage caster lock.

5. Recheck 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 has started.

9. When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.

10. Press the E-stop button on unit when cycle has completed before moving unit to next repair or in to storage position.

4.

5.

6.

7.

8.

Positioning/Set-Up of an arm on rocker panels (heavy reinforcements/multiple metal thickness)

1.

2.

3.

9.

10.

Follow any of the instructions previously mentioned in the precautions and instructions section.

Position heaters parallel to the surface, the length of the heater along the length of the rocker panel. If there is an auxiliary heater head, use both heaters and bend them at about a 135° angle to focus more direct heat around the curve of the rocker panel. The heater should be spaced about 8" from the surface for the heavy reinforcement in the rocker panel.

Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive materials

Engage caster lock.

Recheck heat sensor aim with the positioning beam.

Set the temperature and time settings.

Start heat cycle.

Approximately 3-5 minutes after start, check that the temperature is at set point and the timer has started.

When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.

Press the E-stop button on unit when cycle has completed before moving unit to next repair or in to storage position.

6. Maintenance

The AutoCure™5000 will require some basic maintenance when used on a regular basis. Failure to do so may degrade the performance of the unit.

Disconnect main power at the source before performing any maintenance procedures.

Gas Spring

1. Check nylock nut connecting the gas spring for tightness monthly. Check gas spring for leaks, If gas spring becomes weak, raising the heater will become difficult.

Pivot Points

1. Single head units have three (3) 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 points 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 points monthly.

3. To adjust spring tension; remove cotter pin, tighten castle nut (usually one or two notches) and replace cotter pin through bolt.

Lamps, Reflectors and Heat Sensor (Pyrometer) Lens

1. Clean with soft cloth and alcohol monthly. Heat sensor accuracy is dependent on a clean lens.

Tension Spring/

Castle Nut (2)

Single Head

Tension Spring/

Castle Nut

Dual Head

Pyrometer

Nylock Nut

Tension Spring/

Castle Nut (4)

(under heater skin)

Tension Spring/

Castle Nut (2)

7. Troubleshooting Guide

Heater Power Problems

Problem

Heater lamps come on immediately when disconnect is closed.

Possible Cause and Corrective Action

With power OFF, measure the resistance from the lamp wires to ground. The measurement should be more than 100 K ohms. If it is less than 100 K, check the lamp wiring and heater head for shorts to ground. Check for a bad firing circuit board or a shorted 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 component.

Contactor held closed – failed ON. Replace the contactor.

Problem

Heater lamps do not come on.

Possible Cause and Corrective Action

Is the Power On/Off button illuminated, is the temperature controller on? - Check that incoming line power is present; transformer fuses, primary and secondary are good.

Do the contactors energize when the Cycle Start button is pressed? – Check for loose wires associated with the contactors,change the temperature controller.

Check that the set point (bottom display) is higher than the process temperature (top display).

Are the line fuses in front of the contactors good – check voltage on the load side of the fuses or remove the fuses and check with an ohmmeter.

• Is the green LED on the firing circuit lit? – Check that the firing circuit has 24 vac, with an ammeter check that the 4-20ma input signal is present from the temperature controller. If the 4-20ma signal is not present, see the section “No Output Signal from Temperature Controller”.

• Do any of the zones function? – If the above points have been checked, confirm that there is a complete circuit through the lamps and all wiring is tight – change the

SCR.

Are all zones dead? – Zone A should function regardless of the zone switch setting, there is only one firing circuit for all zones - change the firing circuit

Temperature Controller Problems

Problem

Temperature controller has no display.

Possible Cause and Corrective Action

Check the supply voltage (24 VAC) to the unit at terminals 11 and 12. If voltage is present, replace the controller. If voltage is not present, check source of power (fuses, transformers, wiring, etc.)

Problem

No output signal from temperature controller.

Possible Cause and Corrective Action

• Check that the set point (bottom display) is higher than the process temperature

(top display).

• Check the 0-5v input to the temperature controller at pins 9 & 10. If the 0-5v signal is not present, confirm that the Raytek pyrometer is functioning.

• Is the LCD display lit? If not, check that the Raytek input power (12 vdc) is present, check that the power supply board is supplying 12 vdc (TB 4) – replace the temperature controller, Raytek, or the power supply board.

Problem

Temperature controller output signal is present, but heater lamps do not come on.

Possible Cause and Corrective Action

Possible defective power controller firing circuit board and/or SCR. Check for a bad firing circuit 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 component.

Temperature Problems

Problem

The heater reaches set-point temperature, but the paint isn't cured properly or is darkened, or the heater does not reach set-point temperature.

Possible Cause and Corrective Action

• Read the instructions in the manual on how to position and run the heater.

• Clean the temperature sensor lens as described in maintenance section.

• The optical pyrometer is not seeing the surface of the object being heated. The pyrometer has about a 1-inch diameter field of view on the objects’ surface. Position the heater head with the pyrometer so it sees the surface being heated. Make sure the pyrometer is not seeing parts of a window, wheel well, tape, masking, etc.

Problem

The temperature display jumps up or down many degrees within a second.

Possible Cause and Corrective Action

• Check for loose connections on the heat sensor (pyrometer) wiring.

• While the heater is running at temperature, gently wiggle the pyrometer cable and have someone watch for sudden temperature changes. If this happens – replace the cable.

Problem

Positioning Beam does not work

Possible Cause and Corrective Action

Check that the power supply board is supplying approximately 3.25 vdc (TB 3). Check that the wires are secure on the power supply board and on the push button. Open the cover on the

H eat sink assembly on the back of the heater and retest for the 3.25 v. If the power supply 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.

8. T

emperature

C

ontroller

E

rror

C

odes

Display

Err.H

Err.L

LPbr

0100

0101

0202

0303

3865

36 Plus other

2 digit code

Problem

Open Sensor

Reversed Sensor

Loop Break

Checksum Error

RAM Error

Defaults Loaded

EEPROM Write Failure

Power Fail Resume

Feature Disabled

Unexpected or invalid interrupt

Ramp/ Soak Errors

02= Recipe Empty (i.e. no non-zero ramp times)

05= Insufficient Setpoint - Process Value Deviation

Actions

Check sensor,wiring, and input

Check Sensor polarity

Correct problem and

Reset controller

Press Any Key to perform a soft reset and reinitialize controller

No further resume actions available

Reset Controller

10.

Service Instructions For Pyrometer

RAYTEK PYROMETER REPLACEMENT CALIBRATION VERIFICATION ON

OVERHEAD OR PORTABLE REPAIR ARM USING A HAND HELD PYROMETER

(Raytek MID Pyrometer with BGK Temperature Controller ONLY)

Purpose:

This procedure is to be completed to verify the temperature display is correct on the

BGK temperature controller. Then the BGK “ Auto-Cure ” series repair arms will heat the painted spot repair to the correct temperatures to achieve the proper cure of the paint.

Equipment Required:

 Hand-held Infrared pyrometer in good working order with a current calibration label. Pyrometer with laser aiming is preferred.

 A good condition scrap painted door, fender, or test panel on which to perform the calibration is required. (White or light color is preferred).

 A #1 Phillips screwdriver.

RAYMID10LT Pyrometer Sensor manufactured by Raytek has been discontinued. It has been replaced by model number RAYMI3D10LTS. This Change affects the following

Autocure units AC3, AC5, AC6 & AC7, and AC8.

Shown below are photos of the differences between sensors:

OLD UNIT (RAYMID10LT)

Sensor Connections –

Brown, white, green and yellow remain the same colors between old and new units.

NEW UNIT (RAYMI3D10LTS)

Power Connections –

Black Wire – GND next to +8-32V

Red Wire – +8-32V

White Wire – OUT2

Blue Wire – GND next to TC

Additional modifications required – The AWG gage size of the laser wires that are typically connected inside the sensor with wire nuts. The wire gauge will be changing from 20 AWG to 22 AWG effective upon change over in February 2015.

Figure 1-3

Figure 1-4

The new unit is hinged as shown in Figure 1-3.

Performance - the new sensor is equal, a direct replacement to the older unit. There is no change in emissivity or response time between units, they are equal.

The front cover over lay is solvent resistant. Figure 1-4.

Both the old and new Raytek units are not rated for hazardous environment nor are they ATEX approved.

They are CE rated only.

Replacement of New Pyrometer Sensor

1. Open Cover for Raytek Sensor, loosen and remove wire from terminals shown below.

2. Undo wires from two wire nuts, as shown.

3. Loosen nut on pyrometer side, and remove wires from housing.

4. Open enclosure on top of heat sink, and isolate wires for laser (black/red leads)

5. Clip leads, leaving enough wire to strip and re-connect with crimp connections

6. Loosen and remove standoffs

7. Remove insulating plate

8. Remove heat sink, then remove pyrometer.

9. Install new pyrometer into heat sink, making sure to adjust fit using varnish tape wrapped on the outside.

10. Install heat sink onto lower insulators

11.Install intermediate plate

12.Crimp laser leads to leads in pyrometer bundle – red to green and brown to black.

13.Install standoffs

14.Replace cover and tighten nuts.

15.If new pyrometer, replace grommet into side of housing.

16.Reconnect leads in Raytek sensor housing using schematic in Step 1.

17.Reconnect wires in wire harness as shown above.

Replacement of Pyrometer Controller

1. Open Housing and loosen 4 terminals to remove pyrometer. Loosen 4 terminals to remove connection to AutoCure Arm as shown below.

Black

2. Open New Housing, and loosen 4 terminals as shown above to remove pyrometer.

3. Disconnect wires in wire nuts.

4. On New Housing, Loosen and remove nut, grommet, and three washers on thermocouple 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 installed, insert leads for thermocouple into terminals indicated in Step 1.

8.

Insert and tighten down to 20 Nm.

9.

From AC arm, insert nut, AC-200104 Nylon washers and Grommet, similar to diagram in step 5.

10.

Insert leads into terminals indicated in step 1. Reconnect leads into wire terminals.

11.

Tighten down nut to 20 Nm.

12.

Verify calibration per SI-B-11-02.1 (see next page).

Verification / Calibration Procedure

1.

Position the good condition testing surface (door, fender, etc.) in front of the heater head. Adjust the heater head about 10” away from the painted test surface. (Approx.

an open hand width.)

2. On the good condition, scrap painted testing surface with a pen, pencil or grease pen make a small “X” or dot where the surface is mainly flat and there are NO reinforcements or multiple thickness metals within about

12 inches of the mark.

3. Then on the arm control panel, push the “Positioning

Beam On” button. Locate the positioning beam (red dot) on the test surface on the “X” or dot you made above. Make sure you maintain the 10-inch gap between the test surface and the heater head. This dot is also the point where the hand-held pyrometer will be aimed during calibration to read the same area the arm pyrometer is reading (temperature reading area). Again, ensure the red dot is not aimed at areas with reinforcements or multiple thickness metals within about

12 inches of the dot.

Begin Verification / Calibration Cycle

1.

Verify that the Ramp 1 and Ramp 2 (if used) cure temperatures (ct1 and ct2) settings are at the proper temperature set points used for the area.

2.

Press the “Cycle Start” button two times with in two seconds .

Lamp cycle should begin with a ramp-up to the final cure ramp settings. They will be “rp1” set points on a single ramp setup and “rp2” on a dual ramp setup. (See figure A). The temperature set point will be displayed on the bottom display of the temperature controller. The upper display will alternate between “rp_” and the actual temperature feedback from the pyrometer.

After the “rp_” has completed the ramp and flashing, the hold cycle will begin with a constant temperature on the upper display at the “ct_” set point.

Using the handheld pyrometer, measure the temperature of the target about 1” to the right of the positioning beam spot. (Figure D). Hold the hand-held pyrometer as close to 90° to the testing surface as possible by the edge of the heater head. This is critical for an accurate and consistent reading.

3.

Compare the handheld reading with the process temperature (upper display) on the temperature controller. If they are within 5 degrees, no further changes are required. If they are not, continue with doing the following calibration procedure.

Verify "Lock" Status of Raytek Comm Module

1. Verify lock status on Raytek box – Observe the display for a “Padlock” on the screen as shown. If the icon is displayed the unit is “Locked out” preventing any parameter changes. Complete steps below to “Unlock” the unit, otherwise continue with next section.

2.

The unit can be unlocked by pressing the button and the simultaneously for 3 seconds or alternatively by pressing the seconds.

button

button for 5

Adjusting Raytek Calibration Procedure

1. Verify correct settings on Raytek box – Press the page button

“BOX SETUP” is displayed.

until

OUT2 Mode

Using the arrow keys until “OUT2 Mode” is displayed. Verify the setting for mode is 0-5V. If the setting is incorrect, press the enter button and the setting should be highlighted. Press the arrows keys until the correct settings is display, 0-5V. After settings is correct, press the enter button

to save setting.

OUT2 Value

Using the arrow keys until “OUT2 Value” is displayed. Verify the setting for mode is “Tobject”. If the setting is incorrect, press the enter button and the setting should be highlighted. Press the arrows keys

After settings is correct, press the enter button setting. until the correct settings is display, “Tobject”.

to save

Temperature Unit

Using the arrow keys until “Temperature Unit” is displayed. Press the enter button and the setting should be highlighted. Press the arrows keys

until the correct setting is displayed, ˚F or ˚C. After settings is correct, press the enter button to save setting.

2.

Position the testing surface (door, fender, etc.) in front of the heater head. Adjust the heater head about 10” away from the painted test surface. (Approx. an open hand width.)

3.

On the scrap painted testing surface with a pen, pencil or grease pen make a small “X” or dot where the surface is mainly flat and there are NO reinforcements or multiple thickness metals within about 12 inches of the mark.

4.

Then on the arm control panel, push the “Positioning

Beam On” button. Locate the positioning beam (red dot) on the test surface on the

“X” or dot you made above. Make sure you maintain the 10-inch gap between the test surface and the heater head. This dot is also the point where the hand-held pyrometer will be aimed during calibration to read the same area the arm pyrometer is reading (temperature reading area). Again, ensure the red dot is not aimed at areas with reinforcements or multiple thickness metals within about

12 inches of the dot.

Begin Calibration Cycle

1.

Verify that the Ramp 1 and Ramp 2 (if used) cure temperatures (ct1 and ct2) settings are at the proper temperature set points used for the area.

2.

Press the “Cycle Start” button two times with in two seconds .

Lamp cycle should begin with a ramp-up to the final cure ramp settings. They will be “rp1” set points on a single ramp setup and “rp2” on a dual ramp setup. (See figure A). The temperature set point will be displayed on the bottom display of the temperature controller. The upper display will alternate between “rp_” and the actual temperature feedback from the pyrometer.

After the “rp_” has completed the ramp and flashing, the hold cycle will begin with a constant temperature on the upper display at the “ct_” set point.

Using the handheld pyrometer, measure the temperature of the target about 1” to the right of the positioning beam spot. (Figure D). Hold the hand-held pyrometer as close to 90° to the testing surface as possible by the edge of the heater head. This is critical for an accurate and consistent reading.

Compare the handheld reading with the process temperature (upper display) on the temperature controller. If they are within 5 degrees, no further calibration is required. If they are not, continue with the calibration.

Calibration Adjustment

1.

Depress the page button

until “BOX SETUP” is displayed. Press the arrow buttons until “OUT2 high temp” is displayed. Press the enter button to allow the temperature setting to be changed.

2.

If the reading on the handheld pyrometer is higher than that of the process temperature on the temperature controller, decrease the temperature number using the down button . After adjusting the value press the enter button to save the value.

3.

If the reading on the handheld pyrometer is less than the process temperature on the temperature controller, increase the temperature number using the up button

. After adjusting the value press the enter button to save the value.

4.

When you are within 5 degrees difference between the handheld pyrometer and the process temperature, no further calibration is required.

Calibration is complete.

5.

Press the page button until display returns to main screen.

“Lock” out the Comm Box

1.

Press the page button until “BOX SETUP” is displayed.

Key Enter Lock

2.

Using the arrow keys until “Key Enter Lock” is displayed. Verify the setting “YES”. If the setting is incorrect, press the enter button and the setting should be highlighted. Press the arrows keys until the correct settings “Yes” is displayed. After settings is correct, press the enter button to save setting.

3.

Verify the padlock is displayed as shown.

Procedure is completed.

AUTOCURE MODEL NUMBERS

AC

8

-

4350-480

AC5-

4450-380

AC5-

4450-480

AC 8-4350-480 -SP

ELECTRICAL BILL OF MATERIAL (BOM)

TO ORDER:

CONTACT: SPARE PARTS ORDER ENTRY

PHONE: 1-800-726-8097

E-MAIL: [email protected]

AC8-4 3 504 80

110

121

110

121

122

103

107

HDCRD

HDCRD

HDGRD

117

LINCRD

LINCRD

LINGRD

111

111

111

110

Reference

Number

116,117

101

ENCL

ENCL

114

114A,114B

107A,107B

114A,114B

Qty Part Number

2 E-835

1 E-225

1 018839

1

2

2

2

2

063753

038120

E-641

E-143

AC-200070

101A,101B,104B,104A 4 048378

101,104 4 047859

Part Description

CONTACTOR,30A.24VAC

DISTRIBUTION BLK115A,1 IN 4 OUT

ENCLOSURE,INNER PNL,18 X 14

ENCLOSURE,CONCEPT,20 X 16 X 10

TERMINAL END ANCHOR

FUSE HOLDER,5x20,DIN MNT

FUSE,1A,600V,CLASS CC

FUSE,2A,250V,TIME DELAY,GLASS

FUSE,30AMP 600V CUBE

FUSE HOLDER,60AMP,CUBE

1 034777

14 AC-200115-4

35 000125

FUSE HOLDER,2 PLE,600V,30A,

CORD,CONNECTOR,3/4..500-.625D

CORD,TYPE SO,3-CONDUCTOR - #12

1 032570 GROUND LUG,3 CONDUCTOR,)

1 AC-74816-480-C-75 TEMPERATURE CONTROLLER

1 053666 CORD,CONNECTOR,3/4,0.750-0.88

30 000123

1 054481

CORD,TYPE SO,3-CONDUCTOR - #4,

LUG,ALUMINUM MECHANICAL,1 POLE

1 064296

1 067326

1 063920

1 E-985

1 AC-46847

1 075372

PUSH BUTTON,PWRMOD,24V,2NC,RED

PUSHBUTTON,CONTACT BLOCK, 2 NO

PUSH BTN,40MM MUSHRM HD,RED

PUSH BUTTON ,2 FUNC,MOMEN,FLUSH

POWER SUPPLY,24VAC - 12VDC & 3.25VDC

PWR CTRLR,480,3-30A,1-4-20,10

1 065265

3 064923

1 065184

1 E-2016

PUSHBUTTON,CONTACT BLK,1 NO,

PUSH BUTTON,1NC,EB

SELECTOR SW OP, 4 POS, MAINT

TRANSFORMER,25VA

-� �

I

-�

©

I

I

=

.

61.658

.

=

A

=

I

I

SYM

A

B

REVISION

DESCRIPTION

REPLACED LAMP WITH LAMP ASSY DRAWING

ADDED CERAMIC TERMINALS

BY

CTL

CTL

DATE

11126103

6121104

USE 118 ALUM RIVETS TO ATTACH

ITEM 5 TO ITEM 4

T

'

_f7V5\ ffi

+J

(

�-- .. p :

"

"

����

SECTION A-A

8

9

10

11

12

13

14

6

7

4

5

ITEM

1

2

3

15

2

2

1

1

1

1

2

4

QTY

4

30

4

2

12

3

2

Parts List

TYPE PART NUMBER p 002455 p 011799 p 021794 p 039917 p 047799 p 058833 p 059058

DESCRIPTION

#10-32 X 3/4 TRUSS HEAD SCREW

SCREW,MACH,TRUSS,PH,8-32 X .500,SST

SCREW,CAP,SOCKET HD,8-32 X .750

3/8 STUD HANDLE

#8-32 SST MACH. NUT

TERMINAL,3 POLE,CERAMIC,600V

SCREW,CAP,SOCKET HD,8-32 X .625

M AC-60819

M 61665-5

M AC-63940

M 64070

M 64071

M 64072

M AC-64098

M 67469

INSULATOR.END COVER,4 LAMP

ASSY,LAMP,T3 5000

J-BOX,HEATER

SKIN,4 LAMP,5000

REFLECTOR,INNER,4 LAMP,5000

REFLECTOR,OUTER,4 LAMP,5000

PLATE,REINFORCEMENT,HANDLE

ENDCOVER,4 LAMP,AC8000,4150

JOB NO: reproduced in any manner,norsubmitted to other parties

DRAWN fo<e,am;nationw;thout p'°;��:=�ES ar

39181

�t

-

---+= E

-

A

-

---J

DRAWN DATE·

A

� ;:

R

�1

.

CTL

NEXT ASSY:

65185

FINISH:

DEBURR SHARP EDGES m

MINNEAPOLIS MN

--

SCALE:

SIZE:

1:8 B 64069

I

!

DRAWING NO:

/2½

ASSY, H EATER,4150

-

-4

FLUID TECHNOLOGIES

SHEET:

1 OF 1

A

B

B

4

4

3 2 1

A

B

3

3

6

1

A

SECTION B-B

SCALE 1:8

5

4

8

1

2

24

10

2

4

2

7

1

11

1

3

1

4

DETAIL C

SCALE 1 / 4

3

3

9

2

C

SECTION A-A

SCALE 1:8

ITEM

1

2

3

4

5

6

7

8

9

10

QTY

4

24

3

2

4

1

2

2

1

1

M

M

M

M

M

M

M

TYPE

P

PART NUMBER

002455

P

P

011799

058833

60819

61665-5

63940

64086

64087

64098

67468

Parts List

DESCRIPTION

#10-32 X 3/4 TRUSS HEAD SCREW

SCREW,MACH,TRUSS,PH,8-32 X .500,SST

TERMINAL,3 POLE,CERAMIC,600V

INSULATOR,END COVER,4 LAMP

ASSY,LAMP,T3 5000

J-BOX,HEATER

REFL,INNER,4 LAMP,5000,SP PYRO MOUNT

REFL,OUTER,4 LAMP,5000,SPC PYRO MOUNT

PLATE,REINFORCEMENT,HANDLE

ENDCOVER,4 LAMP,AC8000,4150

QTY

11

2

1

REL BY

CTL

M 94444

ENG REL

SKIN,4 LAMP,5000,SPECIAL PYRO MOUNT

SHOP VENDER P.O. NO PROD REL DUE JOB NO

39649

BGK FINISHING SYSTEMS

DRAWN: SCALE: TOLERANCES

CTL

DATE: JOB NO:

2 PLACE FRACT.

` .030

` 1/32

3 PLACE ANGULAR

MINNEAPOLIS MN

THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS

IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT

AUTHORIZATION z 2016 BGK FINISHING SYSTEMS

ASSY,HEATER,4150,SPECIAL PYRO MOUNT

11/3/2010

MATERIAL: SEE P/L

` .030

`

FINISH:

MAINTAIN QUALITY FINISH

2

NEXT ASSY: PART NO:

65185

DRAWING NO:

B 94445

1

REV: SHEET:

1

OF

1

A

B

D

8

9

6

7

10

11

ITEM

1

2

3

4

5

12

13

1

4

2

2

1

1

QTY

4

2

4

9

1

1

2

M

P

P

P

P

P

M

M

P

P

P

P

4

TYPE PART NUMBER

P 008806

Parts List

DESCRIPTION

COLLAR SPLIT 1 1/2"

012695

054438

054439

054452

054488

058441

060022

074862

120507

22955T36

57416

64069

1/4 X 1.000 FLAT HEAD

HANDLE,ADJUSTMENT,1/4-20 STUD

CABLE,STEEL,1/8" DIA 1,700 LBS CAP.

SLEEVE,STOP,OVAL,1/8"

BLOCK,FLAT MOUNT,2" DIA,7/32 CABLE

WINCH,BRAKE,DLB800A

EYEBOLT,1/4-20 THREADED

CASTER,SWIVEL,6" DIA,2" WIDE

PANEL,SPACER,HEATER

BRAKE KIT,CASTER,6"

HOOK,CABLE

ASSY,HEATER,4150

19

20

21

22

23

24

ITEM

14

15

16

17

18

25

26

1

1

2

1

2

3

QTY

2

2

2

2

2

4

1

M

M

M

M

M

M

M

M

M

M

M

M

3

TYPE PART NUMBER

M 64076-1

Parts List

DESCRIPTION

WELD,BRACKET,FIXED

64076-2

64089

64090-1

64090-2

64091

64096

82898

85426

87233

94445

97188

AC-61231

WELD,BRACKET,FIXED

COVER,CLOSE-OFF

BRACKET,ROTATING

BRACKET,ROTATING

HINGE,HEATER

GUARD,4 LAMP,5000,SP

WELD,FRAME,FINAL,AC8

PANEL,MOUNT,CONTROL BOX

PANEL,SPACER,HEATER

ASSY,HEATER,4150,SPECIAL PYRO MOUNT

WEARSTRIP BLOCK

ASSY, PYROMETER

C

B

61.658

24.438

TRAVEL DISTANCE

FOR PYROMETER

24

1

20

3

RELEASE TENSION ON BRACKETS

JUST ENOUGH TO MOVE HEATERS.

POSTION HEATERS TO DESIRED ANGLE

AND THEN RETIGHTEN HANDLES.

DETAIL A

3

4

23

2

16

2

13

2

D

(3

)

12

.2

51

4

1

1

°

45

D

2

19

2

18

2

DETAIL B

14

2

23

2

17

2

A

10

2

B

8

1

6

1

SYM

A

B

C

REVISION

1

DESCRIPTION

ADDED HIGH SPEED WINCH

MODIFIED HEATER HEADS AND FRAME

REVISED & REPLACED FRAME

25

4

22

1

4

9

5

1

7

1

15

2

2 12

2 1

HEATER CONTROL PANEL

(WITH A/B/C SELECTOR SWITCH)

9

4

1

4

11

2

21

1

11

2

26

1

BY

CTL

CTL

CTL

DATE

6/17/04

6/23/04

11/30/07

D

C

B

APPROX. 40"

OF VERTICAL

TRAVEL

SECTION D-D

49.404

A

4 3

JOB NO:

39649

QTY AS SHOWN (-1): QTY OPPOSITE (-2):

2

REL DATE: PROJ MGR:

CTL

NEXT ASSY:

IMPORTANT NOTE: this print is confidential property of

Carlisle Fluid Technologies. It is not to be used or reproduced in any manner,nor submitted to other parties for examination without proir approval.

DRAWN:

CLAMEYER

DRAWN DATE:

6/22/2017

MATERIAL:

SEE P/L

TOLERANCES

2 PLACE : FRACT :

` .03

` 1/32

3 PLACE : ANGULAR :

` .015

`

FINISH:

DEBURR SHARP EDGES

MINNEAPOLIS MN

SCALE:

1:16

SIZE:

C

DRAWING NO:

65185

ASSY,AC8-4350

2 1

REV: SHEET:

1 OF 1

A

RECOMMENDED SPARE PARTS

TO ORDER:

CONTACT: SPARE PARTS ORDER ENTRY

PHONE: 1-800-726-8097

E-MAIL: [email protected]

AC8-4 3 504 80

Reference Number

107A,107B

114A,114B

101A,101B,104B,104A

117

103

103

Spares

Qty

4

1

3

2

4

6

Part number Part Description

E-143

AC-200070

048378

FUSE,1A,600V,CLASS CC

FUSE,2A,250V,TIME DELAY,GLASS

FUSE,30AMP 600V CUBE

AC-74816-480-C-75 TEMPERATURE CONTROLLER

002986 POWER CONTROLLER,SCR,30A

003317 PWR CTRLR,FIRING CIRCUIT,4-20ma

AC 8-4 4 503 80 -SP

ELECTRICAL BILL OF MATERIAL (BOM)

TO ORDER:

CONTACT: SPARE PARTS ORDER ENTRY

PHONE: 1-800-726-8097

E-MAIL: [email protected]

AC8-4 4 503 80

110

121

110

121

122

103

107

HDCRD

HDCRD

HDGRD

117

LINCRD

LINCRD

LINGRD

111

111

111

110

Reference

Number

116,117

101

ENCL

ENCL

114

114A,114B

107A,107B

114A,114B

Qty Part Number

2 E-835

1 E-225

1 018839

1

2

2

2

2

063753

038120

E-641

E-143

AC-200070

101A,101B,104B,104A 4 048378

101,104 4 047859

Part Description

CONTACTOR,30A.24VAC

DISTRIBUTION BLK115A,1 IN 4 OUT

ENCLOSURE,INNER PNL,18 X 14

ENCLOSURE,CONCEPT,20 X 16 X 10

TERMINAL END ANCHOR

FUSE HOLDER,5x20,DIN MNT

FUSE,1A,600V,CLASS CC

FUSE,2A,250V,TIME DELAY,GLASS

FUSE,30AMP 600V CUBE

FUSE HOLDER,60AMP,CUBE

1 034777

14 AC-200115-4

35 000125

FUSE HOLDER,2 PLE,600V,30A,

CORD,CONNECTOR,3/4..500-.625D

CORD,TYPE SO,3-CONDUCTOR - #12

1 032570 GROUND LUG,3 CONDUCTOR,)

1 AC-74816-480-C-75 TEMPERATURE CONTROLLER

1 053666 CORD,CONNECTOR,3/4,0.750-0.88

30 000123

1 054481

CORD,TYPE SO,3-CONDUCTOR - #4,

LUG,ALUMINUM MECHANICAL,1 POLE

1 064296

1 067326

1 063920

1 E-985

1 AC-46847

1 075372

PUSH BUTTON,PWRMOD,24V,2NC,RED

PUSHBUTTON,CONTACT BLOCK, 2 NO

PUSH BTN,40MM MUSHRM HD,RED

PUSH BUTTON ,2 FUNC,MOMEN,FLUSH

POWER SUPPLY,24VAC - 12VDC & 3.25VDC

PWR CTRLR,480,3-30A,1-4-20,10

1 065265

3 064923

1 065184

1 E-2016

PUSHBUTTON,CONTACT BLK,1 NO,

PUSH BUTTON,1NC,EB

SELECTOR SW OP, 4 POS, MAINT

TRANSFORMER,25VA

4

B

SECTION B-B

SCALE 1 / 8

A

B

A

10

11

12

13

14

15

6

7

4

5

8

9

ITEM

1

2

3

1

1

1

1

2

2

2

12

3

2

2

4

QTY

4

30

4

P

P

P

P

TYPE

P

P

P

M

M

M

M

M

M

M

M

PART NUMBER

002455

011799

021794

039917

047799

058833

059058

60819

61665-5

63940

64070

64071

64072

64098

67468

4

Parts List

DESCRIPTION

#10-32 X 3/4 TRUSS HEAD SCREW

SCREW,MACH,TRUSS,PH,8-32 X .500,SST

SCREW,CAP,SOCKET HD,8-32 X .750

3/8 STUD HANDLE

#8-32 SST MACH. NUT

TERMINAL,3 POLE,CERAMIC,600V

SCREW,CAP,SOCKET HD,8-32 X .625

INSULATOR,END COVER,4 LAMP

ASSY,LAMP,T3 5000

J-BOX,HEATER

SKIN,4 LAMP,5000

REFLECTOR,INNER,4 LAMP,5000

REFLECTOR,OUTER,4 LAMP,5000

PLATE,REINFORCEMENT,HANDLE

ENDCOVER,4 LAMP,AC8000,4150

A

3

3

12

1

4

2

2

13

1

11

1

2

30

9

4

14

2

C

B

DETAIL C

SCALE 1 / 4

6

3

8

2

15

2

SECTION A-A

SCALE 1 / 8

7

2

1

4

10

1

6

3

5

12

1

QTY ENG REL SHOP VENDER P.O. NO PROD REL JOB NO

39067

REL BY

CTL 1

BGK FINISHING SYSTEMS

DRAWN: SCALE: TOLERANCES

CTL

DATE: JOB NO:

2 PLACE FRACT.

` .030

` 1/32

3 PLACE ANGULAR

ASSY,HEATER,4150

MINNEAPOLIS MN

THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS

IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT

AUTHORIZATION z 2016 BGK FINISHING SYSTEMS

1/28/2011

MATERIAL: SEE P/L

` .030

`

DUE

FINISH:

MAINTAIN QUALITY FINISH

2

NEXT ASSY: PART NO: DRAWING NO:

B 95329

1

REV: SHEET:

1

OF

1

A

B

A

B

B

4

4

3 2 1

A

B

3

3

6

1

A

SECTION B-B

SCALE 1:8

5

4

8

1

2

24

10

2

4

2

7

1

11

1

3

1

4

DETAIL C

SCALE 1 / 4

3

3

9

2

C

SECTION A-A

SCALE 1:8

ITEM

1

2

3

4

5

6

7

8

9

10

QTY

4

24

3

2

4

1

2

2

1

1

M

M

M

M

M

M

M

TYPE

P

PART NUMBER

002455

P

P

011799

058833

60819

61665-5

63940

64086

64087

64098

67468

Parts List

DESCRIPTION

#10-32 X 3/4 TRUSS HEAD SCREW

SCREW,MACH,TRUSS,PH,8-32 X .500,SST

TERMINAL,3 POLE,CERAMIC,600V

INSULATOR,END COVER,4 LAMP

ASSY,LAMP,T3 5000

J-BOX,HEATER

REFL,INNER,4 LAMP,5000,SP PYRO MOUNT

REFL,OUTER,4 LAMP,5000,SPC PYRO MOUNT

PLATE,REINFORCEMENT,HANDLE

ENDCOVER,4 LAMP,AC8000,4150

QTY

11

2

1

REL BY

CTL

M 94444

ENG REL

SKIN,4 LAMP,5000,SPECIAL PYRO MOUNT

SHOP VENDER P.O. NO PROD REL DUE JOB NO

39649

BGK FINISHING SYSTEMS

DRAWN: SCALE: TOLERANCES

CTL

DATE: JOB NO:

2 PLACE FRACT.

` .030

` 1/32

3 PLACE ANGULAR

MINNEAPOLIS MN

THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS

IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT

AUTHORIZATION z 2016 BGK FINISHING SYSTEMS

ASSY,HEATER,4150,SPECIAL PYRO MOUNT

11/3/2010

MATERIAL: SEE P/L

` .030

`

FINISH:

MAINTAIN QUALITY FINISH

2

NEXT ASSY: PART NO:

65185

DRAWING NO:

B 94445

1

REV: SHEET:

1

OF

1

A

B

B

SYM

A

4

REVISION

DESCRIPTION

MODIFIED FRAME;ADDED NEW CASTER BRAKE

BY

CTL

DATE

3/7/17

12

.2

50

61.658

3

(3

)

12

.2

51

A

ITEM QTY TYPE PART NUMBER

1

2

3

4

5

6

7

4

2

4

9

1

1

1

P

P

P

P

P

P

P

008806

012695

054438

054439

054452

054488

058441

Parts List

DESCRIPTION

COLLAR SPLIT 1 1/2"

1/4 X 1.000 FLAT HEAD

HANDLE,ADJUSTMENT,1/4-20 STUD

CABLE,STEEL,1/8" DIA,1700 LBS

SLEEVE,STOP,OVAL,1/8"

BLOCK,FLAT MOUNT,2" DIA,7/32 CABLE

WINCH,BRAKE,DLB800A

8

9

11

13

14

15

16

1

4

1

2

2

2

2

P 060022

P 074862

M 57416

M 64069

M 64076-1

M 64076-2

M 64090-1

EYEBOLT,1/4-20 THREADED

CASTER,SWIVEL,6" DIA,2" WIDE

HOOK,CABLE

ASSY,HEATER,4150

WELD,BRACKET,FIXED

WELD,BRACKET,FIXED

BRACKET,ROTATING

25

26

27

40

41

42

ITEM QTY TYPE PART NUMBER

17

18

19

21

22

23

24

2

2

4

1

1

2

2

M

M

M

M

M

M

M

64090-2

64091

64096

84794

85426

87232

87233

Parts List

DESCRIPTION

BRACKET,ROTATING

HINGE,HEATER

GUARD,4 LAMP,5000,SP

WELD,FRAME,FINAL,AC8

PANEL,MOUNT,CONTROL BOX

PANEL,SPACER,HEATER

PANEL,SPACER,HEATER

3

1

1

4

1

2

M 87355

M 94445

M 95329

M 97188

M AC-61231

P 22955T36

COVER,CLOSE-OFF

ASSY,HEATER,4150,PYRO MOUNT

ASSY,HEATER,4150

WEARSTRIP BLOCK

ASSY, PYROMETER

BRAKE KIT,CASTER,6"

4 3

8

1

49.404

2

15

2

17

2

40

4

DETAIL B

13

2

20

3

25

3

13

2

24

2

21

1

5

1

4

9

6

1

19

4

26

1

2

2

23

2

11

1

A

B

21

1

16

2

18

2

9

4

40

4

DETAIL A

14

2

3

4

JOB NO

1 39620

BGK FINISHING SYSTEMS

DRAWN: SCALE: TOLERANCES

CTL

DATE: JOB NO:

2 PLACE FRACT.

MINNEAPOLIS MN

THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS

IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT

AUTHORIZATION z 2015 BGK FINISHING SYSTEMS

3 PLACE ANGULAR

ASSY,AC8-4450

5/1/2008

MATERIAL:

QTY

SEE P/L

REL BY

± .030

FINISH:

DEBURR SHARP EDGES

2

ENG REL SHOP VENDER

NEXT ASSY: PART NO:

P.O. NO

1

DRAWING NO:

84792

1

9

4

PROD REL

1

4

DUE

7

1

B

REV: SHEET:

A 1

OF

1

A

RECOMMENDED SPARE PARTS

TO ORDER:

CONTACT: SPARE PARTS ORDER ENTRY

PHONE: 1-800-726-8097

E-MAIL: [email protected]

AC8-4 4 503 80

Reference Number

107A,107B

114A,114B

101A,101B,104B,104A

117

103

103

Spares

Qty

4

1

3

2

4

6

Part number Part Description

E-143

AC-200070

048378

FUSE,1A,600V,CLASS CC

FUSE,2A,250V,TIME DELAY,GLASS

FUSE,30AMP 600V CUBE

AC-74816-480-C-75 TEMPERATURE CONTROLLER

002986 POWER CONTROLLER,SCR,30A

003317 PWR CTRLR,FIRING CIRCUIT,4-20ma

AC 8-4 4 50-480 -SP

ELECTRICAL BILL OF MATERIAL (BOM)

TO ORDER:

CONTACT: SPARE PARTS ORDER ENTRY

PHONE: 1-800-726-8097

E-MAIL: [email protected]

AC8-4 4 504 80

110

121

110

121

122

103

107

HDCRD

HDCRD

HDGRD

117

LINCRD

LINCRD

LINGRD

111

111

111

110

Reference

Number

116,117

101

ENCL

ENCL

114

114A,114B

107A,107B

114A,114B

Qty Part Number

2 E-835

1 E-225

1 018839

1

2

2

2

2

063753

038120

E-641

E-143

AC-200070

101A,101B,104B,104A 4 048378

101,104 4 047859

Part Description

CONTACTOR,30A.24VAC

DISTRIBUTION BLK115A,1 IN 4 OUT

ENCLOSURE,INNER PNL,18 X 14

ENCLOSURE,CONCEPT,20 X 16 X 10

TERMINAL END ANCHOR

FUSE HOLDER,5x20,DIN MNT

FUSE,1A,600V,CLASS CC

FUSE,2A,250V,TIME DELAY,GLASS

FUSE,30AMP 600V CUBE

FUSE HOLDER,60AMP,CUBE

1 034777

14 AC-200115-4

35 000125

FUSE HOLDER,2 PLE,600V,30A,

CORD,CONNECTOR,3/4..500-.625D

CORD,TYPE SO,3-CONDUCTOR - #12

1 032570 GROUND LUG,3 CONDUCTOR,)

1 AC-74816-480-C-75 TEMPERATURE CONTROLLER

1 053666 CORD,CONNECTOR,3/4,0.750-0.88

30 000123

1 054481

CORD,TYPE SO,3-CONDUCTOR - #4,

LUG,ALUMINUM MECHANICAL,1 POLE

1 064296

1 067326

1 063920

1 E-985

1 AC-46847

1 075372

PUSH BUTTON,PWRMOD,24V,2NC,RED

PUSHBUTTON,CONTACT BLOCK, 2 NO

PUSH BTN,40MM MUSHRM HD,RED

PUSH BUTTON ,2 FUNC,MOMEN,FLUSH

POWER SUPPLY,24VAC - 12VDC & 3.25VDC

PWR CTRLR,480,3-30A,1-4-20,10

1 065265

3 064923

1 065184

1 E-2016

PUSHBUTTON,CONTACT BLK,1 NO,

PUSH BUTTON,1NC,EB

SELECTOR SW OP, 4 POS, MAINT

TRANSFORMER,25VA

4

B

SECTION B-B

SCALE 1 / 8

A

B

A

10

11

12

13

14

15

6

7

4

5

8

9

ITEM

1

2

3

1

1

1

1

2

2

2

12

3

2

2

4

QTY

4

30

4

P

P

P

P

TYPE

P

P

P

M

M

M

M

M

M

M

M

PART NUMBER

002455

011799

021794

039917

047799

058833

059058

60819

61665-5

63940

64070

64071

64072

64098

67468

4

Parts List

DESCRIPTION

#10-32 X 3/4 TRUSS HEAD SCREW

SCREW,MACH,TRUSS,PH,8-32 X .500,SST

SCREW,CAP,SOCKET HD,8-32 X .750

3/8 STUD HANDLE

#8-32 SST MACH. NUT

TERMINAL,3 POLE,CERAMIC,600V

SCREW,CAP,SOCKET HD,8-32 X .625

INSULATOR,END COVER,4 LAMP

ASSY,LAMP,T3 5000

J-BOX,HEATER

SKIN,4 LAMP,5000

REFLECTOR,INNER,4 LAMP,5000

REFLECTOR,OUTER,4 LAMP,5000

PLATE,REINFORCEMENT,HANDLE

ENDCOVER,4 LAMP,AC8000,4150

A

3

3

12

1

4

2

2

13

1

11

1

2

30

9

4

14

2

C

B

DETAIL C

SCALE 1 / 4

6

3

8

2

15

2

SECTION A-A

SCALE 1 / 8

7

2

1

4

10

1

6

3

5

12

1

QTY ENG REL SHOP VENDER P.O. NO PROD REL JOB NO

39067

REL BY

CTL 1

BGK FINISHING SYSTEMS

DRAWN: SCALE: TOLERANCES

CTL

DATE: JOB NO:

2 PLACE FRACT.

` .030

` 1/32

3 PLACE ANGULAR

ASSY,HEATER,4150

MINNEAPOLIS MN

THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS

IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT

AUTHORIZATION z 2016 BGK FINISHING SYSTEMS

1/28/2011

MATERIAL: SEE P/L

` .030

`

DUE

FINISH:

MAINTAIN QUALITY FINISH

2

NEXT ASSY: PART NO: DRAWING NO:

B 95329

1

REV: SHEET:

1

OF

1

A

B

A

B

B

4

4

3 2 1

A

B

3

3

6

1

A

SECTION B-B

SCALE 1:8

5

4

8

1

2

24

10

2

4

2

7

1

11

1

3

1

4

DETAIL C

SCALE 1 / 4

3

3

9

2

C

SECTION A-A

SCALE 1:8

ITEM

1

2

3

4

5

6

7

8

9

10

QTY

4

24

3

2

4

1

2

2

1

1

M

M

M

M

M

M

M

TYPE

P

PART NUMBER

002455

P

P

011799

058833

60819

61665-5

63940

64086

64087

64098

67468

Parts List

DESCRIPTION

#10-32 X 3/4 TRUSS HEAD SCREW

SCREW,MACH,TRUSS,PH,8-32 X .500,SST

TERMINAL,3 POLE,CERAMIC,600V

INSULATOR,END COVER,4 LAMP

ASSY,LAMP,T3 5000

J-BOX,HEATER

REFL,INNER,4 LAMP,5000,SP PYRO MOUNT

REFL,OUTER,4 LAMP,5000,SPC PYRO MOUNT

PLATE,REINFORCEMENT,HANDLE

ENDCOVER,4 LAMP,AC8000,4150

JOB NO

39649

QTY

11

2

1

REL BY

CTL

M 94444

ENG REL

SKIN,4 LAMP,5000,SPECIAL PYRO MOUNT

SHOP VENDER P.O. NO PROD REL DUE

BGK FINISHING SYSTEMS

DRAWN: SCALE: TOLERANCES

CTL

DATE: JOB NO:

2 PLACE FRACT.

` .030

` 1/32

3 PLACE ANGULAR

MINNEAPOLIS MN

THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS

IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT

AUTHORIZATION z 2016 BGK FINISHING SYSTEMS

ASSY,HEATER,4150,SPECIAL PYRO MOUNT

11/3/2010

MATERIAL: SEE P/L

` .030

`

FINISH:

MAINTAIN QUALITY FINISH

NEXT ASSY: PART NO: DRAWING NO:

B 94445

65185

REV: SHEET:

1

OF

1

2 1

A

B

B

SYM

A

4

REVISION

DESCRIPTION

MODIFIED FRAME;ADDED NEW CASTER BRAKE

BY

CTL

DATE

3/7/17

12

.2

50

61.658

3

(3

)

12

.2

51

A

ITEM QTY TYPE PART NUMBER

1

2

3

4

5

6

7

4

2

4

9

1

1

1

P

P

P

P

P

P

P

008806

012695

054438

054439

054452

054488

058441

Parts List

DESCRIPTION

COLLAR SPLIT 1 1/2"

1/4 X 1.000 FLAT HEAD

HANDLE,ADJUSTMENT,1/4-20 STUD

CABLE,STEEL,1/8" DIA,1700 LBS

SLEEVE,STOP,OVAL,1/8"

BLOCK,FLAT MOUNT,2" DIA,7/32 CABLE

WINCH,BRAKE,DLB800A

8

9

11

13

14

15

16

1

4

1

2

2

2

2

P 060022

P 074862

M 57416

M 64069

M 64076-1

M 64076-2

M 64090-1

EYEBOLT,1/4-20 THREADED

CASTER,SWIVEL,6" DIA,2" WIDE

HOOK,CABLE

ASSY,HEATER,4150

WELD,BRACKET,FIXED

WELD,BRACKET,FIXED

BRACKET,ROTATING

25

26

27

40

41

42

ITEM QTY TYPE PART NUMBER

17

18

19

21

22

23

24

2

2

4

1

1

2

2

M

M

M

M

M

M

M

64090-2

64091

64096

84794

85426

87232

87233

Parts List

DESCRIPTION

BRACKET,ROTATING

HINGE,HEATER

GUARD,4 LAMP,5000,SP

WELD,FRAME,FINAL,AC8

PANEL,MOUNT,CONTROL BOX

PANEL,SPACER,HEATER

PANEL,SPACER,HEATER

3

1

1

4

1

2

M 87355

M 94445

M 95329

M 97188

M AC-61231

P 22955T36

COVER,CLOSE-OFF

ASSY,HEATER,4150,PYRO MOUNT

ASSY,HEATER,4150

WEARSTRIP BLOCK

ASSY, PYROMETER

BRAKE KIT,CASTER,6"

4 3

8

1

49.404

2

15

2

17

2

40

4

DETAIL B

13

2

20

3

25

3

13

2

24

2

21

1

5

1

4

9

6

1

19

4

26

1

2

2

23

2

11

1

A

B

21

1

16

2

18

2

9

4

40

4

DETAIL A

14

2

3

4

JOB NO

1 39620

BGK FINISHING SYSTEMS

DRAWN: SCALE: TOLERANCES

CTL

DATE: JOB NO:

2 PLACE FRACT.

MINNEAPOLIS MN

THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS

IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT

AUTHORIZATION z 2015 BGK FINISHING SYSTEMS

3 PLACE ANGULAR

ASSY,AC8-4450

5/1/2008

MATERIAL:

QTY

SEE P/L

REL BY

± .030

FINISH:

DEBURR SHARP EDGES

2

ENG REL SHOP VENDER

NEXT ASSY: PART NO:

P.O. NO

1

DRAWING NO:

84792

1

9

4

PROD REL

1

4

DUE

7

1

B

REV: SHEET:

A 1

OF

1

A

RECOMMENDED SPARE PARTS

TO ORDER:

CONTACT: SPARE PARTS ORDER ENTRY

PHONE: 1-800-726-8097

E-MAIL: [email protected]

AC8-4 4 504 80

Reference Number

107A,107B

114A,114B

101A,101B,104B,104A

117

103

103

Spares

Qty

4

1

3

2

4

6

Part number Part Description

E-143

AC-200070

048378

FUSE,1A,600V,CLASS CC

FUSE,2A,250V,TIME DELAY,GLASS

FUSE,30AMP 600V CUBE

AC-74816-480-C-75 TEMPERATURE CONTROLLER

002986 POWER CONTROLLER,SCR,30A

003317 PWR CTRLR,FIRING CIRCUIT,4-20ma

WARRANTY POLICY

This product is covered by Carlisle Fluid Technologies ’ materials and workmanship limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid

Technologies, will void all warranties. Failure to reasonably follow any maintenance guidance provided, may invalidate any warranty.

For specific warranty information please contact Carlisle Fluid Technologies.

For technical assistance or to locate an authorized distributor, contact one of our international sales and customer support locations.

Region Industrial / Automotive Automotive Refinishing

Americas

Europe, Africa

Middle East, India

China

Japan

Australia

For the latest information about our products, visit www.carlisleft.com

Carlisle Fluid Technologies is a global leader in innovative finishing technologies.

Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.

BGK ™, Binks ® , DeVilbiss ® , Hosco ® , MS ® , and Ransburg ® are all registered trademarks of Carlisle Fluid Technologies, Inc.

©2020 Carlisle Fluid Technologies, Inc.

All rights reserved.

www.carlisleft.com

AutoCure 8 000 - All Models

Operating and Assembly Manual (Revised 0 4 /2021)

advertisement

Related manuals

advertisement

Table of contents