AP30 - 5000 AP30 - 8000 High Resolution Printer Service Manual O

AP30 - 5000 AP30 - 8000 High Resolution Printer Service Manual O

AP30 - 5000 AP30 - 8000

High Resolution Printer

Service Manual

94MS36 Rev. F2 S/W Ver 2.06

O

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.

94MS36 Rev. F2 S/W Ver 2.06

0.

Contents

1.

Specifications

Crated dimensions ....................................................................... 1-1

Shipping weight ........................................................................... 1-1

Actual dimensions ....................................................................... 1-1

Effective exposure frame area ..................................................... 1-1

Optional reflectors ....................................................................... 1-2

Intensity ....................................................................................... 1-2

Cooling ........................................................................................ 1-2

Exhaust ........................................................................................ 1-2

Room Air Supply ......................................................................... 1-2

Water Drain ................................................................................. 1-2

Electrical specifications and connections .................................... 1-3

Connecting power ........................................................................ 1-4

2.

Integrator Functions and Features

Integrator ..................................................................................... 2-1

Feature Quick Reference ............................................................. 2-3

Operator Control Panel ................................................................ 2-4

Table Showing the 12 Calibration Positions ............................... 2-4

Calibration 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

Split Exposure Mode ................................................................... 3-4

Single Surface Mode ................................................................... 3-5

Board Count Display Mode ......................................................... 3-5

Frame Control Interface Mode .................................................... 3-6

Automatic Vacuum Mode ........................................................... 3-6

Auto Step Mode ........................................................................... 3-7

Set Default Vacuum Delay .......................................................... 3-7

Tray Mode ................................................................................... 3-8

Type Mode ................................................................................... 3-8

Exposure Statistics (Elapsed Hours) ............................................ 3-9

Exposure Statistics (Total Exposures) ......................................... 3-9

94MS36 Rev. F2 S/W Ver 2.06

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0-2

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

94MS36 Rev. F2 S/W Ver 2.06

9.

Exposure Trays

Mylar® Replacement .................................................................. 9-1

If Mylar® Pulls Out of the Frame ............................................... 9-1

Outer Frame Replacement ........................................................... 9-1

Tray Assembly Drawing .............................................................. 9-3

Mylar Frame Assembly ............................................................... 9-5

Gas Strut Removal ....................................................................... 9-7

Replacing the linear bearings ...................................................... 9-7

Frame Glass Replacement ........................................................... 9-8

Gas Strut Replacement ................................................................ 9-8

10. Center/Drive Assembly

Center/Drive Assembly Diagram .............................................. 10-1

Frame Transport System ............................................................ 10-3

Frame Drive Motor Replacement .............................................. 10-3

Frame Drive Clutch Adjustment................................................ 10-3

Frame Speed Adjustment........................................................... 10-4

Adjust the 'FAST' pot on the control box. ................................. 10-5

Light Block 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) ............................................. 12-8

Unit Wiring and Tubing Diagram ............................................. 12-9

Base Assembly Diagram ......................................................... 12-10

13. Light Source

Component Layout .................................................................... 13-1

Ballast/Tap Switch Wiring ........................................................ 13-5

Interlock System ........................................................................ 13-8

Lamp Voltage ............................................................................ 13-9

Lamp Power Path....................................................................... 13-9

Trigger Board .......................................................................... 13-10

Capacitors and Level Switching .............................................. 13-11

Opening the Lamp Head .......................................................... 13-15

Shutter ...................................................................................... 13-16

Shutter Switch ......................................................................... 13-16

Shutter Brake ........................................................................... 13-16

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Shutter Motor ........................................................................... 13-17

Installing the Motor ................................................................. 13-17

Shutter Removal ...................................................................... 13-18

LT1 Shutter Assembly Drawing .............................................. 13-19

LT8 Shutter Assembly Drawing .............................................. 13-21

Idle Setting ............................................................................... 13-22

Lamp Head Blowers ................................................................ 13-23

Blown Fuse on PC Board ........................................................ 13-23

Lamp Head Signals .................................................................. 13-24

Light Function States ............................................................... 13-25

Printed Circuit Board Layout .................................................. 13-27

Signal Description ................................................................... 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

No Strike Fault Tree .................................................................. 15-1

Shutter Rotation Fault Tree ....................................................... 15-2

16. Parts List

Parts List .................................................................................... 16-1

17. Warranty

Limited Warranty ...................................................................... 17-1

Lamp Warranty .......................................................................... 17-1

94MS36 Rev. F2 S/W Ver 2.06

1.

Specifications

72"

81"

38"

35"

45"

89" with A/C

Crated dimensions

Length

95"

241 cm

Shipping weight

Width

60"

152 cm

45.5"

48.5"

Height

80"

203 cm

Crated

Uncrated

1600 lbs.

1375 lbs.

727 kg.

625 kg.

Actual dimensions

Cabinet welded heavy gauge steel construction with access doors on both sides.

Length

89"

226cm

Width

48.5"

123cm

Height

81"

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

Depth:

30"

25"

76 cm

64 cm

94MS36 Rev. F2 S/W Ver 2.06

1-1

Optional reflectors

Width

Depth:

24"

18"

61 cm

46 cm

Intensity

AP 30-5000

AP 30-8000

Low

1kW

2kW

Medium

2.5kW

4kW

High

5kW

8kW

Cooling

A self-contained air conditioning system is integrated into the rear of the

AP 30-5000 / AP 30-8000.

Exhaust

Two exhaust ducts, diameter 8 in.(203 mm)

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.

Power

Rear

36"

A/C Filter

36"

36"

1-2

Top View Front

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 fumes into the printer.

Water Drain

A water drain or sump pump is necessary for the air conditioner condensation.

94MS36 Rev. F2 S/W Ver 2.06

Electrical specifications and connections

L1

380 / 415V~

OLITE

Power Supply

L2

380 / 415V~ 50Hz Connection

Wye: 3 Wires + Neutral + Ground

Terminal Block

L1 L2 L3 N

Figure A

N

Blowers

Vacuum

Pumps

Electronics

Drives

Etc.

L3

Earth

Ground

L1

L2

208V~

OLITE

Power Supply #1

208/240V~ 50Hz Connection

DELTA: 3 Wires + Ground

Terminal Block

L1 L2 L3 N

L1

Blowers

Vacuum

Pumps

Electronics

Drives

Etc.

Figure B

L3

208V~

OLITE

Power

Supply #1

Earth

Ground

L2

480V~

OLITE

Power Supply #1

480V~ 60Hz Connection

DELTA: 3 Wires + Ground

Terminal Block

X1 X2 X3 L1 L2 L3

Blowers

Vacuum Pumps

Electronics

Drives, Etc.

X4

X3

X2

H1

H2

H3

H4

X1

Figure C

L3

480V~

OLITE

Power

Supply #2

Earth

Ground

L1

L2

480V~ 60Hz Connection

Single Phase: 2 Wires + Ground

Terminal Block

X1 X2 X3 L1 L2 L3

Figure D

480V~ OLITE

Power Supply #1

480V~ OLITE

Power Supply #2

H1

H2 H3

H4

X4

X3 X2

X1

Blowers

Vacuum Pumps

Electronics

Drives, Etc.

Earth

Ground

94MS36 Rev. F2 S/W Ver 2.06

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1-4

AP 30 - 5000 printer input

3 phase (Delta) See Figure C

3 phase (Delta) See Figure B

3 wires + ground

3 wires + ground

480V~ 60 Hz, 18 amp.

208/240V~ 60 Hz, 44 amp.

3 phase (Wye) See Figure A 3 wires + neutral + ground 380/415V~ 50 Hz, 24 amp.

Single phase See Figure D 2 wires + ground 480V~ 60Hz, 35 amp.

AP 30 - 8000 printer input

3 phase (Delta) See Figure B 3 wires + ground 208/240V~ 60 Hz, 65 amp.

3 phase (Wye) See Figure A 3 wires + neutral + ground 380/415V~ 50 Hz, 34 amp.

Connecting power

• Remove the lower rear panel of the printer by unscrewing the

5

/

32

" Allen head screws that attach it. Remove the two screws from the rear that secure the sliding side doors. Slide both doors to the front.

• Run the main power cord through the round retaining plate 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. Make sure the air conditioner drain hose is uncoiled and connected to a drain or allowed to drain into a suitable container.

• Reinstall the side door securing screw.

• Install the lower front and rear black trim pieces over the forklift channels, using a

5

/

32

" Allen wrench.

• Connect two 8" exhaust hoses to the outlets on the top rear of the printer.

!

This will remove the expended heat from the working environment.

Cl

PLEASE BE SURE THE DUCT HOSE IS VENTED TO AN

OPEN CHAMBER, AS BACK PRESSURE WILL

GREATLY REDUCE THE COOLING CAPABILITIES OF

THE PRINTER.

94MS36 Rev. F2 S/W Ver 2.06

2.

Integrator Functions and Features

Microprocessor-controlled light integrator with LED display, 40 memories, battery backup, single button control, lamp statistics and selfdiagnostics. The operator control panel is composed of two sections, the display board and the memory board.

Note: The number of digits in each window.

[39]

Memory Window

[0120]

Vacuum Window

[034.5]

Exposure Window

_____________________________________________________________________________________________________

P

[00]

Y

[0000]

V

[0000] e

I

T

D

U

F m

0

2

4

6

8

7

4

1

8

5

2

0

9

6

3

1

3

5

7

9

Integrator

P

POWER

Press the power button on the integrator to turn the OV 45/33HD on or off. When the unit is off, the light system blowers will run for 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.

e

EXPOSURE

Press the exposure key and use the numerical keypad to enter an exposure.

The window shows the exposure units selected. This key can also be used to move forward through the selectable features in the setup mode.

I

INTENSITY

Press this key to select Low, Medium or High power. LEDs lit will indicate the level selected.

D

DIFFUSER

Press this key to select the motorized diffuser option.

F

FILTER

Press this key to select the motorized filter option.

T

SECONDS

Press this key to expose by time, not integrated light units. This key also can be used to move backward through selectable features in the setup mode.

94MS36 Rev. F2 S/W Ver 2.06

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2-2

U

MENU

This key is used as the autostep indicator and for the continuous vacuum feature.

Note: U MENU Special Function

The U key has the optional function to be used to set auto-step and continuous vacuum per memory in normal operating mode. The frame control switch feature must be turned ON and the automatic vacuum feature must be turned OFF. Press the U key the memory window will read [AC] and the exposure window will read [AStP]. Press the V key to turn 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 40 independent memory locations, the first ten of which are on the lower section of the integrator for instant access. There is a space provided to write down the application of these memories.

Simply press the lower 0 through 9 key that corresponds to the most commonly used applications.

94MS36 Rev. F2 S/W Ver 2.06

Feature Quick Reference

The following feature descriptions appear in the exposure window while setting each feature. In order to select or setup the following 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

94MS36 Rev. F2 S/W Ver 2.06

2-3

2-4

Operator Control Panel

P

The AP 30 heavy duty exposure system has a power key on the integrator.

• Press the P key to turn on the unit.

• Press the P key again after use, and the system will run through a 2 minute cool down cycle and then turn off all blowers.

S

STOP Button

• Press the S button once. Frame movement will stop.

• Press the S button once more, the frame will return, at slow speed, to the original position and vacuum will turn off.

• Press the S button twice to cancel an exposure.

• Holding the S button down then pressing the G button starts a blank cycle - no vacuum or exposure.

G

GO Button

• Press the G button once to initiate vacuum drawdown on the exposure frame.

• Press the G button a second time to move the frame into the unit and start an exposure.

• If frame switch [FrCl] and auto vacuum [AUAC] are turned on, press the

G button once to move the frame into the unit and start an exposure.

• If frame switch [FrCl] and auto vac [AUAC] are turned on, press the G button once without 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.

Table Showing the 12 Calibration Positions

[Ut]

[Ub]

[Lt]

[Lb]

Upper Frame, Top Surface

Upper Frame, Bottom Surface

Lower Frame, Top Surface

Lower Frame, Bottom Surface

1st

2nd

3rd

4th

5th

6th

7th

8th

9th

10th

11th

12th

Calibration Procedures

Note: The AP30 high resolution printer has been calibrated at the factory.

Note: The following calibration procedures can be applied to all three light intensities, if starting calibration from scratch. To adjust existing calibration set the integrator to 500 mj and make the exposure. Increase or decrease the calibration number the same percentage the 500 mj is off.

94MS36 Rev. F2 S/W Ver 2.06

• Press the P key on the integrator to power up the lights, the front switches, and the printer's computer system.

Note: Allow the printer a 5 minute warm-up period before any calibration procedures. This will allow for complete and accurate light level stabilization.

• Press the integrator I key to select the desired light level to be calibrated, always start at Low Intensity.

For 8kW

For 6kW

For 5kW

Low 2000 W

Low 2000 W

Low 1000 W

Medium 5000 W

Medium 3500 W

Medium 2500 W

High 8000 W

High 6000 W

High 5000 W

• In order to prevent possible damage to the high resolution printers Mylar® while calibrating we recommend you set the no vacuum feature.

• Press the V key on the keypad, the Memory and Exposure windows will dim.

• Press the 9 key three times.

• Press the V 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 calibration factor numbers to 500 units. Place a slim UV meter facing up on the center of the top frame, below the Mylar®.

• Enter a 500 unit exposure into the integrator. Be sure the seconds mode is off.

• Press the G button twice. This will send the frame into the unit and start the exposure.

• After the exposure, retrieve your frame by holding down the S button and press G button. When the frames start to move, release both buttons.

• Record the resulting mj reading from the meter.

94MS36 Rev. F2 S/W Ver 2.06

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2-6

Example:

Let's say our 500 unit exposure gave us 600 mj. That means we got 1.2 mj per unit or a 1.2:1 ratio. The objective is to get a 1:1 ratio. To get that we would multiply our current calibration number of 500 by 1.2, 500 x 1.2 = 600.

• Since we are working with the Upper Tray Top Surface or [Ut], we have to change the preset 500 to 600.

• Change to 600 as described earlier in Calibration Procedures Section.

Remember:

The lower the CAL number, the longer the exposure and the higher the mj reading.

• Now make a 500.0 unit exposure with the UV meter and record the resulting mj reading. It should be 500 ±3%. Perform this procedure on the remaining three surfaces.

[_SEL]

Press 1, 2, 3 t 4 on the numerical keypad. The Vacuum window will read [_SEL]. This places you in select mode.

• Press the V key once and press the0 key to clear, then V key, then the 0 key to activate the vacuum after being turned off earlier in this procedure.

Changing the Calibration Number

• Press the m key on the integrator. The Memory window will read [Ut] , the Exposure window will show the existing calibration number for the top surface of the upper frame at the selected intensity.

• Press the Y key to select frame surface ( [Ut], [Ub], [Lt], [Lb]).

Remember: For top frame calibration use [Ut] and [Ub] and for bottom frame calibration use [Lb] and [Lt]. Also, the larger the calibration number the faster that surface will count and the less accumulated energy will result on the frame.

• Enter the new calibration number on the desired surface by pressing e key to open the program, then use numerical keypad.

Example: To change [Ut] from 500 to 650 simply press 6,5,0,0.

• Press the e key to close the program.

• Press the 0 key twice to return to the operating mode.

94MS36 Rev. F2 S/W Ver 2.06

Matching Exposure Surfaces

• Do a test exposure in the frame being calibrated to the reference frame.

• Determine the correction necessary to make each surface the same at the reference surface. If this is done with a step scale the correction is as follows.

-1.00

-0.75

-0.50

-0.25

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

.15 Density Scale

Step

-2.00

-1.75

-1.50

Correction

0.50

0.55

0.60

-1.25

0.65

0.71

0.77

0.84

0.92

1.00

1.09

1.19

1.30

1.41

1.54

1.68

1.83

2.00

1.00

1.25

1.50

1.75

2.00

-1.00

-0.75

-0.50

-0.25

0.00

0.25

0.50

0.75

.05 Density Scale

Step

-2.00

-1.75

-1.50

-1.25

Correction

0.79

0.82

0.84

0.87

0.89

0.92

0.94

0.97

1.00

1.03

1.06

1.09

1.12

1.15

1.19

1.22

1.26

[_SEL]

Press 1, 2, 3 t 4 on 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 double the calibration number, the integrator will count twice as fast consequently the exposure energy will be cut in half.

[_SEL]

Press 1, 2, 3 t 4 on the numerical keypad. The Vacuum window will read [_SEL]. This places you in select mode.

[0163.]

Then press the m key and the exposure window will show previous calibration number. (for example [1063.]).

• Press the e key, the memory window will dim and you will be able to enter the new calibration number by pressing the new number into the key pad.

94MS36 Rev. F2 S/W Ver 2.06

2-7

Splitting Steps

A densitometer can be used to assist in determining a fractional difference in step scales. When measuring density, make several measurements to avoid being influenced by pinholes.

Example

Original Reference Second Scale

2-8

A

B

• Pick a step from the reference with a density greater than .15 and less than 2.0.

• Find the steps on the second 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 then the surface to be adjusted.

• Divide the reading on the surface to be adjusted by the reading from the reference surface.

• Multiply the current calibration number by the result above.

94MS36 Rev. F2 S/W Ver 2.06

3.

Integrator Program Set Up

To Enter the Select Mode

Note: This step must be followed in several of the program set ups.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 in sequence. The Vacuum window will read

[SEL_]. This places you in the select mode.

Lock Level Feature

The lock levels are provided to keep operators from accessing any features and functions that should be left alone. There are five different lock levels available. Lock levels 1 - 3 allow the locking of individual memory locations, while lock levels 0 and 4 apply to all of the memory locations.

• Level 0 - No locks. Most of the features and functions can be accessed by any operator.

• Level 1 - Locks functions per memory (seconds, exposure, vacuum, intensity, filter, diffuser) to prevent accidental changes to these settings.

Locks 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 required to change any operating parameters.

Note: You must ensure the lock level is set to 0 before continuing with the Integrator Program Set Up Features and the exposure memory options detailed below in Lock Level Description and Operation.

When programming is completed return to Lock Level Feature and set the desired lock level.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 in sequence. The Vacuum window will read

[SEL_]. This places you in the select mode.

[LocK]

Press the Y key once, the Exposure window will read [LocK].

• Press the V key once.

• If the Lock Level is set at 0 or 1 the Memory and Exposure windows will

94MS36 Rev. F2 S/W Ver 2.06

3-1

dim. Enter the lock level desired.

• Press the V key to set entry.

• If the Lock Level is set for 2, 3 or 4, the Exposure window will read

[codE]. Enter your 3 digit code.

• Press the V key.

• Press the 0 key.

• Press the V key.

Note: If you want a higher Lock Level after you have completed the

Integrator Program Set Up and/or made any changes return to

Lock Level Feature and set the lock level described in Lock Level

Description and Operation).

3-2

Lock Level Description and Operation

[0000]

Lock Level 0

The Vacuum window will read [0000].

[0001]

Lock Level 1

The Vacuum window will read [0001]. Locks functions for seconds, enter, vacuum and intensity per memory. Once this mode is turned ON and the set up programing has been completed, enter all needed information into a memory location. Then press the U key, the Memory window will read [Ac] and the Exposure window will read [LocK]. Press the V key to turn the lock for this memory ON or OFF, then press the U key. When the lock is turned ON, 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 [_oFF] and the

Exposure window will read [LocK]. Press the V key to turn the lock ON or OFF for this memory. When the lock is turned ON a decimal point will be displayed after each digit in the Memory window. Once this level is turned ON you will not be able to unlock the features described above without the Lock Code. See Setting or Changing your Lock Code Feature.

[0004]

Lock Level 4

The Vacuum window will read [0004]. This locks all functions. When the lock is turned ON, a decimal point will be displayed after each digit in the Memory window. Once this level is turned ON and the set up programing has been completed, before you can change any programed features or the exposure statistics you must use the Lock Code to set the

Lock Level back to 0, see Setting or Changing your Lock Code Feature.

94MS36 Rev. F2 S/W Ver 2.06

Setting or Changing your Lock Code feature

Note: If you are setting the code you must know the existing code.

Note: Lock Level must be set to 0 to program this step and reset when finished see Lock Level feature.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

[codE]

Press and release the e key until the Exposure window reads [codE].

• Press the V key the Memory and Exposure windows will dim. Enter your new 3 digit code

• Press the V key to set entry.

• Press the 0 key twice to exit 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 on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 in sequence. The Vacuum window will read

[SEL_]. This places you in the select mode.

• Press the 7 key five (5) times.

• Press the 0 key once to exit this mode.

To Clear Memory and Exposure Statistics

!

C This step clears all information stored in the memory.

Note: You can abort clearing the memory by pressing the 0 key before the display counts down to [SEL_] and you will not change any memory and exposure statistics.

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3-3

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 in sequence. The Vacuum window will read

[SEL_]. This places you in the select mode.

• Press the 9 key five (5) times.

• Press the 0 key once to exit this mode.

Two Value Exposure Mode

Note: The two value mode enables the operator to run a different job or resist on each frame. With this feature turned ON, a value entered in the Vacuum window becomes an exposure value. For instance, if you enter 800 in the Vacuum window and 450 in the Exposure window, during an exposure both surfaces on the upper frame will receive 800 mj while both surfaces on the lower frame will receive 450 mj. To activate this option:

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

[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 to select separate exposure values for the upper and lower surfaces of each frame, in case different exposures are required for each surface of the panel. An exposure can be entered in the center display which will be used on the top surface of each frame and a separate exposure value can be entered in the lower display which will be used on the bottom surface of each frame.

3-4

Note: The two value mode MUST be selected ON for the split exposure mode to function.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

94MS36 Rev. F2 S/W Ver 2.06

[SPgt]

Press and release the e key until [SPgt] appears in the Exposure window.

This places you in the split exposure option.

• Press the V key to cycle the split exposure mode ON or OFF.

• Press the 0 key twice to exit this mode.

Single Surface Mode

The printer may be programmed to use the top light only, the bottom light only, or both lights. For exposing phototools or single sided exposures, you may want to use only one light. Each of the 40 memories is independent, to allow for any combination you wish on a particular memory. While programming:

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

[SSur]

Press and release the e key until [SSur] appears in the Exposure window.

This places you in the single surface mode.

• Press the V key to turn the 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 have top lamp only, the left memory digit displays upper segment only and means only the upper lamp is selected.

If the left memory digit displays lower segment only it means only the lower lamp is selected.

Board Count Display Mode

The printer will constantly display all the exposure information. With the board count display option turned ON, the Vacuum window will show a running total of the number of exposures that have taken place.

This can be very useful in verifying that all exposures were made for a particular job.

Note: It is recommended to leave this feature OFF when the two value or split features are activated. To activate the board count display option:

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

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3-6

[SEL_]

Press 1,2,3t 4 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].

[bcnt]

Press and release the e key until [bcnt] appears in the Exposure window.

This places you in the board count option.

• Press the V key to cycle the board count ON or OFF.

• Press the 0 key twice to exit this mode.

Frame Control Interface Mode

The frame control interface works in conjunction with each frame's magnetic switch. If either frame is open, motorized transport will not function. This prevents inadvertent frame movement with the outer frame open. It is recommended that this safety feature be turned ON at all times.

In the event of a switch failure or a unit without switches, it can be bypassed.

Note: This safety feature will always be ON unless you turn it OFF. To deactivate the frame control interface mode:

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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 the 0 key twice to exit this mode.

Automatic Vacuum Mode

The automatic vacuum mode allows the printer to start vacuum automatically by closing the frame. If a preset vacuum delay is used, such as default vacuum delay, the center display will show the vacuum countdown. The G button then only needs to be pressed once to start frame movement. With this feature turned ON, a blank frame cycle will be initiated simply by pressing the G button once when the frame has not been opened. To activate this option:

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

94MS36 Rev. F2 S/W Ver 2.06

[AUAC]

Press and release the e key until [AUAC] appears in the Exposure window.

This places you in the automatic vacuum option.

• Press the V key to cycle the automatic vacuum mode ON or OFF.

• Press the 0 key twice to exit this mode.

Auto Step Mode

Note: This feature allows you to run a series of exposures in sequence.

Note: If Auto Step is selected, the LED over the U key will indicate if the feature is ON or OFF. If ON, press the V key to turn it OFF.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

[AStP]

Press and release the e key until [AStP] appears in the Exposure window.

This places you in the autostep option.

• Press the V key to cycle the Auto-Step mode ON or 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 not start until the time is completed.

Note: This default delay time will be ignored if a delay time other than

0 has been programed into the memory location being displayed.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

[dUAC]

Press and release the e key until the Exposure window reads [dUAC].

• Press the V key and enter the time you wish the vacuum turned ON before the exposure begins. The time you selected has now been programed for all memories.

• Press the 0 key twice to exit this mode.

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3-8

!

Tray Mode

C The default tray speed is set at the factory to 5 seconds. OLEC does not recommend changing this setting without consulting the

OLEC factory. Damage to the transport can occur.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 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].

[trAY]

Press the e key until [trAY] appears in the Exposure window.

• Press the V key once. The Vacuum window will read [----] and the

Exposure window will read [codE]. If lock mode was turned ON, enter your code now, then press the V key, (If the lock code has never been changed section 4.3, the default code is 000).

• Enter the time you wish to have the tray speed set for. For example, for a

5.0 second travel time, 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 computer system.

[SEL_]

Press 1,2,3t 4 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].

[tYPE]

Press the e key until [tYPE] appears in the exposure window. This places you in the System Type option.

• Press the V key once. The Vacuum window will read [----] and the

Exposure window will read [codE]. If lock mode was turned ON, enter your code now, then press the V key, (If the lock code has never been changed, the default code is 000).

[AP30]

Press the V key to cycle the Vacuum window to read [AP30]. This setting applies to both the AP30 5kW and AP30 8kW, air conditioned and closed loop models.

• Press the 0 key twice to exit this mode.

94MS36 Rev. F2 S/W Ver 2.06

Exposure Statistics (Elapsed Hours)

Note: The exposure statistics should be reset to zero when the lamps are changed.

Note: This provides the operating hours on the lamps in total and at each intensity since the last reset. This function should be used whenever the exposure lamps are replaced.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 in sequence. The Vacuum window will read

[SEL_]. This places you in the select mode.

[LE__]

Press the 1 key. The letters [LE__] will appear in the Vacuum window.

The Exposure window will display the exposure time, in seconds, of the last exposure, regardless of its memory position or intensity.

[tot_]

Press the 1 key a second time, the letters [tot_] will appear in the

Vacuum window. The total elapsed time, in hours, that the 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 power will show in the Exposure window.

[tHi_]

Press the 1 key a fifth time. The letters [tHi_] will appear in the Vacuum window. The elapsed time, in hours, that the lamp has been used at high power will show in the Exposure window.

• Press the 0 key twice to exit this mode.

Exposure Statistics (Total Exposures)

Note: To find out how many exposures your system has made since the last reset.

Note: The exposure statistics should be reset when the lamps are changed.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[SEL_]

Press 1,2,3t 4 in sequence. The Vacuum window will read

[SEL_]. This places you in the select mode.

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3-9

[EHI_]

Press the 2 key. The letters [EHi_] will appear in the Vacuum window.

The Exposure window will display the number of exposures made at high power.

[ELo_]

Press the 2 key a second time. The letters [ELo_] will appear in the

Vacuum window. The Exposure window will display the number of exposures at low power.

[ECr_]

Press the 2 key a third time. The letters [ECr_] will appear in the Vacuum window. The number of exposures at medium power will be displayed in the Exposure window.

• Press the 0 key twice to exit 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.

0

2

4

6

8

1

3

5

7

9

Quick Keypad

Instant access by pressing any of the memory locations from 0 to 9.

Entering an Exposure Time

Press the e key on the integrator.

Note: The Memory and Vacuum windows will dim.

[1825]

Enter desired exposure time by depressing corresponding number on key pad. For example 1,8,2,5

• Press the e key to confirm the entry.

3-10 94MS36 Rev. F2 S/W Ver 2.06

Low

Medium

High

Setting the Light Intensity

• Press the I key to set intensity. Press I for the first time. The first

LED on the left indicates the intensity is set to low ( 1kW on 5kW units,

2kW on 8kW units).

• Press: I for the second time. The first two LEDs light to indicate the intensity is set to medium ( 2kW on 5kW units, 4kW on 8kW units ).

• Press: I key for the third time. All three LEDs light to indicate the intensity is set to high (5kW on 5kW units, 8kW on 8kW units ).

Optional:

Press the T key to set for time or integrate mode. The

LED ON indicates a timed exposure and OFF an integrated exposure.

Note: During operation, ensure that the T mode is OFF.

Making an exposure

Place material in the exposure frame and close the frame.

• If [FrCL] and [AUAC] options are turned ON, vacuum will start automatically when the frame is closed. If [FrCL] and [AUAC] are OFF, press the G button 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 move if the previous exposure is still in progress.)

• Remove the material from the frame that was previously exposed and repeat for the next exposure.

• To stop the frame after it has started moving, press the S button once.

To retrieve it, press S again, or to continue with the exposure, press the G button. The frame will move in at a slower speed.

Blank frame cycle

To change frame position with no vacuum or exposure:

Note: If [FrCL] is turned ON and you do not open the frame, press the

G button and the frame will move in without vacuum or exposure.

STOP

GO

Front right arm of operator control panel

• Press and hold the S button.

• Press the G button.

• Release both buttons when the frames start moving

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3-11

Error Handling System

If an error occurs, the machine displays an error code to aid in troubleshooting. The error codes defined are:

[Err_]

The message [Err_] will appear in the Vacuum window, and a number in the Exposure window. Look up the number below for a description of the condition.

Description

[0001]

Frames did not reach intended position after the maximum amount of time.

Solution: Determine why. Were the frames moving at all? Did they get close? Is something obstructing their movement?

See I/O test mode for instructions on how to test motors and switches.

[0002]

Not used.

[0003]

Internal error. Please call your service rep.

Solution: Cycle the power switch.

Please note the circumstances under which this error occurred; was the machine exposing? Calibrating? Idle? Were new exposure values 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.

[0005]

Switch error. The machine thinks both frames are at the exposure position.

Possible causes are: Bad cable between master board and memory board, switches have failed, bad or no connection to switches.

[0006]

Communication error. Remote board is not communicating with the master board.

Possible causes are: no power to remote board, bad or disconnected communication cable.

[0007]

Remote board has reset or temporarily lost power. After clearing the error, normal function should continue.

[0008]

At least one lamp intensity/frame/surface has not been calibrated.

Solution: Ensure the unit has been completely calibrated.

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4.

Diagnostics

Output Diagnostics

One of the many advancements OLEC has introduced to the field is the ability of its equipment to run a self-diagnostic check. All computeractivated functions and all internal and external switches can be checked out on the integrator display by using the numerical keypad.

Output Functions Check

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[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.

• Press the number key to actuate the desired function. The numerical value shown in the table should appear in the Vacuum window.

• Press the function key number again to turn off the function. Press the

9 key to turn off all functions.

• Press the 0 key twice to return to normal operation.

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4-2

Functions Table

3

4

5

6

7

8 e

1

2

9

0

Function

A/C Compressor On/Off

A/C Blower On/Off

Upper Vacuum Pump On/Off

Lower Vacuum Pump On/Off

Work Light and Nose Section Fans On/Off

Motor Direction Control

Frame Motor On/Off

Motor Fast/ Slow

All controls off

Return to Select mode

1

A/C Compressor

5

Viewing Lights

6

Motor Direction

7

8

Motor Power

Motor Speed

4

3

Top Vacuum Pump

Bottom Vacuum Pump

2

A/C Blowers

Value

[0001]

[0002]

[0004]

[0008]

[0016]

[0032]

[0064]

[0128]

[0000]

[SEL_]

94MS36 Rev. F2 S/W Ver 2.06

Input Diagnostics

• Switch Check

The switch check can be done while in the Select mode.

• Press the P key on the integrator to power up the light, the front remote switches, and the exposure unit's computer system.

[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. The Exposure window on the integrator will show various numbers as the switches or keys are closed.

Examples:

With the upper frame moved in, the side access door switches closed, 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

128 +32 +4 +1

128 +32 +4 +8

• Switch Table

NUMBER DISPLAYED

= [0165] (Upper Frame In)

= [0172] (Lower Frame In)

Switch Value

1

4

8

16

32

128

Function

Upper frame in (labeled "frame")

Frame switch

Lower frame in (labeled "frame")

S key, nose section

Door/emergency z switch

G key, nose section

Typical values that you will see when all switches are good.

• Upper tray in, Frame switch closed, Door and Emergency switches closed.

[0037]

The bottom display should read [0037].

[0165]

When the G button is pushed the value should change to [0165].

[0053]

When the S button is pushed the value should change to [0053].

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4-4

• Lower tray in, Frame switch closed, Door and Emergency switches closed.

[0044]

The Exposure window should read [0044].

[0172]

When the G button is pushed the value should change to [0172].

[0060]

When the S button is pushed the value should change to [0060].

Typical values that you will see when a fault occurs.

[0004]

Indicates neither frame in position, magnetic frame switches closed, and does not have the correct reading from either 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 reads when the G button is pressed and the value does not increase by a value of 128 the G switch is bad.

• Whatever the switch value display reads when the S switch is pressed and the value does not increase by a value of 16 the S switch is bad.

94MS36 Rev. F2 S/W Ver 2.06

5.

Lamp Changing Instructions

!

W The lamps and safety glass may be very hot and cause burns.

Prior to changing the lamp, ensure the lamp head is turned off and allowed to complete its cooldown cycle.

OLEC recomends that every year you unplug your light, remove the safety glass, and clean the glass and reflector with denatured alcohol and a soft cloth. Lamps should be checked for excessive exposure times and should be replaced if exposure 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 each end of the lamp (one end at a time) out of the holders and remove the lamp from the lamp head.

6

7

10

5

Shutter

Lamp

4

• Clean the reflector with a mild solvent, such as denatured alcohol, and a clean soft cloth. Use glass cleaner to clean the safety glass. Dirty

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5-1

reflectors and glass can substantially reduce light output.

• Wear the white lightweight fabric gloves that are provided and unpack the new lamp. Clean the lamp with the alcohol wipe included.

• Place each end of the new OLITE lamp (one end at a time) on the holders.

DO NOT touch the lamp with your hands. Contamination of the quartz tube of the lamp with skin oils will shorten the life considerably and may lead to failure.

• Reconnect the lamp by fully inserting the spade lugs on the connecting wires under BOTH thumbscrews and tighten. Ensure the wires are positioned so they do not touch the lamp body 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 safety glass is properly installed, it will be able to move slightly.

If the safety glass is installed too tight, it may be damaged during use.

Note: OLITE Lamps are specifically designed for OLEC and undergo careful testing and preperation before shipment. They carry the

OLEC Warranty of Satisfaction. Substitutes and copies of lamps are not approved by OLEC, nor do they carry our Warranty. Use approved OLEC replacement parts ONLY!

5-2 94MS36 Rev. F2 S/W Ver 2.06

6.

Preventive Maintenance

Preventive Maintenance Daily (Approximately 15 minutes required)

• Clean exposure frame glass and Mylar. The exposure frame glass and

Mylar should be kept meticulously clean. Dirt and resist flakes on these surfaces will cause exposure defects.

• Inspect Mylar for cuts and tears. Check the condition of the Mylar on both exposure frames. The film should be clear and free of holes, creases, and scratches. Replace the Mylar whenever necessary. Replacement procedures are in the Service section of this manual.

• Inspect exposure frame vacuum seals for cracks. Check the condition of the inner and outer rubber seals on the frame glass. Cuts or nicks in the seals could cause vacuum leaks and slow frame evacuation. Replace the seals as necessary. Replacement procedures are in the Service section of this manual.

Preventive Maintenance Monthly (Approximately 1 hour required)

Perform daily maintenance steps plus the following:

!

C Do not use silicone spray lubricants in the printer.

• Lightly oil frame tracks. Lightly oil the upper and the lower exposure 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 half of each exposure frame.

Preventive Maintenance Semi-Annually (Approximately 2 hours required)

Perform daily and monthly maintenance steps plus the following:

• Clean unit and power supplies. The inner cabinet and power supply areas should be cleaned to prevent dust buildup.

• Turn the printer off and allow the internal blowers to run through their cool-down cycle. Disconnect the power and lock it out.

• Open both side cabinet doors. Remove both power supply covers by removing the two top forward screws and lift the covers up and forward.

Using a vacuum or compressed air, remove all accumulated dust and debris from the cabinet and the power supplies.

• Clean reflectors and lamp head safety glass. Clean the lamp reflectors and the safety glass on the upper and lower lamp heads. Refer to the lamp replacement procedures in the Service section of this manual for disassembly information.

94MS36 Rev. F2 S/W Ver 2.06

6-1

!

C Do not use silicone spray lubricants in the printer.

• Lubricate frame drive chain and check tension.

• Apply a light coat of machine oil to the exposure frame drive chain by rubbing an oil wetted rag along the chain. Do not wet the chain enough to cause the oil to run or drip.

• The chain tension adjustment is along the inner left hand side of the nose section. Turning the adjuster nut clockwise tightens the chain; counterclockwise loosens it. Adjust the chain to allow no more than a 1 inch (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 clean the filters in each vacuum pump. Replace the filter if plugged with debris. Refer to “Vacuum

System” in the Service section of this manual for more detailed information.

!

C Do not use silicone spray lubricants in the printer.

• Lubricate frame latches. Apply a small drop of light machine oil to each of the four frame latches.

6-2 94MS36 Rev. F2 S/W Ver 2.06

7.

Vacuum System

Vacuum Pumps

Description:

The printer uses two 1/4-hp oilless rotary vane vacuum pumps, one for each exposure frame. Pressing the GO button on the front nose assembly activates the pump for frame that is out of the cabinet. The vacuum gauge on the front panel indicates which pump is activated.

!

Pump Construction:

C This is an oilless vacuum pump; it should never be lubricated. The pump end plate, body, rotor, and mounting bracket are cast iron. Consequently, any moisture that accumulates in the pump will corrode the interior, especially if it stands idle.

The muffler box on the front of the unit is made of aluminum.

• The vanes are hard carbon and are precision ground. They should last many thousands of hours, depending upon the degree of vacuum or pressure at which the pump is run. The carbon 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 performance, and early pump failure. Check the filters semi annually or when necessary. The filters can be dried with compressed air. Filters should be cleaned or replaced every 1500 to 3000 hours, depending on the application.

!

Flushing the Pump

W Wear eye protection and flush the pump in a well-ventilated area.

Do not use kerosene or other combustible solvents to flush

the pump. Use Gast AH 255 flushing solvent or its equivalent.

If excessive dirt, foreign particles, moisture, or oil enter the pump, the vanes will act sluggish or may even break. Flushing the pump should remove these materials. There are two options for flushing the pump.

94MS36 Rev. F2 S/W Ver 2.06

7-1

7-2

Flushing Option #1

This option requires two pipe nipples at least 4" (102 mm) long with

3/

8

"

NPT threads on one end.

• Remove the filter elements from the front of the muffler box and screw the nipples into the same holes.

• With the pump running, allow about 2 tbsp. of flushing solvent to be ingested into the vacuum side of the unit.

• Repeat the flushing procedure. If it does not correct and clear the pump, remove the end plate for further examination.

Flushing Option #2

• Remove the filter elements from the front of the muffler box.

• Carefully remove the five bolts that hold the muffler box in place (be careful not to damage the gaskets). Tap the box with a small hammer to

!

break it loose.

C Prying with a screwdriver will damage the gasket. This will allow access to the intake and exhaust ports.

• Follow through with steps 2 and 3 for Flushing Option #1.

Pump Disassembly

Pump disassembly is required if flushing does not remove the foreign materials.

• Disconnect the power to the pump motor.

• Remove the six bolts holding the end plate to the body.

• Remove the end plate and the four vanes (do not remove the rotor or loosen 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 tapping on the pump body and turning the rotor, while setting this clearance, to assure that all points on the rotor clear the body.

Pump Checkout

If the pump does not activate when the G button is pressed, see the

Diagnostics section, then:

• Ensure that the exposure frame is in its full outward position.

• Check for G switch continuity at the switch connector. The switch harness connector is under the nose assembly, where it meets the front bulkhead.

• Check if the vacuum pump LED is lit at the control box. If so, check for voltage at the pump. If voltage is present at the pump connector, but the pump fails to operate, replace the pump. If the control box LED is not on, check the wiring and connections from the switch to the control box.

94MS36 Rev. F2 S/W Ver 2.06

Pump Replacement

Vacuum pump replacement is straightforward. The left-hand pump controls the lower frame; the right-hand pump controls the upper frame.

(Left and right as viewed by the operator.)

• Open either the left or right side cabinet door, depending on which pump is to be replaced.

• Disconnect the vacuum tubing from the pump. Push the outer ring on the connector and pull the vacuum tubing out.

• Disconnect the in-line electrical pump connection located approx. 6" from the motor end of the pump.

• Remove the four 1/2" nuts that secure the pump mounting plate to the isolation mounts. Then lift the pump out of the unit.

• 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 soon as possible. A faulty vacuum line or connection will greatly increase the vacuum drawdown time required, if not eliminate full vacuum altogether. All vacuum lines are separated from the connectors by pressing down and holding the connection outer ring while pulling the vacuum line out. To replace the vacuum line into the connections, simply push the line all the way into the connection.

Vacuum Gauge Replacement

See section Nose Assembly.

94MS36 Rev. F2 S/W Ver 2.06

7-3

Vacuum Seal Replacement

A cut, torn or otherwise damaged vacuum frame seal will greatly inhibit, if not prevent, full vacuum. A bad seal can be lifted and peeled off the frame glass. If necessary, use a razor blade or other suitable item to remove

!

any leftover seal adhesive. Install the new seal as shown in Figure 1.

C If using a razor blade or any other sharp object, be careful not to damage or scratch the glass. It is VERY IMPORTANT to not stretch the seal as it is being placed onto the frame glass.

9 5 11 7 6 8

11.50

CUT SEAL ENDS FLUSH, AND BOND

ENDS TOGETHER USING A THIN COAT

OF GASKET ADHESIVE. CLEAN ANY

EXCESS (NO GAP ALL0WED) FROM

SEAL SURFACE.

12.50

10 10

12

REF.

REF.

5

7-4

REF. TEXTURE NEARSIDE (TYP.)

9 1

ITEM

1

2

3

4

5

6

7

QTY.

1

2

2

4

11'

2

1'

DESCRIPTION

GLASS, AP30D

VACUUM BLOCK

INTAKE PORT

O-RING Ø.50 I.D.

SEAL, "WAVE" SHAPE

HOSE ADAPTER

TUBING, CLEAR VINYL

PART NO.

18D1734A00

12D1738A71

12D1728A62

44ORNG01

44GKT13

44ADT03

49DCT24

ITEM

8

9

10

11

12

13

QTY.

1

2

2

1

11'

2

DESCRIPTION

TAPE, TEFLON SEALANT

STRIP, FRONT & REAR

STRIP, R.H. & L.H. SIDE

GASKET ADHESIVE

TAPE, TRANSFER

STRIP, CORNER

PART NO.

81TAP12

13D2213A99

13D2214A99

82ADH11

81TAP09

13D3006A00

94MS36 Rev. F2 S/W Ver 2.06

Vacuum Seal Replacement (cont.)

• Unless otherwise specified

Dimensions are in inches.

Dwg. per ANSIY14.5

Tolerances are: Angles ±5 deg. .X±1 .XX±.03 .XXX±.010

.XXXX±.0030.

• Clean glass perimeter. Press transfer tape onto glass. (as shown) Trim tape along edge of glass. Peel off paper.

• Peel off paper from seal, press seal onto transfer tape. Align seal with

!

outside edge 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 strip. (Item 13) Peel paper off tape and align as shown.

2

SEAL MITER

CUTTING TOOL

90°

.20 DEEP

4 PL

DETAIL "B"

12

.68

TYP.

3

4

9

REF.

.10

TYP.

(.31)

2 PL

(.31)

2 PL

13

94MS36 Rev. F2 S/W Ver 2.06

(45°)

2 PL

DETAIL "A"

DETAIL

"A"

7-5

7-6

Glass Photo Tool (Optional)

• If the unit is equipped with the Glass Photo Tool Option you will have a third vacuum pump installed in the bottom of the unit..

• See section Vacuum Pumps and section Tubing/Fitting Replacement for vacuum problems.

• The vacuum pump used for the glass tool is independent of the integrator and is used to hold the art work to the glass tool. The operation of the pump is controlled by the buttons on the left front on the nose of the unit.

• The button labeled *xpump must be pressed to turn on the vacuum pump.

• Once the pump has been turned on then the button for the upper tool or lower tool can be pressed to activate the respective solenoid in order to hold the art work to the glass tool.

• 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

NEUTRAL

240VAC

RELAY

4

5

DC COM

12 VDC 6

J22

1

2

3

LOWER

VALVE

(12VDC)

(ORANGE, 22 GA)

(RED, 22 GA)

GTOOL

UPPER

VALVE

(12VDC)

SOL5 SOL4

(RED, 18 GA)

(BLACK, 18 GA)

(GRN/YEL)

(18 GA)

P72

1

2

3

(BROWN, 18 GA)

(BLUE, 18 GA)

(GRN/YEL, 18 GA)

16D2741A00

(BLACK, 22 GA)

(WHITE, 22 GA)

16D3211A00

(BLACK, 22 GA)

(BLACK, 22 GA)

(BLACK, 22 GA)

(BLACK, 22 GA)

P70

1

2

P71

1

2

(RED, 22 GA)

(BLACK, 22 GA)

(ORANGE, 22 GA)

(WHITE, 22 GA)

VAC3

GTOOL PUMP

(240V)

PUMP

SW 15

4

5

P69

1

2

6

3

7

4

8

(BLACK, 22 GA)

(RED, 22 GA)

(BLACK, 22 GA)

(ORANGE, 22 GA)

(WHITE, 22 GA)

(GREEN, 22 GA)

16D3212A00

3

L1

(a) (b)

(BLACK, 22 GA)

(RED, 22 GA)

4

UPPER

TOOL

SW 16

L2

(a) (b)

3

(BLACK, 22 GA)

(RED, 22 GA)

4

LOWER

TOOL

SW 17

L3

(a) (b)

3

94MS36 Rev. F2 S/W Ver 2.06

8.

Nose Assembly

Removing the Nose

• Turn unit off, allow the unit to complete its cool down cycle and disconnect power.

• While standing in front of the unit locate and disconnect all multi-pin connectors and vacuum lines below the nose on the right side.

Tower

Nose

Remove these bolts

Side View Right Side

Note: It may be necessary for one person to be working from the inside of the unit and one person working from outside the unit unless you completely remove the door.

• Locate the four

7

/

16

" hex bolts (two on each side) holding the nose to the main tower. On older models these bolts are accessed through a clearance hole in the tower structure. Remove all four bolts.

• Carefully slide the nose piece out as far as needed or off of the structure.

• 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 order to remove them.

• Install the new p.c.boards in reverse order and reassemble the nose.

• Slide the nose out (see section Removing the Nose) but it is not necessary to completely remove it, the nose just needs to be slid out far enough to access the switch.

• Disconnect the plug 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 twist the switch base to separate the switch into two pieces and remove it from the nose.

• Install the new switch in reverse order.

94MS36 Rev. F2 S/W Ver 2.06

8-1

8-2

Replacing the S and G Buttons

• Slide the nose out (see section Removing the Nose) but it is not necessary to completely remove it, the nose just needs to be slid out far enough to access the switches.

• Use a small screw driver inserted between the switch and the sheet metal to break the glue holding the two black retainer clips on each side of the switch from the nose.

• Press together the switch retainer clips on the base of the switch and push the switch out the top and replace wire for wire onto the new switch.

• Install in reverse order, Put a drop of super glue on each retainer clip to hold it to the nose.

Replacing the Glass Tool Vacuum Buttons

• 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.

• 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 Removing the Nose) and place it on carpet or any surface that will not damage the keypad overlay or the paint.

• Remove the vacuum tubing from the gauge.

• Remove the gauge retaining bracket and the faulty vacuum gauge.

• Install in reverse order.

Nose Section Autoformer

Note: The work lights and nose fans receive their power from this autoformer, if both the fans and the work lights are not working check this autoformer first.

• Remove the nose (see section Removing the Nose)

• Meter input and output of the autoformer from 0 to 240, 0 to 208 and 0 to

120. If defective replace.

94MS36 Rev. F2 S/W Ver 2.06

Work Lights

Note: The work lights are controlled by a rocker switch on the underside of the right front corner of the nose. If the work lights are not turning on check the rocker switch and power to the switch. The work lights receive their power from the autoformer in the nose section

• To change the lamps the trays must first be moved to the center position, this is done by:

• Press and hold the S button.

• Press the G button.

• Release both buttons when trays start moving.

• Just before the trays reach the center turn the power off.

• Lift the diffusion cover off of the light assembly.

• Twist the lamp to disengage it from the socket and remove it.

• Install in reverse order.

Nose Fans

Note: The nose fans are controlled by a rocker switch on the underside of the right front corner of the nose. If the nose fans are not turning on check the rocker switch and power to the switch.

• Remove the nose (see section Removing the Nose).

• Disconnect the power leads to the blower(s).

• Remove the blower(s).

• Install in reverse order.

Cleaning or Replacing Nose Filters

• Slide the filters toward the front of the unit and out of the brackets.

• Clean metal filters with water or environmentally safe solvent.

94MS36 Rev. F2 S/W Ver 2.06

8-3

Nose Assembly Drawings

10 11

4 PL

50

43

46

2 PL

56

9 10 11

4 PL

50

43

46

9

BOTTOM VIEW

8-4

55

54

53

52

51

50

58

57

56

49

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

ITEM

8

2

4

2

4

8

16

14

6

4

2

1

QTY

10

10

2

3"

4

10

8"

4

8

6

8

16

6

3

3

2

16

NSI 6-32 KEP NUT ZINC

6-32 X .312 HEX THD. SPACER

SWITCH, CW

TRIMLOCK

41-06NKP

44HHS9292

55SW01

44TRM02

NSI 6-32 X 3/8 PHIL PAN MS BLK

29

28

27

26

25

24

23

22

20

19

18

17

16

15

14

13

1

-

1

4

1

1

1

2

2

1

1

2

80"

1

2

REMOVED

BARRIER

BUTTON, YELLOW "STOP"

KEYBOARD FOR OV45

TUBING, NYLON 1/4" OD-.180 ID

BLOWER

OVERLAY, RAIL COVER, AP30

NSI WASHER, SPLIT LOCK 1/4

DESCRIPTION

41-F0WLS 12

11

10

NSI 8-32 X 3/4 PPMS ZINC

9

NSI 10-32 X 1/2 PPMS ZINC 8

NSI 6-32 X 1/2 BLK SELF TAP 41B06PST.50

7

NSI 8-32 X3/8 PFMS 100-ZINC

NSI 6-32 X 3/8 PHIL PAN MS BLK

1/4-20 X 5/8 SOCKET BTN HD BLK

HARNESS, EMERGENCY SWITCH

PART NO.

3

2

1

2

2

2

2

1

1

1

1

1

1

1

ITEM QTY

BEZEL, WORKLIGHT, 2 LAMP

FILTER, TOP AP30

BRACKET, NOSE SUPPORT

AIR DIRECTOR No.3- NOSE

AIR DIRECTOR No.2- NOSE

AIR DIRECTOR No.1- NOSE

DIVIDER, NOSE AP30 RIGHT

DIVIDER, NOSE AP30 LEFT

REFLECTOR, WORK LT. AP30

RAIL COVER, AP30

DESCRIPTION

REMOVED

55SW45-5

55SW45-2

55SW45-1

55SW45

64MI478

49DCT27

39BLO11

15D2270A00

18D2430A00

19D1942A99

11D1791A02

11D2438A08

11D2433A08

11D2427A08

11D2426B62

11D2426A62

11D3255A07

11D2425A00

PART NO.

Continued on next page

94MS36 Rev. F2 S/W Ver 2.06

Nose Assembly Drawings (cont.)

41

47 16

3 PL

44

41

33 3 4

4 PL

45

42

54 14

3 PL

44

41

33 16

44

47

A

14 PL

34

6 PL

35

5 PL

35

18

2 PL

38

B

1

4 PL

39

51

37

4 PL

2

2 PL 45 40

3 PL

49

48

15 17

2 PL

55

7

6

5

A

5 PL

35

94MS36 Rev. F2 S/W Ver 2.06

TOP VIEW

4 PL 46 43 36

Continued on next page

B

REF.

34

4 PL

36

43

46

8-5

8-6

Nose Assembly Drawings (cont.)

22

13

21 53 10 PL

57 10 PL 1

REF.

58 10 PL

8

29

DETAIL A

VIEW B B

32

4 PL

32

4 PL

DETAIL B

8

30

2 PL 26

2 PL

23

VIEW A A

2 PL

20

52

31

2 PL

19

DETAIL A 2 PLACES

STOP

(TOP POS.)

GO

(BOT. POS.)

27

RED BLK

RED

BLK

30

REF.

DETAIL B

VIEW C C

94MS36 Rev. F2 S/W Ver 2.06

9.

Exposure Trays

Mylar® Replacement

• Close the Mylar® frame and open the six cam latches.

• Remove the inner Mylar® frame and position the pre-cut Mylar® sheet into the frame, make sure that the Mylar® is overlapping on all side.

Cam Latch

Closed

Position

Open

Position

• Reinstall the inner Mylar® frame and ensure all cam latches are closed.

• Trim the excess Mylar® from between the inner and outer frames.

If Mylar® Pulls Out of the Frame

• Make sure the Mylar® is not cut to small. The 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 pull the gas shocks off of the mounting ball joints then lower the frame.

• Remove the 3 Allen screws from each of the two hinges in the back of the frame and lift the frame off.

Note: The frame MUST be aligned when it is reinstalled.

• Place the new frame flat on the tray, line up and insert the Allen head

94MS36 Rev. F2 S/W Ver 2.06

9-1

screws through the hinge into the frame make sure the frame is

1

/

32

" to

1

/

16

" above the top of the hinge to avoid the possibility of damaging the glass, then tighten them down.

1/32" to

1/16"

Allen

Screw

Hinge

Bar

Outer

Frame

End View

• 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

1

5

7

9-2

8

6

4

2

• Lift the frame and push the gas shocks back onto the ball joints.

• Reinstall the safety clips into the ends of the gas shocks.

94MS36 Rev. F2 S/W Ver 2.06

Tray Assembly Drawing

36

38

37

DETAIL B

FRONT BEARING

ASSY.

27

2 PL

40

24

REF.

2 PL

39

1

VIEW AA

6

2 PL

13

VIEW AA

4 PL

11

2 PL

50

4 PL

8

2 PL

13

52

10

VIEW AA

4 PL

20

4

9

2 PL

37

39

2 PL

36

38

2

44

45

49

12

7

2 PL

2 PL

5

39

DETAIL C

FRONT WHEEL

ASSY.

VIEW AA

DETAIL A

4 PL

49

2 PL

3

(BOTH SIDES)

8 PL

37

38

47

(BOTH SIDES)

2 PL

41

8 PL

46

36

2 PL

38

37

21

22

2 PL

(BOTH SIDES)

28

2 PL

39

2 PL

37

38

36

29

2 PL

37

38

36

2 PL

24

40

SEE DETAIL D

REAR WHEEL

ASSY.

23

W/CONNECTOR

36

38

37

51

18

3 PL

35 33

9 PL

19

2 PL

6 PL

42

20

43

1 REF.

30

7 REF.

Continued on next page

94MS36 Rev. F2 S/W Ver 2.06

9-3

Tray Assembly Drawing (cont.)

9-4

25

17

34

DETAIL A

34

25

15

DETAIL B

31

26

16

31

26

32

32

14

DETAIL C

DETAIL D

52 34" SEAL "SOLID D" 44GKT07

51

50

1

4

49

48 1 CABLE, MAGNETIC TRAY SWITCH

47 8

NSI 8-32 X 1/4 PHIL PAN BLK

TOP, HINGE, GLASS TRAY -AP30

41B08PPS.25

11D2422A62

45

43

1

6

NSI 6-32 X 1/2 PHIL PAN BLK

1/4 SAE FLAT WASHER

10-32 X 3/4 SHCS

41BO6PPS.50

NSI #6 KEP NUT ZINC 41-06NKP

1/4-20 X 3/8 BOTTON HEAD 41-F0SHB.37

41-40WFR

41B12SHC.75

42 26 NSI #10 FLAT WASHER BLACK

41 2

NSI 1/4 - 20 X 1 SKT HD CAP 41BOSHC1.0

1/4-20 X 5/8 BTN HD SCREW 41BFOSHC.62

NSI #6 SPLIT LOCK WASHER 41-06WLS

40 4

39 7

38 18

37 18

36 10

35 9

34 3

33 1

32 2

NSI 6-32 X 3/8 PHIL PAN BLK 41B06PPS.37

NSI 6-32 X 1/4 PHIL PAN BLK 41B06PPS.25

WASHER, .380 ID .625

41WFR03

12

11

8

7

6

10

9

5

4

3

2

1

31 2

30 1

29 1

28

27

26

25

24

23

22

1

1

2

2

2

1

2

21 2

20 10

19 2

18 3

15 1

14 1

13 122"

PIVOT BAR, AP30/OV33 12D1727A99

WHEEL

LINEAR BEARING 1/2" DIA.

12D1735A08

43BLB12

LIGHT BLOCK GUIDE MOUNT

SWITCH, MAGNETIC INTE.

12D1737A62

55SW50-B

STUD, BALL FOR GAS SPRING 43SDB01

GAS SPRING 30 LBS

NSI #10 SPLIT LOCKWASHER

HINGE, BLOCK

END PIVOT BLOCK

17 1 FRONT WHEEL BLOCK

16 1

FRONT BEARING BLOCK

REAR BEARING BLOCK

TAPE, OV24 1/8" X 1" X 50

43SPR13-1

41-10WLS

12D2418A71

12D1895A99

12D1731A71

12D1733A00

12D1730A71

12D1732A71

81TAP07

1

4

92"

2

4

1

1

4

2

1

1

TIE WRAP ADHESIVE MOUNT BASE

NSI #10 KEP NUT ZINC

44PAD03

41-10NKP

TAPE OV24 1/8" THK, 1/4 W. 81TAP06

HANDLE, 6". ALUM., BLK, 10X32T 44HDL03

NSI 10-32 C 1/2 PHIL FLAT MS

GLASS FRAME - AP30

GLASS, WATERWHITE AP30

41B12PFO.50

11D1726A02

18D1734B00

11D1657A62

41-12PPMS2.0 10-32 X 2 PPMS ZINC

NSI #6 X .125 ROUND SPACER

RAMP, SWITCHES, AP30/OV33

42HHS8500

11D2971A71

TRAY AP30/OV33 11D1892A02

ITEM QTY DESCRIPTION PART NO.

94MS36 Rev. F2 S/W Ver 2.06

Mylar Frame Assembly

Outer Frame Assembly

19

2 PL

OUTER FRAME ASSEMBLY

TOP VIEW

18 2 PL

(GLASS TRAY ASSEMBLY)

15

REF.

1

24 32

2 PL

9

32

ADD WASHERS AS NEEDED

TO ADJUST CATCH TO LATCH

LATCH / HANDLE

ASSEMBLY SIDE VIEW

14

2 PL

8

2 PL

VIEW A

2

REF.

6

2 PL

2 PL

17

21

6 PL

7

2 PL

12

3

2 PL

15 2

APPLY GASKET ALL AROUND

FRAME ASSEMBLY AS SHOWN

2

SEE VIEW A

3 20

8 PL

94MS36 Rev. F2 S/W Ver 2.06

Continued on next page

9-5

9-6

8.0

6 PL

4.0

6 PL

Inner Frame Assembly

INNER FRAME ASSEMBLY

BOTTOM VIEW

15 2

CUT TO LENGTH AND

APPLY AS SHOWN

REFERENCE VIEW B

6 PL

6 PL 30

6 PL 10

16 6 PL

31 6 PL

6 PL

25 6

29

4

2 PL

20

3

16 PL (FARSIDE)

5

2 PL

29

28

27

26

25

24

23

22

21

20

19

18

17

32

31

30

NSI #10 FLAT WASHER BLK

NSI #8 FLAT WASHER, BLK

NSI #8 X .250 SPACER

PRE-PUNCHED MYLAR

NSI 6-32 FLEXLOCK NUT

NSI #6 SPLIT LOCK WASHER

NSI 6-32 X 3/8 PHIL BLK

WAVE WASHER .25 ID

NSI 10-32 X .50 PHIL PAN

NSI, #6 FLAT WASHER BLK

NSI 6-32 X 3/8 FLT BLK

SHCS, 10-32 X 3/4

SHCS, 8-32 X 3/8

BALL STUD, SHRT.

KEP NUT, #10-32

SCREW, SHLDR ø.187 X 1.25

41B10WFR

41B08WFR

42HHS8521

91PPMC-04-H

41-06NLM

41-06WLS

41B06PPS.37

41-F0WSW

41B12PPS.50

41B06WFR

41B06PFO.37

41B12SHC.75

41B08SHC.37

12D2476A00

41B12NKP

41-0BSBL1.25

1

2

2

3

6

6

2

2

2

2

6

2

2

6

24

2

15

REF.

VIEW B

SCALE: 1/1

.03

.00

6 PL

26

2 PL

27 23

2 PL

28 22

11 13

SEE VIEWB

16

15

14

13

12

NSI #8X1/2 PPMS BLACK

GASKET, .33W X .06THK.

SPRING, 7/16 X 9/16 COMP.

SWITCH, MAGNETIC INTE.

HANDLE, 6 INCH

11

10

9

8

7

6

MOUNT, MAGNETIC SWITCH

CAM LATCH

CATCH

LATCH

MOUNT, HANDLE

BASE, HANDLE/LATCH

FRAME, MYLAR, INNER-F/R 5

4

3

2

FRAME, MYLAR, INNER-SIDES

FRAME, MYLAR, OUTER-SIDES

FRAME, MYLAR, OUTER-FRONT

1

ITEM NO.

FRAME, MYLAR, OUTER-REAR

DESCRIPTION

P A R T S L I S T

41B08PPS.50

44GKT11

43SPR12

55SW50-B

44HDL03

11D2971A71

12D2379A76

11D2392A62

12D2391A76

12D2390A76

12D2389A76

12D2382B76

12D2382A76

12D2381A76

12D2380B76

12D2380A76

OLEC P/N

2

2

1

1

QTY.

2

6

1

2

2

2

2

6

-

2

1

1

94MS36 Rev. F2 S/W Ver 2.06

Gas Strut Removal

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 retaining ball mounts.

• Install the new strut in the reverse order.

Replacing the linear bearings

There are two linear bearings on the left-hand side of each exposure frame, one in the front and one in the rear. They move along the track when the frames move in and out of the unit. Check the linear bearings if frame transport becomes noisy.

Note: At this point locate items 14, 15, 24, 25, 27, 34, 36, 37, 38 & 39 in the Tray Assembly Drawings.

To remove the front bearings:

• Loosen the nose and slide it forward about 2" (See section 9.1 Removing the Nose.).

• 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 the linear bearing to the linear bearing retainer block and replace it.

• Install in reverse order.

To replace the rear bearings:

Disconnect the molex plug at the tray motor and move the frame to be worked on to the rear.

• Remove light block guide mount from the frame using a 5 /

32

" Allen wrench.

• Remove the remaining linear bearing retainer block screw using a

5

/

32

"

Allen wrench.

• Lift the frame and slide the linear bearing and linear bearing retainer block back and off.

• Remove the Phillips screw attaching the linear bearing to the linear bearing retainer block and replace it.

• Install in reverse order.

94MS36 Rev. F2 S/W Ver 2.06

9-7

Frame Glass Replacement

Note: Wear leather gloves and safety glasses when performing this procedure.

• Open the frame to be changed.

• Remove the two glass retaining screws on the front edge of the glass frame.

• Push up on the glass from 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 retaining ball mounts.

• Install the new strut in the reverse order.

9-8 94MS36 Rev. F2 S/W Ver 2.06

10. Center/Drive Assembly

Center/Drive Assembly Diagram

4 PL

34

32

2 PL

40

33

9

8

2 PL

8 PL

2

15

2 PL

37

4 PL

39

2 PL

36

42

47

2 PL

CHAIN

TENSIONER

ASSY., DETAIL B.

40

33

9

8

3

74"

46

12 PL

38

18 PL

37

36

4 PL

34

35

DRIVE MOTOR ASSY.

DETAIL A.

TIMING SWITCH ASSY.

DETAIL C.

1

94MS36 Rev. F2 S/W Ver 2.06

17

21

2 PL

19

22

4

WHT

18

2

1

3

2

1

2 PL

27

2 PL

13

20

BLK 23

62D3566A00

26

2 PL

BLK

24

2 PL

DETAIL A

28

2 PL

5 14

3 PL

26

TOP POS

RED BLK

RED

BLK

BOT POS

30

2 PL

27 29

DETAIL C

2 PLACES

Continued on next page

6 7 25

10

11

41

43

DETAIL B

44

16 45

2 PL

12

LOWER/

UPPER

4 PL

31

UPPER/LOWER DETAIL D

10-1

10-2

Center/Drive Assembly Diagram (cont.)

9

8

12

11

10

7

6

5

4

3

2

1

27

26

25

24

23

22

31

30

29

28

21

20

19

18

17

16

15

14

13

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

ITEM

QTY

2

1

2

1

1

2

1

INSUALTION PAD AL13/14 15D725

NSI 3/8 X 3/4 SOC. SHLD. 41BF2SHF.62

THREADED ROD 12D1751A00

5/16 - 18 X 3/4 HEX BOLT BLK. 41BF2BHX.75

3

4

12

18

NSI 8-32 5/8 FLAT HEAD 82

41B08PF2.62

NS #10 LOCK WASHER SPLIT

41-10WLS

20

4

8

3

4

NSI 1/4 SAE FLAT WASHER 41-FOWLS

4

4

2

2

NSI 6-32 X 3/4 PPMS ZINC

4/40 X 5/8 PHIL FLAT MS

41-06PPS.75

41-04PFO.62

NSI 4/40 KEP NUT

41-04NKP

6

8

1

NSI CABLE TIE, UV, 4"

44TIE08

NSI 1/4-20 X 1.25 HEX BOLT BLK

41B40BHX1.25

2 TERMINAL, FEMALE MINIFIT

51TML05

10" WIRE, 22 GAUGE, BLK 2 CON.

8"

43OSD01

1

2

1 RECEPTACLE, 2 PIN, MINIFIT 52RCP28

1

1

8

CHAIN, #35 RLR- 10 FT

43CHA05

1 HARNESS, MOTOR- POS SWT

4 SWITCH, TIMING-ROLLER

55SW02

2 CHAIN YOKE

12D1757A62

1

1

TENSIONER SPROCKET 12D1996A00

3

3

IDLER BUSHING

IDLER SPROCKET

12D1754A00

12D1753A00

1

1

SLIDER

SLIDE

12D1752A62

12D1750A62

2

1

148"

2

1

ACCUTRACK

CABINET, WELDMENT AP30

12D1634A00

63D3326A08

DESCRIPTION PART NO.

94MS36 Rev. F2 S/W Ver 2.06

Frame Transport System

The printer has two aluminum exposure frame assemblies. Vacuum for frame evacuation is drawn through two ports in the glass; one at each of the rear corners. The top coversheet frame is hinged in the back, with a gas strut on each side that hold the cover-sheet frame open.

The exposure frame transport system is powered by a

1

/

8

-hp PMDC gear motor. It is controlled and operated by the computer system, through the nose section G and S switches.

Pressing the G switch once will start a vacuum cycle. The second time G is pressed, the frames will move into position and an exposure will start. The frames can be operated through a blank frame cycle by holding down the S switch before pressing the G switch.

The frames move at two speeds; a fast speed initially, then to a slow speed near the end of their travel. This prevents a noisy, hard-stop condition and possible machine damage. For added safety, the drive motor has a slip clutch to prevent machine damage. A system switch inside the cabinet stops frame movement when it is actuated by the frame moving into the exposure position. If the system switch fails, the frame contacts a second switch that turns off power to the frame drive motor.

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 object blocks frame movement. Refer to “Frame

Drive Clutch Adjustment” for procedures.

Note: Remove your watch when working on the drive motor. The drive motor magnet could damage watches or similar devices.

• Remove the left side cabinet door.

• Disconnect the motor connector from the control box.

• Position both frames to approximately a mid-point state.

• Disconnect the two wire connectors at the motor end of the drive motor.

• Remove the four

1

/

4

-20 x

3

/

8

" bolts that attach the motor to its mounting plate and lift out the motor.

• Install the new motor in the reverse order.

Frame Drive Clutch Adjustment

A personnel safety hazard may exist, or machine damage may occur if the slip clutch on the exposure frame drive motor is set too tight. If the clutch is set too loose, the frame drive will be too slow and a transport error may occur. Use the following procedure to set the clutch at the minimum setting for operation.

94MS36 Rev. F2 S/W Ver 2.06

10-3

• Open the left side sliding door on the printer and locate the drive motor at the left rear corner of the cabinet.

• Loosen the two set screws which lock the hex nut to the motor shaft.

• Adjust the hex nut until the minimum setting is found that provides frame movement with no slippage.

• Retighten the set screws in the hex nut.

• Close the sliding door.

Frame Speed Adjustment

Note: Frame speed is set at the factory and normally does not require adjustment.

Note: An adjustment of the frame speed must be preformed whenever the Control Box PCB, part #64CT464, or the Motor Speed Control

Board, part #31MSC02 is replaced. This adjustment is critical, failure to do so can damage the board and/or hardware.

• Locate the 'FAST' and 'SLOW' potentiometers in the upper lefthand corner of the Control Box. The frame speed adjustments will be made from these pots.

FAST

SLOW

MOTOR SPEED

STOP

IN

SLOW

OUT

MOTOR

L - SWT

A/C

COMMUNICATION

12 VDC

ACCESSORY

VACUUM

PUMPS

LINE VOLTAGE

SELECTION

SWITCH

POWER SUPPLY

HF1 BLOWER HF1 BLOWER

POWER SUPPLY

Activate the Diagnostics Mode through the keypad;

[SEL_]

Press the 1, 2, 3 t 4 keys, the center display will read [SEL_].

Press the 6 key: this will activate the diagnostic mode.

[0000]

Press the 9 key: this will reset the Vacuum window to [0000].

[0064]

Press the 7 key to set motor drive: the Vacuum window should read

[0064].

[0096]

Press the 6 key: upper tray should move in, the Vacuum window should read [0096].

[0064]

Press the 6 key: lower tray should move in, the Vacuum window should read [0064].

10-4 94MS36 Rev. F2 S/W Ver 2.06

[0096]

Press the 6 key again: upper tray should move in, the Vacuum window should read [0096].

• Set volt meter for VDC and measure across pins 5 & 6 on motor speed connector. Adjust the 'SLOW' pot on the control box to read 25 to 32

VDC. Notice that the frame moves slower than normal. The total travel time of the frame should be 12 seconds.

FAST SLOW

MOTOR SPEED

STOP

IN

SLOW

OUT

MOTOR

L - SWT

A/C

POWER SUPPLY

ACCESSORY

VACUUM

PUMPS

LINE VOLTAGE

SELECTION

SWITCH

HF1 BLOWER

COMMUNICATION

12 VDC

HF1 BLOWER

POWER SUPPLY

• Exit the diagnostic mode by 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 slower speed and stop about 0.750" to 1" from the end of the tray rod.

!

C Verify the adjustment by noting the position of the frame when it is inside the Unit. Check the frame position switches for each frame. When adjusted properly, the frame will come to a stop depressing the first switch, but not the second. If the second switch is depressed, check slow speed adjustment.

94MS36 Rev. F2 S/W Ver 2.06

10-5

34

Light Block Assembly

Light Block Assembly Drawing

5 PL

21

37

TORSION SPRING

ASSY., BOTH SIDES

SEE DETAIL A

9

26

33

4 PL

WHEEL ASSY.

BOTH SIDES

SEE DETAIL C

5 PL 33

26

26

33

4 PL

2

4

10-6

37 8 PL

34

4 PL

33

26

2

9

5

3

WHEEL ASSY.

BOTH SIDES

SEE DETAIL C

37

REF.

5 PL

33 26

TORSION SPRING

ASSY. BOTH SIDES

SEE DETAIL B.

5 PL 33 28 38

Continued on next page

94MS36 Rev. F2 S/W Ver 2.06

Light Block Assembly Drawing (cont.)

2 PL. 2 PL.

27

28

20

22

33

30€

2 PL

DETAIL A

2 PLACES

DETAIL B

2 PLACES

DETAIL C

4 PLACES

6

.2 2 PL

LEG

12

REF.

LH

38 23 7 8

21 16

10 14 15 24 25

19

17

62D2321A00

2 PL.

11 29

18

26

18

17

16

21

20

19

15

14

13

12

11

10

3

2

1

6

5

4

9

8

7

33

32

31

36

35

34

30

29

28

40

39

38

37

24

23

22

27

26

25

1

8

19

8

2

5

8"

41

1

1

FRONT CABINET, AP30

NSI #10 FLAT WASHER SAE

NSI 6-32 X 1/2 PPMS ZINC

NSI 10-32 KEP NUT ZINC

11D2492A06

41-10WFR

41B06PPS.50

41-12NKP

NSI 1/2-13 X 2.O OSHCS-BLK

NSI 8-32 KEP NUT ZINC

41BF5SHC2.0

41-08NKP

TAPE, GLIDE (BLACK UHMW) 81TAP16

2

2

4

9

4

4

2

24

2

14

4

23

NSI #6 FLAT WASHER BLACK 41B06WFR

FRONT, CABINET- AP30 11D2492A06

BEZEL, FRONT PANEL-NEW 11D3173A06

NSI 10-32 X 1/2 PPMS, ZINC

NSI 6-32 X 3/8 PHIL PAN MS ZINC

NSI #6 LOCK WASHER, SPLIT

41-12PPS.50

41B06PPS.37

41-06WLS

2

1

1

1

2

1

NSI 6-32 X 3/4 PPMS ZINC

NSI 6-32 KEP NUT ZINC

#1/2 - 13 HEX NUT

41-06PPS.75

41-06NKP

41-F5NHX

1/2" THICK FLAT WASHER

NSI 1/2 FLAT WASHER

41-F5WFT

41-F5WFR

NSI #10 LOCKWASHER SPLIT 41-10WLS

NSI #8 FLAT WASHER, BLACK

NSI 10 X 24 HEX NUT ZINC

41B08WFR

41-14NHX

NSI 1/4 SAE FLAT WASHER 41-40WFR

1

1

1

1

2

2

2

1

1

4 NSI SHOULDER SCREW .37

4

4

NYLON IDLER PULLY

BRACKET, WHEEL MOUNT

41BF1SHC.37

49PUL01

11D1659A99

SPRING, TORSION LH (LOW) 43SPR22

SPRING, TORSION RH (LOW) 43SPR21

SPRING, TORSION RH 43SPR18

SPRING, TORSION LH 43SPR17

#6 BRASS RND. THD. SPACER 42HHS8779

SPACER, HINGE

MOUNT, SPRING, LOW LT. BLOK-LF

MOUNT, SPRING, LOW LT. BLOK-RT

11D2202A02

11D2051B62

11D2051A62

MOUNT, SPRING,LOW LT. BLK AP30 11D1660A99

LIGHT BLOCK TOP

LIGHT BLOCK LOWER AP30

HINGE 6 FT. LONG

CABINET, WELDMENT AP30

11D1632A17

11D1631A17

43HNG05

63D3326A08

ITEM QTY DESCRIPTION PART NO.

Replacing Lower Light Block Springs

• Move upper exposure frame into the cabinet.

• Disconnect main power.

• Open left and right doors.

• Remove the left mounting bracket first.

Continued on next page.

94MS36 Rev. F2 S/W Ver 2.06

10-7

• Use the new mounting bracket.

• Insert two 8-32 x 0.62" screws and secure to mounting bracket with two

8-32 kep nuts.

• Use the

1

/

2

-13 x 2.0" shoulder screw and large

1

/

2

" washer and insert 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.

10-8 94MS36 Rev. F2 S/W Ver 2.06

11. Air Conditioning System

Compressor

The air conditioning compressor requires no routine maintenance. It is hermetically sealed, properly lubricated at the factory, and should provide years of satisfactory operating service.

Should the refrigerant charge be lost, recharging ports (access fittings) on the suction and discharge sides of the compressor are provided for

!

recharging and/or checking suction and discharge pressures.

Wl The access fitting covers should never be loosened, or removed, except by trained refrigeration service personnel.

Inlet Filter

Proper maintenance of the inlet filter will assure proper operation of the air conditioner. Delaying or ignoring filter maintenance will reduce the maximum ambient temperature under which the unit will operate.

The compressor operating 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 dropped to within the thermal overload switch‘s cutin setting, the compressor will restart automatically.

However, shut downs will reoccur until the inlet filter has been cleaned or replaced.

It is recommended that power to the air conditioner be manually interrupted when abnormally high compressor operating temperatures

!

cause automatic shutdown of the unit.

Cl Continued operation under the above conditions will damage the compressor and shorten its life. The air conditioner features an easily removable inlet filter to facilitate necessary cleaning. There should be no reason to neglect this necessary maintenance.

94MS36 Rev. F2 S/W Ver 2.06

11-1

Intake Filter Removal And Installation

Note: Orient the filter according to AIR FLOW arrow on filter frame.

11-2

• The filter is located on the back of the exposure unit. Lift the filter high enough for the bottom to clear the lower filter retainer.

• Pull the bottom of the filter toward you, pressing downward until the top of the filter clears the upper filter retainer. Remove CAREFULLY if the air conditioning unit is operating, to assure that no dirt from the filter enters the air intake opening.

• If the filter is to be cleaned, see “Intake Filter Cleaning.”

• Install the cleaned or new filter by sliding the top of the filter into upper retainer. Push the filter against it, and slide the filter 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 air filters are designed to provide excellent filtering efficiency with high dust holding capacity, and minimum air flow resistance. Because they are constructed entirely of aluminum, they are light weight and easy to service.

To achieve maximum performance from your air handling equipment, air filters should be cleaned on a regular basis.

• Flush the filter with warm water from the exhaust side to the intake side.

Note: The air flow arrow on the frame.

Note: Never use caustic solutions to clean the aluminum filter.

94MS36 Rev. F2 S/W Ver 2.06

• After flushing, allow filter to drain. Placing it with a corner down will assure complete drainage.

• Amounts of airborne dust and dirt particles are different in every location.

When a fine layer of dust or lint is visible on the surface of the filter, remove and clean the filter.

Condenser & Evaporator Blowers

• The blower motors require no maintenance. All bearings, shafts, etc., are lubricated during manufacturing for the life of the motor.

• Operation of the air conditioners in areas containing airborne caustics or chemicals can rapidly deteriorate filters, condenser coils, blowers, and motors.

• If the condenser blower motor (top blower) should fail, 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 detection equipment during manufacture may require repair and recharging of the system. This work should be performed by qualified professionals only, generally available through an air conditioning repair or service company in your local area.

• Refer to the data on the air conditioner nameplate which specifies the type of refrigerant and the charge size in ounces. Before recharging, make sure there are no leaks and that the system has been properly evacuated by deep vacuum.

94MS36 Rev. F2 S/W Ver 2.06

11-3

11-4 94MS36 Rev. F2 S/W Ver 2.06

12. Diagrams

Control Box Front View

FAST

MOTOR

STOP

SLOW

SPEED

SLOW

COMMUNICATION

1

4

2

-

5

3

+

12 VDC

Blk Red

1

SET SELECT SWITCH TO

LINE UP WITH

LED INDICATOR LIGHT

208

240

L U

IN

OUT

6

3

Blk Red

Wht Red Blk

MOTOR

L - SWT

4

1

POWER SUPPLY

E C

4

Wht Org Wht Blk

A/C

1 4

220~ 120~

Blk Red Blk Red

ACCESSORY

1 4

Blk Red Blk Red

VACUUM

PUMPS

1

6 5 4

3 2 1

GTOOL (optional)

HF1 BLOWER HF1 BLOWER

LINE VOLTAGE

SELECTION

SWITCH

POWER SUPPLY

94MS36 Rev. F2 S/W Ver 2.06

12-1

12-2 94MS36 Rev. F2 S/W Ver 2.06

Control Box Wiring Diagram (Standard with 5kW)

POWER

DISTRIBUTION

BLOCKS

L1

L2

F

G

D

E

F1

RED

BLACK

F2

30ASB

X4

F3

BROWN

BLUE

F4

R1

(240V)

R2

(240V)

WHITE

R3

(240V)

BLUE

BROWN

BLACK

RED

BLUE

4

3

2 1

12VDC

RELAY

L3

N

GND

GSTD

H

J

K

L

YELLOW

VIOLET

F6

F7

ORANGE

WHITE

F8

10ASB

X4

A-240

XFMR

VIOLET

BLUE

B-208

BLACK

C-120

D-COM

WHITE

F10

3ASB

A

VOLTAGE

SELECTION

RED

IN

B

VSEL

POWER SUPPLY,

12VDC

(120V OPERATION)

PS

+OUT

-OUT

4

1

RED

BLACK

BLACK

WHITE F9

1/2ASB

AC INPUT WIRING

TERM.

380 V ~

(W/ 240V P/S)

3-PHASE (WYE)

L1

L2

L3

N

E

G

H, K

D, F, J, L

208/240 V ~

3-PHASE (DELTA)

F, J, L

G, D

E, H, K

NOT USED

208/240 V ~

SINGLE PHASE

D, F, H, K

E, G, J, L

NOT USED

NOT USED

R4

(240V)

BLACK

BLACK

WHITE

64CT464V00

T7

T6

MOTOR/LIMIT

SWITCHES

J11

1

2

3

5

6

4

T1

T2

T3

J17

1

2

1

2

1

2

P10 J10

94MS36 Rev. F2 S/W Ver 2.06

EVAPORATOR

COMPRESSOR

T5

T4

3

4

1

2

2

3

6

1

4

J21

GTOOL

VIOLET

BLACK

J23

1

2

YELLOW

3

4

P23

1

2

3

BLUE

BLACK

YELLOW

WHITE

4

J14

VACUUM PUMPS

(RED, 16GA)

COOLING FAN

(240V)

3

4

J12

A/C

1

2

1

6

4

8

J9

2

3

7

5

P9

2

3

7

5

WHITE

RED

BLACK

GRAY

1

6

4

8

YELLOW

ORANGE

BLUE

SHIELD

MOTOR SPEED CONTROLLER

S3

S2

S1

A2

A1

INHIB +

INHIB -

J13

1

2

3

4

120V

ACC.

220V

T8

T9

1

2

J15

12VDC

INTEG. PWR

RED

BLACK

1

2

J20

12VDC

AUX

L1

SCR

L2

12-3

Control Box Wiring Diagram (Standard with 8kW)

POWER

DISTRIBUTION

BLOCKS

L1

L2

L3

N

GND

GSTD

F

G

D

E

RED

BLACK

BROWN

BLUE

R1

(240V)

R2

(240V)

H

J

K

L

YELLOW

VIOLET

F6

F7

ORANGE

WHITE

F8

10ASB

X4

A-240

XFMR

VIOLET

BLUE

B-208

BLACK

C-120

D-COM

WHITE

F10

3ASB

A

VOLTAGE

SELECTION

RED

IN

B

VSEL

POWER SUPPLY,

12VDC

(120V OPERATION)

PS

+OUT

-OUT

4

1

RED

BLACK

BLACK

WHITE

F9

1/2ASB

WHITE

BLUE

BROWN

BLACK

RED

R3

(240V)

64CT464V00

BLUE

4

3

2 1

12VDC

RELAY

R4

(240V)

T7

T6

MOTOR/LIMIT

SWITCHES

J11

1

2

3

5

6

4

T1

T2

BLACK

T3

J17

1

2

1

2

1

2

P10 J10

BLACK

WHITE

AC INPUT WIRING

TERM.

L1

L2

L3

N

380 V ~

(W/ 240V P/S)

3-PHASE (WYE)

E

G

H, K

D, F, J, L

208/240 V ~

3-PHASE (DELTA)

F, J, L

G, D

E, H, K

NOT USED

208/240 V ~

SINGLE PHASE

D, F, H, K

E, G, J, L

NOT USED

NOT USED

EVAPORATOR

COMPRESSOR

T5

T4

3

4

1

2

2

3

1

4

6

J21

GTOOL

VIOLET

BLACK

J23

YELLOW

3

4

1

2

P23

BLUE

1

BLACK

2

YELLOW

3

WHITE

4

J14

VACUUM PUMPS

(RED, 16GA)

COOLING FAN

(240V)

3

4

J12

A/C

1

2

1

6

4

8

J9

2

3

7

5

P9

2

3

7

5

WHITE

RED

BLACK

GRAY

1

6

4

8

YELLOW

ORANGE

BLUE

SHIELD

MOTOR SPEED CONTROLLER

S3

S2

S1

A2

A1

INHIB +

INHIB -

J13

1

2

3

4

120V

ACC.

220V

T8

T9

1

2

J15

12VDC

INTEG. PWR

RED

BLACK

1

2

J20

12VDC

AUX

L1

SCR

L2

12-4 94MS36 Rev. F2 S/W Ver 2.06

Control Box Wiring Diagram (480V all)

POWER

DISTRIBUTION

BLOCKS

L1

WHITE

BLUE

BROWN

BLACK

RED

L2

L3

X1

X4

X2

GND

GSTD

H1

480V

H4

RED

BLACK

H2

H3

BLUE

X4

120V

X3

X2

240V

WHITE

120V

BROWN

X1

5KVA XFMR

AC INPUT WIRING

TERM.

480V ~

SINGLE PHASE

L1

L2

L3

X1

X4

X2

D, F, H1

E, G, H4

NOT USED

H, K, M

J, L, N

P

480V ~

3-PHASE (DELTA)

F, H1

G, D

E, H4

H, K, M

J, L, N

P

M

F11

5ASB

YELLOW

P

BLUE

R5

(120V)

R6

(120V)

N

5ASB

F12

VIOLET

H

J

K

L

YELLOW

VIOLET

F6

F7

ORANGE

WHITE

F8

10ASB

X4

A-240

XFMR

VIOLET

BLUE

B-208

BLACK

C-120

D-COM

WHITE

F10

3ASB

A

VOLTAGE

SELECTION

RED

IN

B

VSEL

POWER SUPPLY,

12VDC

(120V OPERATION)

PS

+OUT

-OUT

4

1

RED

BLACK

BLACK

WHITE

F9

1/2ASB

R3

(240V)

BLUE

R4

(240V)

F

G

D

E

F1

F2

30ASB

X4

F3

F4

RED

BLACK

BROWN

BLUE

R1

(480V)

R2

(480V)

4

3

2 1

12VDC

RELAY

BLACK

BLACK

WHITE

64CT464V00

T7

T6

MOTOR/LIMIT

SWITCHES

J11

3

5

1

2

6

4

T1

T2

T3

J17

1

2

1

2

1

2

P10 J10

94MS36 Rev. F2 S/W Ver 2.06

EVAPORATOR

COMPRESSOR

T5

T4

3

4

1

2

1

4

2

3

6

J21

GTOOL

VIOLET

BLACK

J23

1

2

YELLOW

3

4

P23

BLUE

1

BLACK

2

YELLOW

3

WHITE

4

J14

VACUUM PUMPS

(RED, 16GA)

COOLING FAN

(240V)

3

4

J12

A/C

1

2

1

6

4

8

J9

2

3

7

5

P9

2

3

7

5

WHITE

RED

BLACK

GRAY

1

6

4

8

YELLOW

ORANGE

BLUE

SHIELD

MOTOR SPEED CONTROLLER

S3

S2

S1

A2

A1

INHIB +

INHIB -

T8

T9

J13

1

2

3

4

120V

ACC.

220V

1

2

J15

12VDC

INTEG. PWR

RED

BLACK

1

2

J20

12VDC

AUX

L1

SCR

L2

12-5

12-6

Control Box Wiring Diagram (CE all)

D

(RED, 8GA)

F

(BROWN, 8GA)

E

(BLUE or BLACK, 8GA)

G

(BLUE, 8GA)

62D4049A00 or 62D4049B00

T1

FILTER

29PLF02

(RF1, RF2)

T2

T1

FILTER

29PLF02

(RF3, RF4)

FIGURE "A"

T2

POWER

SUPPLY

(R1, R2)

RELAY

(12VDC)

K2

6

8

2

(BROWN)

(18GA)

0

C1

4

1

R1

R3

POWER

DISTRIBUTION

BLOCK

L1

L2

L3

N

R4

RELAY

(12VDC)

K1

6 2

H

J

(YELLOW, 10GA)

(BLUE, 10GA)

R5

XFMR

LINE

T2

RF5

FILTER

29PLF02

LOAD

T1

A-240

B-208

C-120

A

(YELLOW, 14GA)

F1

(BLUE, 14GA)

F2

(ORANGE, 14GA)

F3

(BLUE, 14GA)

B

F4

15ASB

X4

(BLUE)

(14GA)

(YELLOW)

(16GA)

B

F5

3ASB

A

D-COM

(YELLOW)

(14GA)

(ORANGE, 14GA)

(BLUE, 14GA)

(BLACK, 16GA)

(BLUE, 16GA)

8 4

GND

GSTD

AC INPUT WIRING

P/S 62D4049A00

TERM.

L1

L2

L3

N

380-415V ~

(W/ 240V P/S)

3-PHASE (WYE)

D

F

H

J,E,G

62D4049B00

208-240V ~

(W/ 240V P/S)

3-PHASE (DELTA)

D,H

E,F

G,J

NOT USED

POWER SUPPLY,12VDC

(WIRE FOR 240V OPERATION)

(YELLOW)

(18GA)

A B

F6

1/2ASB

(YELLOW)

(18GA)

L

N

(BLUE, 18GA)

PS

+

-

0

1

T7

T6

MOTOR/

LIMIT

SWITCHES

J11

1

2

3

5

6

4

T1

T2

(BLACK, 16GA)

T3

J17

(RED, 18GA)

P10

1

(BLACK, 18GA)

2

3

2

1

J10

1

2

(BLUE, 18GA)

(BLACK, 16GA)

(RED, 16GA)

(BROWN, 18 GA)

(BLUE, 18GA)

(BLACK, 18GA)

5

2

3

6

1

4

J22

RESET

64CT464V00

(WHITE, 16GA)

(BLUE, 16GA)

(BROWN, 18 GA)

(BLACK, 18GA)

(RED, 18GA)

6

5

2

3

1

4

J21

GTOOL

T5

T4

1

2

(VIOLET, 16GA)

(YELLOW, 16GA)

(BLACK)

(16GA)

J23

1

2

3

4

J14

VACUUM PUMPS

P23

1

2

(BLUE, 16GA)

(BLACK, 16GA)

3

4

(YELLOW, 16GA)

(WHITE, 16GA)

3

4

(RED, 16GA)

COOLING FAN

(240V)

EVAPORATOR

COMPRESSOR

3

4

J12

1

6

4

8

6

4

8

A/C

2

J9

2

3

7

5

1

P9

2

3

7

5

(WHITE, 22GA)

(RED, 22GA)

(BLACK, 22GA)

(GRAY, 18GA)

1

(YELLOW, 18GA)

(ORANGE, 18GA)

(BLUE, 18GA)

(SHIELD)

MOTOR SPEED CONTROLLER

P3 (S3)

P2 (S2)

P1 (S1)

A- (A2)

A+ (A1)

I1 (INHIB+)

I2 (INHIB-)

SCR

T8

T9

1

2

3

4

1

2

(120V)

J13

ACCESSORY

(240V)

J15

12VDC

(RED, 18GA)

(BLACK, 18GA)

1

2

J20

12VDC

L1 L2

94MS36 Rev. F2 S/W Ver 2.06

Unit Cabling Diagram (old nose)

62D2369A00

UPPER

MAG. TRAY SW

LOWER

62D2369A00

COMPRESSOR

EVAPORATOR

AIR CONDITIONER

EMER. SW

16D2412A00

16D2495B00

DRIVE MOTOR

62D2411A00

POS. SW

TRANSFLOW BLOWER

UPPER

LIMIT SW

LOWER

16D1829A00

CONTROL

BOX

BACK

BLOWER 2

16D0957-5

HF1

(LOWER)

POWER

SUPPLY

(LOWER)

BLOWER 1

POWER

SUPPLY

(UPPER)

LAMPHEAD

(LOWER)

PUMP

(UPPER)

16D2251C00 16D2251A00

16D1830A00

16D2251A00

PUMP

(UPPER)

16D2251C00

DOOR

SWITCH

(LEFT)

BOTTOM

DOOR

SWITCH

(RIGHT)

16D1003A11

16D1003A09

16D1827A00

16D1003A06

16D1003A10

16D1003A08

UPPER TRAY GAGE

DISPLAY

BOARD

16D1831A00

16D1828A00

LOWER TRAY GAGE

MAIN

BOARD

(UPPER)

16D1832A00

16D1695B13

16D1825A00

REMOTE

BOARD

(LOWER)

SENSORS

BOARD

FRONT

16D0957-10

(OF CABINET REAR VIEW)

ACCESSORIES

PUSHBUTTON

SWITCHES

POWER

MEMORY

STOP

GO

SWITCH CONNECTIONS

NC

NOCOM

HF1

(UPPER)

LAMPHEAD

(UPPER)

COM

TOP

NC

NO

C

11, 21

12, 22

94MS36 Rev. F2 S/W Ver 2.06

12-7

12-8

Unit Cabling Diagram (new nose)

B5

BLOWER

(120V)

(NOSE)

BLOWER

(120V)

(NOSE)

B6

(BROWN, 18 GA)

(BROWN, 18 GA)

(BLUE, 18 GA)

(BLUE, 18 GA)

XMR

240V

120V

0V

16D2651A00

16D1003A06

(BLACK, 5 COND.)

L1

(WHITE, 18 GA)

(WHITE, 18 GA)

TERMINAL

STRIP

1

2

3

4

5

FAN

SWITCH

SW11

L2

WORK LIGHTS

(120V)

(WHITE, 18 GA)

(WHITE, 18 GA)

COMPRESSOR EVAPORATOR

AIR CONDITIONER

2

56TMP01

1

39ACD02

THERMOSTAT

(OPTIONAL)

LIGHT

SWITCH

SW12

39BLO10

REAR BLOWER

P74

1

2

(RED, 16 GA)

(BLACK, 16 GA)

3

(RED, 18 GA)

P75

1

LEFT BLOWER

6

3

5

2

4

1

P58

62D3566A00

DRIVE MOTOR

(90VDC)

P62

1

2

(WHITE, 16 GA)

(BLACK, 16 GA)

P60

1

(RED, 16 GA)

2

3

(BLACK, 16 GA)

1

2

(RED, 18 GA)

(BLACK, 18 GA)

P61

6

3

5

2

4

1

P59

6

3

5

MOTOR

4

2 1 4 3

A/C

2 1

CONTROL BOX

4 3 2 1

ACCESSORY

6 5 4

3 2

GTOOL

1

4

VACUUM

PUMPS

3 2 1

COMMUNICATION

2 1

12VDC

2 1

12VDC

(BLACK, 16 GA)

(RED, 16 GA)

16D2469A00

B2

P73

(RED, 18 GA)

(BLACK, 18 GA)

1

2

3

B1

RIGHT BLOWER

SW9

22

SW10

12

21 11

DOOR

MOTOR

EMERGENCY

SWITCH

R1 R5 R3 R4 R6 R2

(RED, 18 GA)

(BLACK, 18 GA)

(GRN/YEL, 18 GA)

P64

1

2

3

(RED, 18 GA)

(BLACK, 18 GA)

(GRN/YEL, 18 GA)

P65

1

2

3

(RED, 18 GA)

(BLACK, 18 GA)

(GRN/YEL, 18 GA)

16D2741A00

(RED, 18 GA)

(BLACK, 18 GA)

(GRN/YEL, 18 GA)

16D2741A00

(RED, 22 GA)

(BLACK, 22 GA)

P1

J5 J4 J3 J2 J1 P2

16D2621B00

(GRAY, 5 COND.)

J5 J4 J3 J2 J1 P2

16D1003A06

16D1003A09

16D1003A08

16D1003A09

(BLACK, 5 COND.)

(BLACK, 5 COND.)

(BLACK, 5 COND.)

(BLACK, 5 COND.)

UPPER

VACUUM PUMP

(240V)

LOWER

VACUUM PUMP

(240V)

MAIN BOARD REMOTE BOARD

P67

16D2656A00

16D1003A06

(BLACK, 15 COND.)

(BLACK, 5 COND.)

MEMORY BOARD

P2

P1

DISPLAY BOARD

P3

1

(RED, 18 GA)

(BLACK, 18 GA)

(RED, 18 GA)

(BLACK, 18 GA)

PUSHBUTTON

STOP

(16)

SW7

NO C

16D2196A00

PUSHBUTTON

GO

(128)

NO C

SW8

8

4

7

3

6

2

5

P50

1

(BROWN, 18 GA)

P52

1

2

(BROWN, 18 GA)

(BLACK, 18 GA)

16D2970A00

UPPER TRAY

MAGNETIC SW

SW1

(4)

(BROWN, 18 GA)

1

2

P54

(BROWN, 18 GA)

(BLACK, 18 GA)

16D2970A00

SW2

LOWER TRAY

MAGNETIC SW

16D2487A00

(RED, 18 GA)

(BLACK, 18 GA)

(RED, 18 GA)

(BLACK, 18 GA)

(BLACK, 18 GA)

(RED, 18 GA)

(BLACK, 18 GA)

(RED, 18 GA)

8

4

7

3

6

2

5

1

P51

CM CM CM CM

(RED, 18GA)

NO

(32)

LEFT DOOR

SWITCH

SW6

CM

NC NC

NO

NC

(1)

NO

NC

(8)

NO

RIGHT DOOR

SWITCH

SW5

CM

COOLING FAN

(HF1)

PHOTOCELL

UPPER LAMPHEAD

16D0957-10

CONTROL

UPPER POWER SUPPLY

COOLING FAN

(HF1)

PHOTOCELL

LOWER LAMPHEAD

16D0957-5

CONTROL

LOWER POWER SUPPLY

94MS36 Rev. F2 S/W Ver 2.06

Unit Wiring and Tubing Diagram

TO LEFT

DOOR SWITCH

1

L DOOR

UPPER VACUUM TUBING

3 PL

25

USED W/CLSD LOOP

ONLY

26

REF.

CONTROL/OUTPUT/INPUT/MOTOR

USED W/CLSD LOOP ONLY

THERMOSTAT, USED

W/ CLSD LOOP ONLY

CONTROL BOX LOCATION

CLSD LOOP ONLY

USED W/CLSD LOOP

ONLY

28

27

11

4

26

45

TRAY ASSY. HARNESS

AND TUBING (UPR)

TO TRAY

ASSY. (UPR)

4

REF.

18

PHOTOC

21

28

27

SEE WIRING DIAGRAM

FOR ASSEMBLY

USED W/CLSD LOOP

ONLY

12

28

27

9

44

FROM AIR

CONDITIONER

NOT USED

W/CLSD LOOP

28

27

R DOOR

TO RIGHT

DOOR SWITCH

23

2 PL

31

30

3 PL

22

26

21

2 PL

17

4 PL

19

20

29

21

24

REF.

9

3 PL

10

REF.

2

A

UPPER VACUUM

TUBING

27

28

NOT USED

W/CLSD LOOP

28

27

EVAP. HARNESS

(CLSD LOOP ONLY)

REF.

9

A

RIGHT & LEFT DOOR SWITCH WIRES/ PHOTOCELL CONNECTOR CABLE

7 6

2 3 2

2

2

UPPER

LOWER

MAIN REMOTE

22 18

LWR TRAY

36

2 PL

TO LOWER TRAY

WIREWAY

33 34 16 33 35

14

PUMP

(LOWER)

15

35

34

33

33

32

VIEW

A A

24

23

22

21

18

17

20

19

16

15

14

13

12

11

10

9

8

7

4

3

2

6

5

1

ITEM

4

1

1

1

1

2

1

1

3

1

1

2

1

-

1

QTY

1

25

3

4

11

4

3

2

1

ASSEMBLY, CONTROL BOX

NSI NYLON TIE UV RESISTANT

TEE, UNION- 3/8 TUBING

ELBOW, UNION- 3/8 TUBING

NSI #6 KEP NUT ZINC

NSI 6-32 X 1-1/4 PPMS ZINC

ELBOW PLUG-IN 3/8 O.D.

VALVE, VACUUM RELIEF

ACCUPRINT PCB-MASTER

CABLE, TELECOM, 6 PIN

TUBING, 3/8 O.D.

HARNESS, EMERGENCY SW-EXT

INTERCONNECT CABEL 5 FT.

INTERCONNECT CABEL 10 FT.

NSI 10-32 KEP NUT ZINC

CABLE, VAC. PUMP/DELAY

HARNRESS, PCB PWR -AP30/OV33

HARNESS, SWITCHES -AP30

HARNESS, ACCESSORY - AP30

GROUND WIRE, FRAME

NSI 10-32 X 3/8 PHIL PAN BLK

CONNECTOR CABLE 8 FEET

CONNECTING CABLE, QC5 (6'-0')

CABINET, WELDMENT

DESCRIPTION

SEE B.O.M.

44TIE10

43FIT09

43FIT07

41-06NKP

41-06PPS1.25

43FIT 08

49VAV01

47

46

45

44

43

42

41

16D2621B00

49DUC23

16D2495A00

16D957-5

16D957-10

41-12NKP

16D2740A00

16D2651A00

16D2487A00

16D2469A00

16D2182A00

41B12PPS.37

16D1003A08

16D1003A06

63D1650A00

PART NO.

35

34

33

32

31

30

29

28

27

26

25

39

38

37

36

1

1

1

4

1

2

2

2

2

2

3

-

2

-

-

12

2

18

2

2

1

1

2

LABEL , CAUTION

LABEL, AP 30 SERIAL No.

STANDOFF #10 X .50 (ALUM.)

CONTINUOUS GROMMET

NSI MARKER TIE, 4"

NSI 1/4 - 20 LOCKNUT NYLON

NSI 1/4 SAE FLAT WASHER

WASHER SPLIT LOCK 1/4"

NSI 1/4 -20 X 5/8 SOCKET BHD

DRIP PAN, AIR

AIR CONDITIONER ASSEMBLY

COVER, PCBA CONTROL BOX

NSI 6-32 X 3/16 PPMS ZINC

NSI 6-32 X .312 HEX THRD SPCR

NSI #6 INTERNAL LOCK WASHER

ACCUPRINT PCB- REMOTE

NSI 4-32 X 1.0 PPMS ZINC

NSI 4-40 HEX NUT ZINC

VAC. PUMP FITTING

WIREWAY COVER

WIREWAY (SELF- ADHESIVE)

NSI CLAMP, 3/8" O.D. 1/2"

HEYCO, ADHESIVE MNT.

2

3

8

28

27

8 PL

20

PUMP

(UPPER)

15D2067

SEE B.O.M.

44HHS8543

44RUB02

44TIE09

41B40NLN

41-40WFR

41-F0WLS

41BF0SHC.62

11D2619A15

SEE B.O.M.

11D2272A17

41-06PPS.18

42HHS9292

41-06WLS

64MI441E-APR

41-04PPS1.0

41-04NHX

SEE B.O.M.

SEE B.O.M.

SEE B.O.M.

42HHS8914

44PAD07

ACCESSORY

(CLSD LOOP ONLY)

18

29

28

27

94MS36 Rev. F2 S/W Ver 2.06

13

21

12-9

12-10

Base Assembly Diagram

48

3 PL

34

21

DETAIL A 62ACA-8K

38 36 49 35

42

47 53

4 PL

WHT

BLK

45

21

2 PL

44

2 PL

46

35

40

43

22

4 PL

35

11

23

12

DETAIL B

2 PLACES

EXHAUST BLOWER ASSY.(POWER SUPPLY)

13

41

2 PL

44

3

1

45

4 PL

52

51

40

50

VACUUM PUMP ASSY.

2 PL.

4

8

58

31

4 PL

32

4 PL

30

31

32

4 PL

32

33

7

4 PL

32

33

1

38

35

4 PL

36

39

6

VIEW A

3

59

4 PL

29

OUT

IN

28

4 PL

26

27

DETAIL B

2 PL

14

35

2 PL

8 PL

38

35

15

6

56

10

19

56

4 PL

66

51

40

9

35

4 PL

36

38

38

6

2 PL

36

37

38

2 PL

36

37

38

5

6

4 PL

34

35

38

36

37

4 PL

36

6

DETAIL A

39

30

31

32

6 PL

2

2 PL

4 PL

66

51

40

53

52

51

50

49

48

57

56

55

54

45

44

43

47

46

42

41

40

39

38

37

36

64

63

62

67

66

65

61

60

59

58

20

19

22

21

18

17

30

29

28

27

33

32

31

26

25

24

23

35

34

3

2

1

5

4

7

6

13

12

11

10

9

8

16

15

14

18

2

38

16

19

27

1

1

2

1

1

2

2

2

2

8

2

7

12

22

22

14

8

1

1

1

1

2

2

2

2

2

1

2

2

2

1

1

5

1

4

24

4

4

16

1

1

2

2

4

2

6

4

2

4

16

24

17"

1

3

37"

2

3

6

20"

16"

2

ITEM QTY

NSI 8-32 X 3/8 PHIL PAN MS BLK

NSI #6 FLAT WASHER SAE

41B08PPS.37

41-06WFR

11D2362B00

EXT. REFL., SIDE(G)

AP30 EXT. REFL., FRONT(G)

NSI 6-32 X 5/16 PPMS ZINC

11D2361B00

41-06PPS.31

HF1 BLOWER, ASSEMBLY

DUCTING, ALUM. 4" DIAM. W/HOSE

INTAKE, UPPER 5K

CONNECTOR, MALE 3/8 TUBING

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

CABLE, VAC. PUMP

SEE B.O.M.

49DCT04

11D1670A02

SEE B.O.M.

41-F0BHX.75

16D2741A00

41-06NKP

NSI 6-32 KEP NUT ZINC

NSI 8-32 X 3/8 PHIL FLAT MS BLK

BRACKET, DOOR SWITCH

41B06PF2.37

11D2192A62

NSI CABLE TIE, UV 4"

NSI #6 FLAT, BLACK WASHER

NSI #6 SPLIT LOCK WASHER

44TIE08

41B06WFR

41-06WLS

GASKET, 1/16 THICK 1/2 WIDE

44GKT01

RING TERM. INS. 16-14 #8

51RI12E

NSI 10-32 X 3/8 PPMS BLACK

HEAT SHRINK TUBING, 1/2"

41B12PPS.37

TRIM-LOCK

RECEPTACLE 3 PIN

48TRM02

NSI GRUMMET, RUBBER 3/4X

42HHS2175

52RCP08

TERMINAL FEMALE 18-22 AWG. 51TML02

49DCT01

HEAT SHRINK TUBING, 1/8"

CABLE CLAMP, 1/2"

49DCT02

49CLM01

NSI 6-32 X 3/8 PHIL PAN MS BLK

SWITCH, INTERLOCK

NSI #8 FLAT WASHER SAE

NSI #8 SPLIT LOCK WASHER

NSI 8-32 X 1/2 PHIL PAN MS BLK

41B06PPS.37

55SW46

41-08WFR

41-08WLS

NSI 8-32 KEP NUT ZINC

NSI 10-32 KEP NUT ZINC

41B08PPS.50

41-08NKP

41-12NKP

41B40NLN NSI 1/4 X 20 LOCKNUT NYLON INS.

NSI 1/4 SAE FLAT WASHER

WASHER SPLIT LOCK 1/4"

1/4-20 X 5/8 SOCKET BTN HD BLK

ISOLATION MOUNT 1/4-20

RUBBER WASHER

MUFFLER

PLATE, PUMP

AIR DUCT (POWER SUPPLY) AP30

BRACKET, AP30 LAMPHEAD

BLOWER, MOTOR

BLOWER, TRANSFLOW, 220V50/60Hz

41-40WFR

41-FOWLS

41BFOSHC.62

44MNT03

13D2170

39MUF01

11D1633A02

11D1668A02

11D1647A62

39BLO05

AIR DEFLECTOR TRANSFER

INTAKE BOX

FILTER, TOP AP30

MOUNTING PAN- LOW L/H AP30

39BLO10

11D2071A17

11D1917A02

19D1924A99

11D2913A17

INTAKE, LOW, LAMPHEAD

BRACKET, DOOR SWITCH

DEFLECTOR, AIR REAR AP30 OV33

PLATE, FRONT PANEL COVER

EXTENSION, SIDE R.H.

EXTENSION, SIDE L.H.

BOX EXHAUST (POWER SUPPLY)

BRACKET, FILTER HOLDER LT

BRACKET, FILTER HOLDER RT

CHANNEL, HOT AIR, LEFT

CHANNEL, HOT AIR, RIGHT

FLANGEPLATE, HF1 AP30-OV33-34

EXHAUST BLOWER- 230V/60

LAMPHEAD ASSEMBLY

VACUUM PUMP

POWER SUPPLY ASSEMBLY

CABINET, WELDMENT

11D2620A17

11D2141A02

11D2168A02

11D2141A02

11D2104B02

11D2104A02

11D2103A17

11D1939B62

11D1939A62

11D1661B17

11D1661A17

11D1648A02

62B2386A00

SEE B.O.M.

SEE B.O.M.

SEE B.O.M.

63D1650A00

DESCRIPTION PART NO.

2 PL

17

4 PL

55

2 PL

18

25

2 PL

94MS36 Rev. F2 S/W Ver 2.06

13. Light Source

Component Layout

Lamphead for AL 54 and AL 64 50/60Hz

64TR408

Trigger Board

62SA

Shutter Assembly

L1250, L1252, L1261

Replacement Lamp

62D142

Lamp Support Assembly

39BLO03

Blower

55SW02

Shutter

Position

Switch

PA91

Photocell

39BLO03

Blower

55SW03

Safety Interlock Switch

45KOB05

Knob

Power Supply for AL 54 60Hz

90RF53-SW

Reflector

31MOT06

Shutter Motor

Power

Output

Power

Input

120 VAC

Coil Voltage

18

Terminal Strip

L1

L2

T1 T2

33RLY04

Sealed Relays

33RLY02

Power Relay

1

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

32TRC01

Autoformer

62D104

Capacitor

Assembly

94MS36 Rev. F2 S/W Ver 2.06

53JKP01

Safety

Interlock

64MV407

Control Board

39BLO03

Blower

52FUH04

Fuse Holder

62D1047 Voltage

Selection Switch

32BAL01

Ballast

13-1

13-2

Power Supply for AL 54-480 60Hz

Power

Output

Power

Input

120 VAC

Coil Voltage

18

Terminal Strip

L1 L2

T1 T2

33RLY04

Sealed Relays

33RLY02

Power Relay

1

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

62D3654A00

Capacitor

Assembly

53JKP01

Safety

Interlock

64MV407

Control Board

39BLO03

Blower

52FUH04

Fuse Holder

Power Supply for AL 64 50Hz

Power

Output

Power

Input

120 VAC

Coil Voltage

18

Terminal Strip

L1 L2

T1 T2

33RLY04

Sealed Relays

33RLY02

Power Relay

1

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

32TRC01

Autoformer

62D1046-64

Capacitor

Assembly

32BAL01

Ballast

53JKP01

Safety

Interlock

Jack

64MV407-50

Control Board

39BLO03

Blower

52FUH04

Fuse Holder

32BAL01

Ballast

94MS36 Rev. F2 S/W Ver 2.06

Lamphead for AL 84 and AL 94 50/60Hz

55SW02

Shutter Position Switch

64MV414

Trigger Board

62SA83

Shutter Assembly

L1280, L1281 or L1282

Replacement Lamp

63D0142

Lamp Support Assembly

39BLO14

Blower

PA91

Photocell

39BLO14

Blower

55SW03

Safety Interlock Switch

45KOB05

Knob

90RF83-C Reflector for AL 84/AL 94

31MOT06

Shutter Motor

Power Supply for AL 84 60Hz

Power

Output

Power

Input

120 VAC

Coil Voltage

18

Terminal Strip

L1 L2

T1 T2

33RLY04

Sealed Relays

33RLY02

Power Relay

1

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

32TRC08

Autoformer

62D2652A00

Capacitor

Assembly

53JKP01

Safety

Interlock

64MV407-83

Control Board

39BLO03

Blower

52FUH04

Fuse Holder

32BAL01

Ballast

Interconnect Cable To

Power Supply

94MS36 Rev. F2 S/W Ver 2.06

13-3

13-4

Power Supply for AL 84-480 60Hz

Power

Output

Power

Input

120 VAC

Coil Voltage

18

Terminal Strip

L1 L2

T1 T2

33RLY04

Sealed Relays

33RLY02

Power Relay

1

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

62D3533A00

Capacitor

Assembly

53JKP01

Safety

Interlock

64MV407-83

Control Board

39BLO03

Blower

52FUH04

Fuse Holder

Power Supply for AL 94 50Hz

Power

Output

Power

Input

120 VAC

Coil Voltage

18

Terminal Strip

L1 L2

T1 T2

33RLY04

Sealed Relays

33RLY02

Power Relay

1

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

32TRC08

Autoformer

62D2723A00

Capacitor

Assembly

32BAL01

Ballast

53JKP01

Safety

Interlock

Jack

64MV407-95

Control Board

39BLO03

Blower

52FUH04

Fuse Holder

32BAL01

Ballast

94MS36 Rev. F2 S/W Ver 2.06

Ballast/Tap Switch Wiring

AL 54 Ballast / Tap Switch Wiring

18 17 16 15 14 13 12 11 10 9 8 7 6 5

TERMINAL STRIP

4 3 2 1

BLK

AC IN

10 GA.

T1 T2

CONTACTOR

L1 L2

ORANGE TO

CAP. PACK

BALLAST

#1

CAP

240

208

COM

COM

208

240

CAP

BALLAST

#2

BALLAST

#3

CAP

240

208

COM

COM

208

240

CAP

BALLAST

#4

3 6 12

YELLOW TO

AUTOFORMER

RED TO FUSE

2 5 11

1 4 10

AUTOFORMER

240 VOLT

VOLTAGE SELECTOR SWITCH

AL 54-480 Ballast Wiring

18 17 16 15 14 13 12 11 10 9 8 7 5

TERMINAL STRIP

4 3 2 1 6

29 (VIOLET).

BLK

AC IN

6 GA.

T1 T2

CONTACTOR

L1 L2

NO. 20 (ORANGE

TO CAP. PACK).

CAP

BALLAST

#1

120

COM

COM

BALLAST

#2

120

CAP

BALLAST

CAP

#3

120

COM

COM

BALLAST

#4

120

CAP

94MS36 Rev. F2 S/W Ver 2.06

13-5

13-6

AL 64 Ballast Wiring

18 17 16 15 14 13 12 11 10 9 8 7 6 5

TERMINAL STRIP

4 3 2 1

NO. 29 (VIOLET).

BLK

T1 T2

CONTACTOR

L1 L2

50 Hz BALLAST

CAP

240

BALLAST

#1

COM

ORANGE TO

CAP. PACK.

50 Hz BALLAST

COM

BALLAST

#2

240

CAP

50 Hz BALLAST

CAP

240

BALLAST

#3

COM

AL 94 Ballast Wiring

50 Hz BALLAST

COM

BALLAST

#4

240

CAP

18 17 16 15 14 13 12 11 10 9 8 5

TERMINAL STRIP

4 3 2 1 7 6

NO. 29 (VIOLET).

BLK

AC IN

6 GA.

T1 T2

CONTACTOR

L1 L2

NO. 20 (ORANGE

TO CAP. PACK).

CAP

BALLAST

#1

120

COM

COM

120

CAP

BALLAST

#2

CAP

BALLAST

#3

120

COM

COM

BALLAST

#4

120

CAP

94MS36 Rev. F2 S/W Ver 2.06

AL 84 Ballast / Tap Switch Wiring

18 17 16 15 14 13 12 11 10 9 8 7 6 5

TERMINAL STRIP

4 3 2 1

BLK

AC IN

6 GA.

T1 T2

CONTACTOR

L1 L2

ORANGE TO

CAP. PACK

BALLAST

#1

CAP

240

208

COM

COM

208

240

CAP

BALLAST

#2

CAP

BALLAST

#3

240

208

COM

COM

208

BALLAST

#4

240

CAP

3 6 12

YELLOW TO

AUTOFORMER

RED TO FUSE

2 5 11

AL 84-480 Ballast Wiring

1 4 10

AUTOFORMER

240 VOLT

VOLTAGE SELECTOR SWITCH

18 17 16 15 14 13 12 11 10 9 5

TERMINAL STRIP

4 3 2 1 8 7 6

NO. 29 (VIOLET).

BLK

AC IN

6 GA.

T1 T2

CONTACTOR

L1 L2

NO. 20 (ORANGE

TO CAP. PACK).

CAP

BALLAST

#1

277

COM

COM

277

BALLAST

#2

CAP

94MS36 Rev. F2 S/W Ver 2.06

CAP

BALLAST

#3

277

COM

COM

277

BALLAST

#4

CAP

13-7

13-8

Path of Power to the PC Board

• This section is useful when there is no power reaching the PC board (no

LEDs lighted). Before tracing the power, check the fuse on the PC board and the incoming power.

• On 240V equipment, the power cord enters the rear of the unit. The two hot conductors are connected by wire nuts to wires that are in turn connected to the front of a terminal strip. One of these two wires passes through a fuse and on 60 Hz units is then connected to a voltage selector switch, then is connected to taps on a step-down autotransformer. This transformer is located under the terminal strip on the component bracket near the dividing wall. The transformer tap marked 120V becomes the unit common and returns to the terminal strip. The other line wire is connected to the transformer common and becomes the hot 120V lead to the PC Board and also returns to the terminal strip. The power is distributed from the strip and a pair of wires goes to the PC board.

Interlock System

• The internal interlock system serves two purposes. The first is for operator safety by insuring the safety glass is in place before operation. This glass 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 interlock is in series with the control circuit of the large relays in the power supply. When the interlock is opened, the relays will open and cut the power to the lamp terminals. The PC board senses the drop in voltage and closes the shutter.

• The first place to check is the glass switch. The switch lever is located near the edge of the glass on the end of the lamp where the cable enters.

By releasing the glass, the lever can be seen. If the lever can slip past the glass, it should be bent slightly toward the reflector. If the switch is closed, the loop can be traced. First measure the voltage between lamp wires (#4

AC Common) and wire (#10 Interlock). The presence of voltage between these terminals indicates an open loop. This loop travels to the lamp head on wire (#10), then to the glass switch, the far end thermostat, the near end thermostat and terminates on wire (#4). The thermostats are mounted in the air tubes leading to the lamp. There are no splices in the air tubes.

94MS36 Rev. F2 S/W Ver 2.06

Lamp Voltage

The lamp voltage measurement can provide useful information for lamp striking, lamp output, and level switching information. The meter used to measure can cause different results. We use traditional needle movement meters in our factory, due to the trigger pulses on the lamp before striking. The waveforms are not sinusoidal, so different meters may produce different results. Here is a chart with typical measurements:

Model

AL54 w/L1250

AL54 w/L1252

AL54 w/L1261

AL64 w/L1250

AL64 w/L1261

AL64 w/L1252

AL84 w/L1280

AL84 w/L1281

AL84 w/L1282

AL94 w/L1280

AL94 w/L1281

AL94 w/L1282

Lamp Voltage (Terminals 2 & 3)

Idle Low Med.

200

200

200

200

230

230

210

200

210

200

210

200

210

200

230

230

230

230

High

270

270

270

270

270

270

360-380 360-380 380-410 415-445 500+

400-430 400-430 425-500 460-530 500+

400-430 400-430 425-500 460-530 500+

360-380 360-380 380-410 415-445 500+

400-430 400-430 425-500 460-530 500+

400-430 400-430 425-500 460-530 500+

Lamp Fan Voltage (Terminals 4 & 5)

Trig.

Idle/Low Med.

High Trig.

500+

500+

60-80

65-90

90-120

90-120

115-125

115-125

115-125

115-125

500+

500+

500+

500+

65-90

55-75

65-90

65-90

90-120

90-120

90-120

90-120

115-125

115-125

115-125

115-125

115-125

115-125

115-125

115-125

75-95

75-95

75-95

70-90

65-90

65-90

90-120

90-120

90-120

90-120

90-120

90-120

115-125

115-125

115-125

115-125

115-125

115-125

115-125

115-125

115-125

115-125

115-125

115-125

Lamp Power Path

The basic path that the power to the lamp takes is almost identical for all units. The basic path is incoming line, main power relay, ballasts, capacitors, trigger board, and then the lamp. See the point to point wiring diagrams for each light source in Section 16.

94MS36 Rev. F2 S/W Ver 2.06

13-9

13-10

Trigger Board

A trigger board is provided in the light head to start the lamp. This board operates on demand by sensing the lamp voltage. This board can be heard when it is functioning, although the sound is faint. By turning the unit on and off, the sound can be compared during trigger and cool-down. In both situations, the fans are running full speed. The fans may be disabled by pulling the blue wire from terminal #5 to aid in determining if the trigger board is functioning. Use caution that the lamp doesn’t run 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 terminal (3) to terminal (1). This arc should be .015 or greater.

TRIGGER BOARD #64TR408 for AL 54, AL 54-480 and AL 64

Lead to Lamp (3)

(High Temp Wire)

Lamp Current (1)

(Purple Wire)

Other Lamp Lead (2)

(Yellow Wire)

TRIGGER BOARD #64MV414 FOR AL 84, AL 84-480 and AL 94

M2

M1

Lead to Lamp (3)

(High Temp Wire)

Other Lamp Lead (2)

(Yellow Wire)

M3

Lamp Current (1)

(Violet Wire)

94MS36 Rev. F2 S/W Ver 2.06

5

5

Capacitors and Level Switching

The capacitors pass all the current that flows through the lamp. They are also used to switch power levels.

• The capacitors for the AL 54, AL 54-480, AL 64, AL 84, AL 84-480, AL

94, are divided into three sections. All units have one or two idle capacitors, they are connected with a yellow wire. High power capacitors are switched in during warm-up and high power exposures. There are two high power capacitors connected with a blue wire. All capacitors have an orange wire which acts as a common.

• The capacitors for high and medium levels are pulled in with relays during warm-up and exposures. The medium relay will pull in to select medium power. In this case the medium relay will also always 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 switch power levels, make a manual exposure, then switch between the power levels, noting the change in intensity. When switching down in power, allow the unit three seconds to respond.

AL 54 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D1048

16µƒ 12µƒ

12µƒ

16µƒ

4

3

2

1

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

6) BLACK

5

1

2

3

WIRES

FROM

HARNESS

1 2 3

FRONT

VIEW OF

PC BOARD

4

3

2

1

WIRES TO

CAPACITOR

TOP

3

SWITCH ON CAPACITOR

MOUNTING BRACKET

4 3 2 1

REAR VIEW OF

PC BOARD

6

1

94MS36 Rev. F2 S/W Ver 2.06

13-11

13-12

AL 54-480 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D3654A00

5

5

5

1

12µƒ 12µƒ

10µƒ

12µƒ

4

3

2

1

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

6) BLACK

5

1

2

3

WIRES

FROM

HARNESS

1 2 3

FRONT

VIEW OF

PC BOARD

4

3

2

1

WIRES TO

CAPACITOR

TOP

3

SWITCH ON CAPACITOR

MOUNTING BRACKET

4 3 2 1

REAR VIEW OF

PC BOARD

6

1

AL 64 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D1046-64

5 3

2

5

16µƒ

4µƒ 12µƒ

1

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

6) BLACK

12µƒ

16µƒ

4

1

2

3

WIRES

FROM

HARNESS

1 2 3

FRONT

VIEW OF

PC BOARD

4

3

2

1

WIRES TO

CAPACITOR

TOP

3

SWITCH ON CAPACITOR

MOUNTING BRACKET

4 3 2 1

REAR VIEW OF

PC BOARD

6

1

94MS36 Rev. F2 S/W Ver 2.06

5

12µƒ

3

10µƒ

4

AL 84 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D2652A00

5

2

12µƒ

1

16µƒ

5

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

5

12µƒ

3

10µƒ

4

AL 84-480 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D3533A00

5

2

12µƒ

1

10µƒ

5

5

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

94MS36 Rev. F2 S/W Ver 2.06

13-13

AL 94 Capacitor Assembly

3

5

16µƒ

CAPACITOR ASSEMBLY PART # 62D2723A00

2

12µƒ

SWA

SWB

SWC

5

5

4µƒ 12µƒ

WIRE COLORS

1) YELLOW

2) BROWN

4

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

1

16µƒ

5

1 2 3

FRONT

VIEW OF

PC BOARD

2

1

4

3

1

2

3

WIRES

FROM

HARNESS

WIRES TO

CAPACITOR

TOP

SWITCH ON CAPACITOR

MOUNTING BRACKET

4 3 2 1

REAR VIEW OF

PC BOARD

6

1

13-14 94MS36 Rev. F2 S/W Ver 2.06

Opening the Lamp Head

• Unplug the unit.

• Remove the glass and the four screws attaching the large outer reflector

!

section.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

Bottom

View

Remove the 2 center screws from the bottom side and the 2 screws from the top side of 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 position switch are located at the opposite end from the shutter motor under the air plenum plate.

End

View

94MS36 Rev. F2 S/W Ver 2.06

13-15

13-16

Shutter

The shutter is controlled by the PC board, with information from a switch in the lamp head to provide position information. During cool-down and exposure, the shutter is open and during warm-up and idle, the shutter is closed.

The PC board compares the shutter position with the requested position.

The shutter motor will run until the switch position matches. The shutter motor has a brake that is magnetically operated. Whenever the power is released from the motor, the brake falls into a slot. There is an LED on the PC board that lights whenever the shutter is being energized. (Look in the PC board pin section for a diagram of the LEDs).

Shutter Switch

The switch provides shutter position information to the PC board. This switch is in the lamp end where the cable enters, inside the manifold cover. The cam is in the chamber with the shutter. A failure of the switch can cause the shutter to rotate continuously or erratically. Similar problems may be due to the shutter motor brake, the idle setting, or the

PC board.

The switch contacts close when the shutter is fully open and remain closed until the shutter closes. This level can be measured on the terminal 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 adjustable on older units. We recommend scribing a line around the switch and the bracket, if replacement is necessary, to return to the same position. The switch roller should be centered on the cam and closed when the cam pushes the wheel on the switch halfway.

Shutter Brake

The motor that drives the shutter has a brake that is magnetically operated.

When the motor core magnetizes, it pulls a lever to release the brake. If the shutter coasts or rotates continuously, look at the shutter LED on the

PC board. On early boards, where there are three LEDs in a row near the front of the power supply, it is the third from the front of the power supply. On the newer models, there are five in a row; it is the fourth from the front of the power supply. When this light goes out, the shutter brake should engage. If the shutter coasts, the brake may have failed. The shutter may coast to the point where the switch will switch again to cause the motor to energize. The LED on the board will flash if this occurs.

94MS36 Rev. F2 S/W Ver 2.06

Shutter Motor

The shutter motor is located in the lamp head on the side with the shutter drive chain. We recommend checking the power and signals from the switch and to the motor coil, before entering the lamp head. These items are covered in the preceding sections. Changing the shutter motor requires a P h illips screw driver and a

3

/

32

" Allen wrench.

• Remove the glass and outer reflector from the light head.

• Open the end of the light head, where the drive chain and the sprocket are located.

• There are four screws that hold the motor; two of them require access through holes in the sprocket. The shutter can be turned counterclockwise

!

to access these screws, by pushing the brake on the motor.

C Turn the shutter only counterclockwise (looking from the motor end) or you may damage the shutter switch on 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 the motor with four screws.

• Install the sprocket in line with the shutter sprocket and tighten.

• Install the chain on the sprockets.

• Set the chain to where it has 3 /

8

" side travel and tighten the two accessible

!

motor screws lightly.

C Turn the shutter only counterclockwise (looking from the motor end) or you may damage the shutter switch on the other end of the light.

• Rotate the sprocket to tighten the other two screws and attach the wires.

• The shutter can be tested with the unit open by disconnecting one of the

!

lamp leads and holding the interlock switch.

C DO NOT light the lamp without the safety glass or when

you are close to the bulb.

94MS36 Rev. F2 S/W Ver 2.06

13-17

13-18

Shutter Removal

LT1 lampheads

• Remove the 2 screws holding the air flow deflectors and remove them.

Then reach through the air tube and remove the thermostat, then the high temp lamp lead (reaching through the bottom of the light a pair of needlenose pliers to remove it from 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 shutter assembly.

END

VIEW

!

• Reassemble in reverse order.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

94MS36 Rev. F2 S/W Ver 2.06

LT1 Shutter Assembly Drawing

19 2 29

2

REF.

DETAIL E

21

31

10 28 8 2 18

12 1

REF.

25

DETAIL F

22

4

2 PL

11

REF.

4 PL

23

2 PL

27

2 PL

26

2 PL

24 22

15

16

13

18

4 PL

25

4 PL

6

REF.

27 32

2 PL 2 PL

6

REF.

DETAIL G

2 PLACES

6

REF.

I

3

4

REF.

DETAIL F

H

DETAIL D

DETAIL E

I

2

DETAIL A

SECTION I-I

7

17 25

8 PL

1

2 PL

DETAIL B

H

6

2 PL

DETAIL C

DETAIL H

SECTION H-H

7 NOTE: Older shutters have one straight and one curved linear spring. If the straight spring needs to be replaced it is upgraded to the curved spring

34

34

9

15

14

13

12

11

10

9

8

7

6

21

20

19

18

17

16

27

26

25

24

23

22

3

2

1

5

4

2

2

3

3

13

8

2

3

2

6

1

2

2

2

4

1

1

1

2

2

4

2

8

1

4

2

21

ITM QTY

#8 WASHER, SPLIT LOCK

#8-32X.25 SCREW, PHIL,PN.HD.

#6 WASHER, SPLIT LOCK

#8 X .250 ROUND SPACER

41-08WLS

41-08PPS.25

41-06WLS

#6 FLAT WASHER

42HHS8521

41-06WFR

BAFFLE, SHUTTER ASSEMBLY

6-32 X 7/16 SOC FLAT

11D878

41B06SHF.43

#6-32X.62 SCREW, 100° FLAT HD. 41B06SHF.62

#6-32X.37 SCREW, 100° FLAT HD.

41-06PF0.37

#6-32X.37 SCREW, PHIL.PN.HD.

41-06PPS.37

#6-32X.25 SCREW, PHIL PN.HD.

41B06PPS.25

#4-40 NUT HEX

#4-40X3/16 PPMS ZINC

#6-32X1.000 RD.THD SPACER

41-04NHX

41-04PPS.18

42HHS8347

FUSE CLIP

#6 WASHER, LOCK INTERNAL

LAMP SUPPORT ASSEMBLY

43CLP02

41-06WLI

63D0142B00

BALL, BEARING 12D3515A00

SPROCKET, DRIVE (MACHINED) 12D1998A99

IDLER ARM, SHUTTER

SPRING, SHUTTER AL83

AIR TUBE LT-1, AL25-53

#6 X .180 ROUND SPACER

REFLECTOR, INNER RF53

SHUTTER ASSEMBLY LT1

TIMING DISC, LT-1

SHUTTER END

63D3530A62

12D2060A07

12D0217A62

42HHS8500

11D886

11D2206

11D210A62

11D1949A71

DESCRIPTION D3214B PART NO.

34

33

32

31

30

29

28

ITM

2

4

2

3

1

1

2

QTY

DETAIL A

2 PLACES

THERMOSTAT

#6-32 NUT, FLEX LOCK

#8-32 X 1/2 PPMS ZINC

#6-32 X 1.7 STANDOFF

SPACER, TUBING (SHORT)

SPACER, TUBING (LONG)

BUSHING, IDLER ARM

DESCRIPTION

19 2

31

REF.

1

2

REF.

12

18

56THM01

41-06NLM

41-08PPS.50

42HHS8761W

12D3588B07

12D3588A07

12D3550A62

PART NO.

DETAIL B

2 PLACES

18

25 25

REF.

1

18

DETAIL

14

D

25

REF.

9

1

8 2

25

14

18

28

33

10

30

DETAIL C

4 PLACES

21

REF.

1 5

23

25

REF.

9

10

20

18

94MS36 Rev. F2 S/W Ver 2.06

13-19

13-20

LT8 lampheads

• Remove the four hex nuts mounting the blowers, disconnect the blower and thermostat wires.

End

View

• Remove the four screws holding the rear reflector to the cooling tubes

!

and remove the reflector and lamp from the lamp head.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

Bottom

View

• Remove the three screws from the blower mounting plate to the cooling tubes on both sides. Compress the cooling tubes into the shutter assembly, remove the chain from the motor sprocket, then remove the shutter assembly.

End

View

!

• Reassemble in reverse order.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

94MS36 Rev. F2 S/W Ver 2.06

LT8 Shutter Assembly Drawing

2

19

REF.

2 22

10

28 21

2

18

4

DETAIL E

14

2

12 1

REF.

25

DETAIL F

11

SECTION G-G

7 2 PL

29

17 25

8 PL

11

4 PL

23

4 PL

27

4 PL

26

15

16

13

18

4 PL

25

4 PL

6 OR 8

REF.

REF.

6 OR 8

REF.

REF.

DETAIL G

9

SECTION H-H

DETAIL G

REF.

DETAIL

E

G

3

29

4

REF.

DETAIL F

H

DETAIL D

1

REF.

8

G

DETAIL A

2

2

4

4

4

2

21

4

2

1

4

1

1

1

2

2

6

1

1

2

6

2

3

2

4

8

2

3

13

7

6

5

4

3

2

1

17

16

15

14

9

8

13

12

11

10

23

22

21

20

19

18

29

28

27

26

25

24

ITM QTY

THERMOSTAT

BUSHING, IDLER ARM

#8 WASHER, SPLIT LOCK

#8-32X.25 SCREW, PHIL,PN.HD.

#6 WASHER, SPLIT LOCK

#6-32 NUT, FLEX LOCK

#6 FLAT WASHER

6-32 X 7/16 SOC FLAT

IDLER ARM, SHUTTER

#6-32X.62 SCREW, 100° FLAT HD.

#6-32X.37 SCREW, 100° FLAT HD.

#6-32X.37 SCREW, PHIL.PN.HD.

#6-32X.25 SCREW, PHIL PN.HD.

#4-40 NUT HEX

#4-40X.25 SCREW, 100° FLAT HD.

#6-32X.687 RD. SPACER

FUSE CLIP

#6 WASHER, LOCK INTERNAL

LAMP SUPPORT ASSEMBLY

BEARING, BALL

SPROCKET, DRIVE (MACHINED)

AIR TUBE, FRONT

SPRING, SHUTTER AL83

AIR TUBE, DRIVE

#6 X .187 ROUND SPACER

REFLECTOR, INNER, RF83-SW-G

LT8 SHUTTER-REFLECTOR ASS'Y

TIMING DISC, LT-1

SHUTTER END, PHOTOCELL, SLOT

56THM01

12D3550A62

41 08WLS

41 08PPS.25

41 06WLS

41 06NLM

41 06WFR

41B06SHF.43

63D3530A62

41B06SHF.62

41 06PF0.37

41B06PPS.37

41B06PPS.25

41 04NHX

41B04PF025

42HHS8779

43CLP02

41 06WLI

63D0142B03

SEE BOM

12D1998A99

12D1874A62

12D2060A07

12D1873A62

42HHS8500

11D1876B99

11D2216

11D0210A62

11D3974A71

DESCRIPTION D4358A PART NO.

18

DETAIL

25

D

DETAIL

2 PLACES

A

19 14

2

REF.

2 21 28

12

10 22

1

2 PL

25

DETAIL

18

B

REF.

1

REF.

1

14 Newer units have fixed spacer here

DETAIL B

2 PLACES

REF.

9

18 18

REF.

1

25

25 14

H

REF.

9

25

18

6

2 APPLY LOCTITE 242 TO THREADS WHERE INDICATED.

DETAIL

24

DETAIL

4 PLACES

C

C

REF.

1

23

5 10

20

94MS36 Rev. F2 S/W Ver 2.06

13-21

13-22

Idle Setting

• The idle level occurs between exposures and low power exposures. The idle setting determines the power and temperature of the lamp, while at idle. It also allows for much lower idle power than was ever attainable before.

• This lower power level provides a wider light output range, low power consumption, lower heat generation, and increased lamp life. At low power levels, the lamps normally become unstable. If over cooled, they begin to dissipate less energy, which causes them to cool more. This can continue until they extinguish. When lamps become hotter at idle, they become more efficient and dissipate more energy, making them hotter still. This becomes stable, and is commonly done in conventional light sources, but will shorten the life of the lamp and wastes energy. We have chosen to servo the cooling, by sensing the lamp condition and adjusting the cooling to regulate the idle temperature.

• The idle setting is done at the factory and is rarely necessary in the field.

Always check all other causes of problems before changing the setting.

• If the lamp becomes too cool during operation, the board will sense this level and initiate a warm-up cycle. During warm-up, the shutter will close and will not open until the unit is sufficiently warm. A symptom of this is: after an exposure is started, the shutter will open, then close again for several seconds, before finishing the exposure. This should only happen if the unit is 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 power level that the lamp idles at. Turning the trimpot counterclockwise will first slow the lamp blowers. As the lamp reaches the new idle setting, the blowers will speed up to hold the new level. Setting with a meter is done by measuring the lamp voltage on terminals 2 and 3. See section on

Lamp Voltage for proper idle voltage setting. The voltage will increase with a counterclockwise and decrease with a clockwise direction. This voltage change is a secondary effect after the lamp has responded to the change in cooling. The changes should be done in small increments, waiting between adjustment for the voltage to stabilize.

• The idle setting affects the power that the lamp attains on warm-up cycle, before switching to idle and the idle temperature of the lamp. If the setting is too high (too far counterclockwise), the unit will run at high power, with no cooling until the thermostats switch the unit off. The idle temperature of the lamp affects its life and reliability. If the idle setting is too low (too far clockwise ), the lamp will be slow to come to power for exposures, and the unit may close the shutter, after the unit has begun to expose to warm back to power. For these reasons, please take care when making this adjustment and check other problems first.

94MS36 Rev. F2 S/W Ver 2.06

Lamp Head Blowers

• The lamp head blowers are controlled by the printed circuit board to provide the correct cooling to the lamp. During warm-up, the blowers are off or run very slowly. At idle and during low exposure, the blowers vary in speed. Both at high exposure and cool-down the blowers run at full speed.

• A symptom of a defective blower would be: during high power exposure, after approximately 10 seconds, the lamp extinguishes and requires 2 to

4 minutes to restart. One blower will speed up to compensate for the defective unit or low power. When the unit switches to high power, the additional heat causes one of the lamp thermostats to open. (See also

Interlock System for information on the thermostats.)

• To test the blowers, turn the power supply main switch on then off. During the cool-down cycle, place a piece of paper over each intake vent located on the lamp end. The paper should be drawn to the lamp end. If one lamp end does not draw, that blower is suspect.

• To replace the blower in the lamp head, see section 14.9 Opening Lamp

Head.

Blown 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 in the power supply. The relay coils rarely cause any problem.

• Plug in the unit and turn on the power switch for 10 seconds. If the fuse blows, the problem is either: the power supply blower, the p.c.board or in one of the relay coils. Unplug the unit and reconnect the red wire to the terminal strip. Plug in the unit and turn on, then off. The shutter should now turn. If the fuse blows, the problem is in the shutter motor or wiring to the motor. Unplug the unit and connect the blue wire to the terminal strip. Turn on the unit, then off for the cool-down cycle to test the lamphead blowers. If the fuse blows during this test, the problem could be with either of the two blowers in the lamp head. Normally, when the coil on a blower fails, the coil will become discolored. See section 14.9 Opening Lamp Head. If the fuse has not blown throughout the test, the power supply blower is suspect.

94MS36 Rev. F2 S/W Ver 2.06

13-23

13-24

Lamp Head Signals

Signals at the Terminal Strip (Cable to the Lamp Head)

A great deal of information about the operation of the lamp may be found at the terminal strip, in the power supply that connects to the lamp head.

The terminals are counted number 1 at the end where the cable begins, and wire number 18 is the last wire. Terminal number 1 is closest to the dividing wall in the power supply.

Terminal# D e s c r ip tio n

# 1 G round to la m p head

# 2

# 3

# 4

Lamp

Lamp

V ~ c o m m o n

# 8

# 9

# 1 0

# 5

# 6

# 7

#11

# 1 2

# 1 3

# 1 4

L a m p fans

Shutter motor

Shutter positio n s w itch

N o t currently used

Shutter positio n s w itch

Interlo c k a nd thermostat switching

N o t currently used

Inc o m ing vo ltage

Autofo rmer

Inc o m ing vo ltage

• #1 The ground terminal is for safety purposes and carries no current.

• #2#3 Lamp terminals 2 and 3 carry the power to the lamp. If the lamp is hot or fails to start, the voltage should be 600 to 950V~. During this time, there are voltage pulses that may damage a sensitive voltmeter.

Immediately after the lamp strikes, the voltage will drop as low as 20V~, then rise as the lamp warms to the operating voltage, between 180 and

240V~.

• #4 V~ common terminal is the V~ return for the lamp fans, the shutter motor, and the interlock switch. On 120V~ equipment, this is the V~ common from the power line. This potential is generated on 208/240V~ equipment and may be 60V~ from the line common.

• #5 The voltage applied to the lamp fan varies as cooling is required.

The voltage is measured referenced to terminal 4 and terminal 5. This voltage starts at 0V~ during unit warm-up and when the lamp temperature rises it increases. As the lamp reaches temperature, the fans speed

94MS36 Rev. F2 S/W Ver 2.06

increases to regulate the lamp. At idle, this voltage is typically 45 - 90V~ and depends on the lamp age and ambient temperature. When an exposure at high power is initiated, the lamp voltage rises to the maximum. The voltage remains there after the lamp returns to low power, until the lamp temperature again stabilizes.

• #6 The shutter voltage is present during the rotation of the shutter.

The shutter motor runs on 120V~ measured to terminal 4.

• #7

• #8

Shutter position DC common (see terminal 9)

Not presently used

• #9 The shutter position switch reports the position of the shutter to the printed circuit board. This switch is open when the shutter is closed, and closes when the shutter opens. This signal is low voltage DC and can be measured (+) on terminal 9, (-) on terminal 7. The meter will read

+12 VDC when the shutter is closed, and 0 VDC when the shutter is opened.

• #10 Interlock and thermostat switching. During normal operation, terminal 10 is shorted to terminal 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 Exp.

Cool Down Trigger

Unit Fans

Power Relay

Shutter

Off / Off

* / *

On / On

On / On

On / On

On / On

On / On

On / On

On / On

On / On

On / On

On / On

On / On On / On

Off / Off Off / Off

Closed / Off Closed / Off Open / Off

Lamp Fans Off / Off

Open / Off Open / Off

Var.Slow / On Slow/Med. / On Med./Fast / On

Open / Off

Fast / On

* / Off

Fast / On

High Relay On / On

Medium Relay On / On

Off / Off

Off / Off

Off / Off

Off / Off

Off / Off

On / On

On / On

On / On

* / *

* / *

Warm-Up - Occurs after the lamp ignites and ends when the lamp has warmed to operating temperatures. The lamp fans are held off and the unit goes to high power. Due to the technology of the power supply, the units do not draw large amounts of current during warm-up. Due to the restrictive cooling, the lamps warm up rapidly, without surge current.

The shutter will not open until the unit reaches temperature.

94MS36 Rev. F2 S/W Ver 2.06

13-25

Idle - Between exposures, the lamp is held in idle. During this period, the lamp fans vary in speed to maintain the proper lamp temperature.

This allows the unit to consume less power on idle, and provides a wider range of exposure capabilities, since this same low power level is available for exposures. The lower idle saves power, generates less heat, and extends the lamp life.

Expose - The units allow exposures at three levels. At high power, the high and medium relays are activated. At medium 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. The unit is responding to conditions to provide these functions. It is therefore not possible to confuse the unit.

If there is a momentary loss of power, the unit will cool the lamp until it strikes. It is recommended that the unit be shut off and allowed to cool, rather than turning off the power supplied to the unit.

13-26 94MS36 Rev. F2 S/W Ver 2.06

Printed Circuit Board Layout

This is a description of the signals and voltages present on the pins of the printed circuit board.

64MV407V03 Control Board layout. Used on all BUT 8kW light sources

64MV407V24 Control Board layout. Used on all 8kW light sources

Note: Graphic of the new style p.c.board is shown. Relay style p.c.board

has the same connector hookups and pin outs, however the LEDs are on the component side of the p.c.board not on the solder side as on the new style. The old style board is replaced by the new style and is interchangeable.

P2

K1

A

U101

TR101

G

R101

F

E

R102

B

U102

H

R103

C

U103

C101

C102

TR102

K

C103

TR103

L

M

I

P1

D

R104

U104

C104

TR104

J

TR105

HS101

REV.

64MV504V

COIL2 COIL1

R10

R11

120K

R59

8.2K

2

R9

22K

U8 U9 U6

J1

Front View of Control Board

K1

TR101

TR102

TR103

TR104

TR105

Triacs & Relay

Unit Power

Shutter Motor

High Relay

Medium Relay

Main Contactor

Lamp head fans

3

4

5

6

1 AC Hot

2

P1 Power Connector

AC Common

7

8

Unit Fan

Power Relay

Lamp Fans

Shutter Motor

High Relay

Medium Relay

9

10

11

12

Not Connected

Aux Terminal

DC Common

Position

5

6

2

3

4

P2 Switch Connector

1 AC Hot 7 High Switch

AC Common

Not Connected

Aux Terminal

8

9

10

Low/Med Switch

Manual Expose

Interlock

DC Com/Ground

Power Switch

11

12

Not Connected

+12 VDC

Check Idle Voltage on Board or on Terminal Strip Lugs #2 and #3

Switch Connector

Power Connector

D18

D13

D17

D15

D16

D14

LED's

Lamp head fans

Power Supply Fan

Shutter Motor

High Relay

Medium Relay

Power Relay

Idle Voltage Adjustment

Back View of Control Board

94MS36 Rev. F2 S/W Ver 2.06

13-27

13-28

Signal Description

Power Connector

P3)

P4)

P5)

P1)

P2)

P6)

P7)

P8)

P9)

P10)

P11)

P12)

V~ Hot: Supply to board approximately 125V~.

V~ Common: Common to board is the common also for relays, shutter fans, and the internal lamp head interlock. (This may not be at ground potential and should be measured with caution).

Lamp Fans: V~ proportional drive output for the blowers in the lamp head.

Shutter: V~ output to drive the shutter motor.

High: V~ Output to drive the high relay, which engages the high power capacitor bank during warm-up and high power exposures.

Medium: V~ Output to drive the medium relay which engages the medium capacitor bank during warm-up and both high and medium level exposures.

Unit Fan: V~ Output to drive the power supply blower or fans.

Power Relay: V~ Output to drive the main relay. This provides power to the lamp circuit.

Not currently used.

Aux: Terminal connects to the signal connector for accessories (Not used in most equipment).

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).

Position: Shutter switch active signal from the lamp head - Low voltage when the shutter is open and 12VDC when closed.

Switch Connection

S1)

S2)

S3)

S4)

S5)

S6)

V~ Hot: Output, V~ supply for internal accessories.

V~ Common: Output, V~ common for internal Accessories.

Not currently used.

Aux: Terminal connects to the power connector for accessories (Not used in most equipment).

DC common: DC circuit common for switches (Not the same as V~

Common).

Power Switch: Switch to turn on power. Low (0V) for power on. The power can also be turned on by the integrator through the outlet. (Only a signal !

Power is always present on the PC Board).

Continued on next page

94MS36 Rev. F2 S/W Ver 2.06

S7)

S8)

S9)

S10)

S11)

S12)

High Switch: Switch to select high power level. Low (0V) for high.

Low/Med Switch: Switch to select power level when high switch is off. Low

(0V) for medium power, High (12VDC) for low power.

Manual Switch: Manual expose switch. Low (0V) to cause exposure.

Interlock: External interlock outlet. Line must be connected to DC common to allow an exposure. (Outlet is normally shorted when plug in not inserted).

Not currently used.

+12V: Output for internal accessories (Not used in most equipment).

DIN Connection

D1)

D2)

D3)

D4)

D5)

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.

DC Common: Common for all signals.

Low Exp: Low expose input.

Power: Signal from integrator to turn on the power.

Medium Exp: Medium expose input.

LEDs

The LEDs are an indicator of an acting command that you are asking the control board to do. For a list of which commands activate which LEDs, look at the chart above, labeled LED indicators. The LEDs light when they detect a ground or negative going pulse.

94MS36 Rev. F2 S/W Ver 2.06

13-29

Circuit Diagram (64MV407 60Hz)

Connector P1

13-30

Connector P2

Input Filters

Input Filters

*No Switches on Models

AL55, 65, 75, 95, 96

94MS36 Rev. F2 S/W Ver 2.06

Lamphead for all Lights

7

5

11

9

3

1

Shutter Position Switch

Thermostat Thermostat

Safety Glass Switch

Shutter Motor

4

2

8

6

12

10

Blowers

Lamp

Trigger Board

94MS36 Rev. F2 S/W Ver 2.06

13-31

13-32

AL 54 Power Supply 60Hz

Din

Socket

P2

L

B

O

N

T

R

O

R

C

O

P

O

W

E

A

R

D

P1

12

11

10 blu

9

8

7

6

5 wht

4

3

2

1

12 gry

11 org

10 brn

9

8 red/wht

7 org/wht

6 brn/wht

5 blu/wht

4 red

3 blu

2 wht

1 blk

Safety Interlock

208

208/240 VAC

INPUT

Tap Switch

240

COM COM

240 208 240 208

Ballast

Ballast

16µƒ 12µƒ 12µƒ 16µƒ

Position 2

Medium

Relay

Position 1

High

Relay

120 0

3 Amp

Slow Blow

Fuse

Power Relay

Voltage

Selection

Board

Power

Supply

Blower

12

10

8

Interconnecting

Beau Plug

Connector

6

4

2

11

9

7

5

3

1

Toward front of unit

18

17

16

15

4 wht

3 pur

6 red

5 blu

2 yel

1 grn/ yel

Toward center of unit

8 brn

7 org

14 blk

13 wht

12 red

11

10 blk

9 clear

L

S

T

M

I

N

A

R

I

P

T

E

R

P

P

L

Y

R

S

U

P

O

W

E

94MS36 Rev. F2 S/W Ver 2.06

AL 54-480 Power Supply 60Hz

Din

Socket

P2

P

O

W

O

N

T

R

O

E

R

C

L

B

O

A

R

D

12

11

3

2

1

10 blu

9

8

7

6

5 wht

4

P1

12 gry

11 org

10 brn

9

8 red/wht

7 org/wht

6 brn/wht

5 blu/wht

4 red

3 blu

2 wht

1 blk

Safety Interlock

277

Ballast

Ballast

10µƒ 10µƒ 16µƒ 16µƒ

Power

Supply

Blower

Medium

Relay

High

Relay

277

Interconnecting

Beau Plug

Connector

6

4

2

12

10

8

5

3

1

11

9

7

94MS36 Rev. F2 S/W Ver 2.06

480 VAC 60Hz

INPUT

120 VAC

INPUT

Power Relay

Toward front of unit

18

17

16

15

3 pur

2 yel

1 grn/ yel

Toward center of unit

6 red

5 blu

4 wht

8 brn

7 org

14 blk

13 wht

12 red

11

10 blk

9 clear

S

T

R

I

N

A

L

I

P

Y

T

E

U

P

P

L

R

M

P

O

W

E

R

S

13-33

AL 64 Power Supply 50Hz

Din

Socket

P2

N

T

R

O

L

R

C

O

P

O

W

E

B

O

A

R

D

P1

12 gry

11 org

10 brn

9

8 red/wht

7 org/wht

6 brn/wht

5 blu/wht

4 red

3 blu

2 wht

1 blk

12

11

3

2

1

10 blu

9

8

7

6

5 wht

4

Safety Interlock

8

Interconnecting

Beau Plug

Connector

6

4

12

10

2

Power

Supply

Blower

7

5

11

9

3

1

240

COM

Ballast

COM

Ballast

12µƒ 8µƒ 16µƒ 12µƒ

240 240

16µƒ

220 VAC 50HZ

INPUT

Voltage

Selection Board

Toward front of unit

18

120 0

3 Amp

Slow Blow

Fuse

Power Relay

17

16

Position 2

Medium

Relay

Position 1

High

Relay

15

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward center of unit

8 brn

7 org

14 blk

13 wht

12 red

11

10 blk

9 clear

P

O

L

Y

T

E

R

M

I

S

U

P

P

W

E

R

N

A

L

S

T

R

I

P

13-34 94MS36 Rev. F2 S/W Ver 2.06

AL 84 Power Supply 60Hz

Din

Socket

P2

T

R

O

L

B

O

A

R

D

C

O

N

P

O

W

E

R

12

11

3

2

1

10 blu

9

8

7

6

5 wht

4

P1

12 gry

11 org

10 brn

9

8 red/wht

7 org/wht

6 brn/wht

5 blu/wht

4 red

3 blu

2 wht

1 blk

Safety Interlock

10µƒ

Ballast

16µƒ 12µƒ

Ballast

12µƒ

220 VAC 50HZ

INPUT

208

COM COM

240

Tap Switch

208

240 208

120 0

3 Amp

Slow Blow

Fuse

Power Relay

Voltage

Selection

Board

Power

Supply

Blower

Medium

Relay

High

Relay

12

Interconnecting

Beau Plug

Connector

6

4

2

10

8

11

9

7

5

3

1

Toward front of unit

18

17

16

15

4 wht

3 pur

2 yel

1 grn/ yel

Toward center of unit

7 org

6 red

5 blu

14 blk

13 wht

12 red

11

10 blk

9 clear

Y

T

E

R

U

P

P

L

P

O

W

E

R

S

T

R

I

P

M

I

N

A

L

S

8 brn

94MS36 Rev. F2 S/W Ver 2.06

13-35

Din

Socket

P2

O

L

B

O

A

R

D

P

O

W

E

R

C

O

N

T

R

P1

12

11

10 blu

9

8

7

6

5 wht

4

3

2

1

12 gry

11 org

10 brn

9

8 red/wht

7 org/wht

6 brn/wht

5 blu/wht

4 red

3 blu

2 wht

1 blk

Safety Interlock

277

277

Ballast

Ballast

10µƒ 10µƒ 12µƒ 12µƒ

Power

Supply

Blower

Medium

Relay

High

Relay

8

Interconnecting

Beau Plug

Connector

6

4

2

12

10

7

5

11

9

3

1

13-36

AL 84-480 Power Supply 60Hz

480 VAC 60HZ

INPUT

Power Relay

120 VAC 60HZ

INPUT

Toward front of unit

18

17

16

15

4 wht

3 pur

6 red

5 blu

2 yel

1 grn/ yel

Toward center of unit

8 brn

7 org

14 blk

13 wht

12 red

11

10 blk

9 clear

R

M

I

N

A

L

S

T

R

I

P

U

P

P

L

Y

T

E

P

O

W

E

R

S

94MS36 Rev. F2 S/W Ver 2.06

AL 94 Power Supply 50Hz

220 VAC 50HZ

INPUT

240

COM COM

240 240

Safety Interlock

Ballast

Ballast

Din

Socket

P2

O

N

T

R

O

L

B

O

A

R

D

P

O

W

E

R

C

12

11

3

2

1

10 blu

9

8

7

6

5 wht

4

P1

12 gry

11 org

10 brn

9

8 red/wht

7 org/wht

6 brn/wht

5 blu/wht

4 red

3 blu

2 wht

1 blk

Power

Supply

Blower

16µƒ 12µƒ 4µƒ

Position 2

16µƒ

Position 1

Medium

Relay

12µƒ

High

Relay

120 0

3 Amp

Slow Blow

Fuse

Power Relay

8

Interconnecting

Beau Plug

Connector

6

4

2

12

10

7

5

11

9

3

1

Toward front of unit

18

17

16

15

8 brn

7 org

14 blk

13 wht

12 red

11

10 blk

9 clear

I

N

A

L

S

T

Y

T

E

R

M

R

I

P

P

O

W

E

R

S

U

P

P

L

4 wht

3 pur

6 red

5 blu

2 yel

1 grn/ yel

Toward center of unit

94MS36 Rev. F2 S/W Ver 2.06

13-37

13-38

Interconnect Cable

WHITE

YELLOW

6

RED

8

BROWN

10

HEAT SHRINK

12

2

4

7

9

11

1

3

5

GREEN

VIOLET

BLUE

ORANGE

BLACK

WHITE

YELLOW

6

RED

8

BROWN

10

HEAT SHRINK

12

2

4

7

9

11

1

3

GREEN

5

VIOLET

BLUE

ORANGE

BLACK

94MS36 Rev. F2 S/W Ver 2.06

14. Printing Light Check List

!

Check List for Printing Light Troubleshooting and Service

C In order for this check list to be effective it must be followed step by step.

1) Disconnect the integrator/timer from the power supply.

This will make sure that a faulty integrator or cable is not responsible for the malfunction and also eliminate a bad DIN socket on the p.c.board.

2) Check the tap switch (208/240V~ power supplies only. If the top LED is lit, make sure the switch is in the UP position, and if the bottom LED is lit, make sure the switch is in the DOWN position (see Printing Light

Installation Manual). Improper setting will most likely cause blower, capacitor, and/or PC board failure and will prematurely age the lamp.

The LEDs next to the switch are not controlled by the switch, the LEDs

!

tell you where to put the switch.

C You MUST NOT flip this switch with the power supply turned on! You will arc the contacts inside and this will damage the switch.

• If the tap switch is set for 240V~ and you have 208V~ coming in, the light source is going to draw excess amperage (as voltage goes down amperage draw has to go up). If when you open the power 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 of the power supply.

• If the tap switch is set for 208V~ and you have 240V~ coming in, the p.c.board and the blowers are usually the two items to get damaged.

Over voltage to the blowers will burn them out and are usually the first to component damaged, the p.c.board will also be damaged under extended usage in an over voltage condition.

• If the voltage fluctuates there is a line that you can not cross 219V~

220V~ the voltage must always stay 220V~ or above or always stay

219V~ or below.

If the switch itself is bad with no external signs of burning make sure that the user is not flipping the switch with the power supply on. Flipping the switch with the light source turned on will cause damage to the switch that may take time to show up.

3) Check the safety glass for proper installation. The long dimension of the glass goes parallel with the long dimension of the lamphead. Improper installation can cause the glass to shatter and/or an 'open' in the safety interlock circuit.

94MS36 Rev. F2 S/W Ver 2.06

14-1

14-2

• You must be able to reach up, place your fingers against the safety glass and there must be play front to back and side to side. Otherwise the glass does not have room for expansion and will more than likely shatter under

!

use.

C NEVER operate the light source without the safety glass in place.

4) Check the beau plug at the lamphead. Make sure it is pushed in all the way. The most likely problem caused by a loose beau plug is an erratic shutter operation or an open safety interlock circuit.

Just push in on the beau plug while rocking it up and down to make sure it is in all the way.

5) Check the lamphead interlock circuit. Remove or lower the safety glass.

Turn the power supply on. Check for 120V~ from terminal 4 to terminal

10; when the glass is reinstalled, the voltage should go low. (See Interlock

System for operation.)

With the interlock open what should happen is the shutter should close and the power supply blower should come on, that's all. After you remove the glass and you turn on the power supply, if the light source comes on turn power off immediately and determine what is shorting out and bypassing the safety interlock circuit. If this does happen it is possible that 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 voltage drops more than 6 V~, the incoming power is most likely a problem.

You can do checks 6 and 7 at the same time. Write down the voltage that you get before turning power on and after turning power on but before the light source completes the warm up cycle. This is maximum amperage draw so the voltage will show maximum drop.

If the voltage in check 6 drops more than 6V~ the incoming power is a problem and it can not be corrected in the power supply (there is nothing you can do in the power supply to correct bad voltage from the wall).

7) Check input voltage to the PC board with the power off at pins 1 & 2 (see p.c.board layout for pin location). Then with power on, intensity level on high, and manual expose set on, check the voltage again. If the voltage drops more than 6 V~, the autoformer is most likely a problem.

• If and only if the voltage on 12 and 14 in step 6 is good can you say that the autoformer is definitely bad, if the voltage on 12 and 14 in step 6 is bad you can not get a correct reading for step 7.

94MS36 Rev. F2 S/W Ver 2.06

8) Check capacitors and relay circuit by:

The capacitors and relays are checked by watching the voltage changes that take place at the different intensity levels. If a capacitor is not in the circuit the voltage readings on input and output will be the same. If the capacitor is pulled into the circuit the input and output voltages will be hundreds of volts apart. Now the tricky part, if a capacitor is pulled into the circuit the way it is supposed to be then we need to look at the voltage itself to see if we see an increase in the overall voltage to make sure that the capacitor is adding voltage to the circuit. If the capacitor is pulled into the circuit when it is supposed to be but the overall voltage does not increase then the capacitor is defective.

9) Check voltage from terminal 3 to the capacitor input (orange wire on top of the capacitors). The voltage should be 500+ V~. If voltage is lower, check the power path to the tap switch and ballasts. 500+V~ is typical for 5kW light sources and 700+ V~ for the 6kW and 8kW light sources.

If the voltage on a 208/240V~ is low, then not all the ballasts are being powered properly. This is usually caused by a bad tap switch or a burnt connector at the tap switch, however any of the wiring between ballast and tap switch is suspect. If the voltage is zero then a burnt wire 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 unit, these are the general voltages you should read. These voltages are a ball park figure depending upon several factors and the actual voltage is not as important as to whether or not the voltages change on the capacitors according to intensity level.

For instance on a 5kW light with an L1250 lamp at low intensity one capacitor will be about 200V~ and three capacitors will be over 500V~.

Now when you go to medium intensity you should see two capacitors at about 230V~ and two capacitors at over 500V~. NOTE the number of capacitors at the lower voltage (i.e. in the circuit) and the voltage increase from the previous intensity 200V~ at low and 230V~ at medium.

• At low power, manual expose on, check voltage from terminal 3 to the capacitor outputs (yellow, brown, and blue wires on top of the capacitors).

• At medium power, manual expose on, check voltage from terminal 3 to the capacitor outputs (yellow, brown, and blue wires on top of the capacitors).

• At high power, manual expose on, check voltage from terminal 3 to the capacitor outputs (yellow, brown, and blue wires on top of the capacitors).

• SEE CHART FOR PROPER VOLTAGE READINGS (ALL VOLTAGES

ARE READ TO TERMINAL 3).

94MS36 Rev. F2 S/W Ver 2.06

14-3

14-4 c.

d.

a.

b.

a.

b.

c.

d.

a.

b.

c.

a.

b.

c.

c.

d.

a.

b.

IDLE/LOW

MEDIUM

HIGH

ORANGE

5kW with L1250 LAMP

YELLOW BROWN

500+ 200 500+

500+

500+

225

270

225

270

BLUE #1

500+

500+

270

BLUE #2

500+

500+

270

IDLE/LOW

MEDIUM

HIGH

5kW with L1252 or L1261 LAMP

ORANGE YELLOW BROWN

500+ 200 500+

500+

500+

230

270

230

270

BLUE #1

500+

500+

270

BLUE #2

500+

500+

270

IDLE

LOW

MEDIUM

HIGH

ORANGE

8kW with L1280 LAMP

YELLOW BROWN

700+

700+

360

360

700+

700+

700+

700+

390

425

390

425

BLUE #1

700+

700+

700+

425

BLUE #2

700+

700+

700+

425

IDLE

LOW

MEDIUM

HIGH

ORANGE

700+

700+

700+

8kW with L1281 LAMP

YELLOW

395

395

425

BROWN

700+

700+

425

700+ 485 485

BLUE #1

700+

700+

700+

485

BLUE #2

700+

700+

700+

485

IDLE

LOW

MEDIUM

HIGH

ORANGE

8kW with L 1282 LAMP

YELLOW BROWN

700+

700+

395

395

700+

700+

700+

700+

430

510

430

510

BLUE #1

700+

700+

700+

510

BLUE #2

700+

700+

700+

510

94MS36 Rev. F2 S/W Ver 2.06

‡ The voltage readings described in the following are typical of 5kW light sources see voltage chart to find high and low values for others.

10) If a reading remains high (500V~ or more see note ‡) and it should be low (less than 300V~ see note ‡), the capacitor is not being pulled into the circuit. Check the respective relay, resistor, and wiring for an open.

11) If a reading remains low (less than 300V~ see note ‡) and it should be high (500V~ or more see note ‡), the capacitor is locked into the circuit.

Check the respective relay, wiring, and PC board for a short.

12) If the readings show voltage changes from high to low and from low to high, but the overall low reading does not increase from the previous power level, then the capacitor being pulled into the circuit has failed.

13) Check the blowers using a piece of paper held up to the intakes at each of the lamphead during a cool-down cycle. The paper should get held up to each intake, if it doesn’t, the blower is bad.

Blowers speed can not be checked until this point because all previous checks affect the operation and can make them appear to be operating incorrectly. Also check blower voltage at terminals 4 & 5 for most lights this voltage should be a MINIMUM of 45V~ some lights this voltage will be higher depending on lamp used and lamp condition.

14) Check 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 check list is used properly (followed step by step) if at this point the lamp voltage is out of specification it can now be adjusted if the lamp is less than two weeks old AND "not or" has no sign of deformation otherwise a new lamp must be installed before adjusting.

Adjusting lamp idle voltage without first checking other causes of the lamp voltage deviation can damage the equipment.

16) If used, check the power supply safety interlock jack next to the power supply power on/off switch. A failure in this circuit will not allow the unit to do an exposure, the only time the shutter will rotate if this circuit is open, is when the power is turned on or off.

If you suspect this circuit is faulty, turn the manual expose switch on, then short the blue and white wires on the jack together with a screwdriver

(make sure you do not short to ground) and see if the shutter opens, if it opens the circuit is at fault.

17) Check for smooth shutter rotation. If the shutter rotates smoothly, skip to step 20, otherwise continue.

18) If the shutter does not rotate smoothly, it may not stop in the correct position and the bearings must be greased.

94MS36 Rev. F2 S/W Ver 2.06

14-5

19) If the shutter fails to rotate at any time, then check the following:

20) When the shutter is supposed to be moving. Check for 120V~ between terminals 4 & 6. If there is voltage, go to the lamphead and check for voltage at the shutter motor then skip to step 22.

21) If there is no voltage between terminals 4 & 6, check the PC board output for voltage at pins 2 & 4 (see PC Board Layout for pin location).

22) Check to make sure the shutter stops immediately 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 it.

26) Before you reassemble everything it is a real good idea to: Check the manual operations of the light source. Just to make sure everything is back together.

27) Reconnect all wires to the integrator and then: Check the remote operations of the light source from the integrator.

14-6 94MS36 Rev. F2 S/W Ver 2.06

15. Fault Trees

Good

Test 1

Is power relay pulling in?

Lamp old

Yes

Lamp new

No Strike Fault Tree

Does shutter rotate when light turned on?

Yes

Check Safety Glass and Lever

No

No

Good

Reinstall safety glass

Test 2 Check wires and vlotages on #12 red & #14 black 200~245 VAC to top of power relay

No

Yes

Go to test 1

Are any LED's lit on the PC

Board?

No

Go to test 2 after checking PC

Board fuse

No good

Repair or replace wires

Replace lamp

Go to test 3

All

O.K.

Still no strike

Test 3

500+ VAC on

#2 yellow & #3 pruple?

No

Good

Check for 0 VAC between #4 white &

#10 black on terminal strip

No

Thermostats, safety switch or associated wiring could be faulty

Yes

Possible faulty lamp or trigger board

Yes

500+ VAC between #3 purple on terminal strip to orange com on cap pac?

No

Yes

Check for 120 VAC on PCB power connector pins 2 white & 8 red

Yes

Check the wires from#2 & #8 to power relay

No

Check PCB fuse

Good

Replace PC

Board

No good

Replace fuse

Check wiring from ballasts and voltage set switch to terminal switch and cap pac.

94MS36 Rev. F2 S/W Ver 2.06

Go to test 2 after checking wires on voltage set switch

15-1

Shutter Rotation Fault Tree

Does shutter rotate at any

Yes time?

Does shutter seam to bind during rotation?

No

Is the lamp lit?

Yes

Is LED #D17 lit on PC Board

Yes

When LED #D17 is lit, check for

120VAC on #4 white and #6 red on the terminal strip when shutter should be rotating

No

No

The shutter will not open for an exposure w/o the lamp being lit. Go to the

No Strike Fault tree

Yes

No

Yes

Chain most likely too tight or bearing surface sufficiently worn

Adjust shutter motor and or replace bearings and air tubes

No

Check set screw on shutter motor gear and the shutter position switch

Possible faulty shutter motor

No

Yes

Check for

120VAC at shutter motor

Yes No

Replace shutter motor

Repair or replace wiring from terminal strip to shutter motor

Yes

If LED #D17 is lit, check for

120VAC at pins

2 and 4 at power connector on PC

Board

No

Replace

PC Board

Repair or replace wiring from

PC Board to terminal strip

15-2

K1

F1

1

K5 K3

D18

U5

K4

P1

Front View of Control Board

12

E1 E2

K2

D13 D17 D15 D16 D14

Q2 Q6 Q4 Q5 Q3

1

P2

12

J1

D18

D13

D17

D15

D16

D14

LED's

Lamp Head Fans

Power Supply Fan

Shutter Motor

High Relay

Medium Relay

Power Relay

94MS36 Rev. F2 S/W Ver 2.06

16. Parts List

41-12PPMS.50

41B12NKP

41B12PF0.50

44GKT07

44HDL03

81TAP06

81TAP07

62D1759A00

12D1728A62

12D1738A71

13D2213E99

13D2213F99

13D2214E99

13D2214F99

13D3006B00

18D1734B00

44ADT03

44GKT13

Part Number

62AP30C

11D1648A02

11D3994A07

15D3830A00

32TRC05

39ACD02

43CLM08

43SPR31

49DCT04

55SW45-GO

55SW45-STOP

56TMP01

62ATA

11D1726A17

11D2392A62

11D2422A62

41-10WLS

Description

Assy Kit Base Expo AP30

Flangeplate, HF1

External Reflector, AP30

Overlay, control panel

Transformer (480V~ units only)

Air Conditioner 8K BTU

4" Hose Clamp

Qty. per unit

1 EA

2 EA

4 EA

1 EA

1 EA

1 EA

4 EA

Gas spring

Ducting, Alum 4" diam.

Button, white "GO"

Button, white "STOP"

Temperature Control

AccuPrint Tray Assembly

Frame, glass

Catch - Latch Handle

Top, Hinge, Glass Tray

NSI #10 washer,split lock

4 EA

2 EA

1 EA

1 EA

1 EA

2 EA

1 EA

1 EA

2 EA

4 EA

10-32 X 1/2 PPMS Zinc

#10 Kep Nut

NSI 10-32x1/2 Phil Flt MS

Seal "Solid D"

Handle

Tape, 1/8" Thk 1/4 W

Tape,OV24 1/8" x 1" x 50

Glass, Seal Assy Grade B

Intake Port AP 30D

Vacuum Block

Strip, front/rear-32.70"L

Strip,front/rea-31.34"Lg

Strip,RH/LH Side 27.75"Lg

Strip,RH/LH Side-26.38"Lg

Strip,corner(ABS)-.50"Lg

Glass

Adapter, Hose

Seal, Wave Shape

2 EA

2 EA

2 EA

2 EA

2 EA

1 EA

2 EA

22 FT

4 EA

4 EA

4 EA

2.83 EA

2 EA

7.670 FT

12 FT

2 EA

2 EA

2 EA

94MS36 Rev. F2 S/W Ver 2.06

16-1

48TRM02

49DCT27

49VAG02

51SI18E

52TS05

54JMP03

55SW01

55SW45-5

55SW45

55SW53

18D2430A00

19D1942A99

26CF4-15-4

32TRC08

39BLO11

39CLF02-C

43FIT13

43FIT14

44PAD03

44TIE02

Part Number

44ORNG02

49DCT24

81TAP12

81TAP17

82ADH11

62D2429A00

11D1791A02

11D1939A62

11D1939B62

11D2426A17

11D2426B17

11D2427A08

11D2433A08

11D2438A08

11D3255A07

16D2196A00

16D2412A00

16D3249A00

16-2

Description

"O" Ring 11/16x9/16x1/16"

Tubing, 5/16 1.D.x1/2 O.D

Tape, Teflon Sealant 1/2"

Transfer Tape,3/4 X 18

Adhesive, rubber gasket

Assy, AP 30 Nose - Integ

Bracket, Nose Support

C-Bracket, Filter Holder

C-Bracket, Filter Holder

Divider, nose AP30 Left

Divider,nose AP30 Right

Air Director No.1, Nose

Air Director No. 2 - Nose

Air Director No 3 - Nose

Reflector,Work Lt.2 Lamp

Harness, SW, Operator OV

Harness, Emergency Switch

Harness

Bezel, Worklight, 3 Lamp

Filter, Top AP30

Resistor,15Kohm,2W,5%

Autoformer 208/225/240 V~

Blower

Coated lamp yellow w/fix

Reducer, Tube 3/8 to 1/4

Connector, 1/4 Tube

NSI Tie wrap adh. mnt. ba

NSI Cable Tie 4" #18 Max

Trim-Lok

Tubing, Nylon 1/4"OD - .1

Vacuum Gauge,0-30"

Spade, Ins. 22-18Ga #8

5 Position Terminal Strip

Kulka Jumpers 602J

Switch, CW

Barrier

Switch, Nose * AP30/33

Pushbutton, Emergency Sw

Qty. per unit

4 EA

2 FT

1 RL

1 RL

1 EA

1 EA

2 EA

2 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

FT

FT

2 EA

4 EA

1 EA

2 EA

2 EA

4 EA

2 EA

1 EA

1 EA

2 EA

1 EA

1 EA

2 EA

2 EA

2 EA

2 EA

3 EA

3 EA

94MS36 Rev. F2 S/W Ver 2.06

52FUH07

52FUH08

52RCP15

52RCP21

52TS20

56FUS14

56FUS15

56FUS16

56FUS20

56FUS38

62D2483A00

62D331A

55SW26

64VS409

64CT464

62D3202A00

16D2641A00

16D3208A00

31MSC02

32PSF01

Part Number

64MI441E-4236

64MI441E-4239

64PCB-DIS01

16D2656A00

64MI477V00

64MI478V00

81TAP12

62D3553A00

16D3208A00

16D3455A00

16D3878A00

31MSC02

32PSF01

32TRC01

33RLY20

44CPG08

44RUB03

52FUH04

94MS36 Rev. F2 S/W Ver 2.06

Description

Inegrator pcb master

Inegrator pcb remote

Assy, PCB, System, Disply

Cable, 15P, Dip to DB 15

Quick Mem Key Bd AP30

Assembly, Key Bd AP30

Tape, Teflon Sealant 1/2"

Assy,Ctrl Bx-5K 208/240V~ 60Hz

Qty. per unit

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 RL

1 EA

Harness, Cntrl Bx -GTools

Harness , CT Box - Closed

Harness, cntrl bx suppl

Motor, speed control

Power Supply, Open Frame, 1

Autoformer 208-240V~

Relay, 12VDC, Chassis

Plug,plastic,black 1.5"

Grommet,Continuous .06

Fuse Holder, 3AG/3AB

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

3 EA

FT

4 EA

Fuse Block- 13/32 x 1.5 4

Fuseholder, 3AG, .25 Tab

Receptacle, 250V/30A

Receptacle, 250V/15A

Pwr. Dist. Block, 2 pole,

Fuse 15A 250V

Fuse, 3A 250V 3AG Slow Blow

Fuse, 1/2A 250V 3AG Slow Bl

Fuse, 20A 250V, Slow Blow 3

Fuse, 30A 500V SlowBlow

Blower, 50 Hz 220V~

Voltage Selector Assembly

Switch, 3PDT, 250V, 10A

Assembled Voltage Sel

PCB Assy Control AP 30

Assy,Ctl Bx 8K 220V~ 50Hz

Harness, Cntrl Bx

Harness, Cntrl Bx -GTools

Motor, speed control-KB

Power Supply, Open Frame, 1

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

2 EA

2 EA

2 EA

2 EA

2 EA

1 EA

1 EA

2 EA

4 EA

16-3

52FUH07

52FUH08

52RCP20

52RCP21

52RCP24

52TS19

56FUS04

56FUS14

56FUS15

56FUS16

16D3074A00

16D3208A00

16D3455A00

16D3878A00

31MSC02

32PSF01

32TRC01

33RLY20

44RUB03

52FUH04

Part Number

32TRC01

33RLY20

44CPG08

44RUB03

52FUH04

52FUH08

52RCP21

52RCP24

52TS20

56FUS14

56FUS15

56FUS16

56FUS20

62D2483A00

62D331A

55SW26

64VS409

62D3558A00

16-4

Description

Autoformer 208-240V~

Relay, 12VDC, Chassis

Plug,plastic,black 1.5"

Grommet,Continuous .06

Fuse Holder, 3AG/3AB

Fuseholder, 3AG, .25 Tab

Receptacle, 250V/15A

Receptacle, 250V/50A

Pwr. Dist. Block, 2 pole,

Fuse 15A 250V

Fuse, 3A 250V 3AG Slow Blow

Fuse, 1/2A 250V 3AG Slow Blow

Fuse, 20A 250V, Slow Blow 3

Blower, 50 Hz 220V~

Voltage Selector Assembly

Switch, 3PDT, 250V, 10A

Assembled Voltage Sel

Assy,Ctl Bx 8K 480VCLS GT

Qty. per unit

1 EA

1 EA

3 EA

FT

4 EA

2 EA

2 EA

2 EA

2 EA

2 EA

1 EA

1 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

Harness, Control Box

Harness, Cntrl Bx -GTools

Harness , CT Box - Closed

Harness, cntrl bx suppl

Motor, speed control-KB

Power Supply, Open Frame, 1

Autoformer 208-240V~

Relay, 12VDC, Chassis

Grommet,Continuous .06

Fuse Holder, 3AG/3AB

Fuse Block- 13/32 x 1.5 4

Fuseholder, 3AG, .25 Tab

Receptacle, 125V/20A

Receptacle, 250V/15A

Receptacle, 250V/50A

Power Dist.Block 3 pole 4

Fuse, 5A/250V Slow Bl 3AG

Fuse 15A 250V

Fuse, 3A 250V 3AG Slow Blow

Fuse, 1/2A 250V 3AG Slow Bl

1 EA

2 EA

2 EA

2 EA

2 EA

2 EA

2 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

0 FT

6 EA

94MS36 Rev. F2 S/W Ver 2.06

41B04PPS.37

41B04WFR

44WFN01

62MFIA01

11D4307A07

12D4471A76

12D4472A76

81TAP16

81TAP25

62MFO01

11D2971A71

12D2389A76

12D2390A76

12D2391A76

12D2476A00

43SPR12

44HDL03

62MFOA01

11D4306A07

12D4473A76

Part Number

56FUS20

56FUS38

62D2483A00

62D331A

55SW26

64VS409

62HF1-2-60

49DCT04

52CTP21

54CAB05

62BA

62BLO02

64VB412V02

62MFA01

13D4470A00

62MFI01

11D4302A62

41-08WSP

94MS36 Rev. F2 S/W Ver 2.06

Description

Fuse, 20A 250V, Slow Blow 3

Qty. per unit

2 EA

Fuse, 30A 500V SlowBlow

Blower, 50 Hz 220V~

4 EA

1 EA

Voltage Selector Assembly

Switch, 3PDT, 250V, 10A

Assembled Voltage Sel

Exhaust System 230V~ 60Hz

Ducting, Alum 4" diam.

1 EA

1 EA

1 EA

1 EA

1 EA

Plug 250V~ 15A

Cable,Int'l 18 Ga

HF1 Beau Tap Bkt Assemble

Assembled HF1 Blower

HF1 Varible blower ctrl

Mylar frame assembly

Sheet mylar,.004 Thk

Mylar frame, inner

Latch

NSI Spring Washer

1 EA

10 FT

1 EA

1 EA

1 EA

2 EA

1 EA

1 EA

12 EA

24 EA

NSI 4-40 x 3/8 Phil Pan Ms

#4 Flat Black Washer

NSI Nylon Washer

Mylar frame inner assembly

Bracket, right angle 02

Frame mylar inner fr/rr

Frame mylar inner side

Tape Glide (Black UHMW)

Tape blue.015"x.50"x10'Rl

Mylar frame, outer

Mount, Magnetic

Base, Handle/Latch

Mount,Handle -Latch

Latch-Latch Handle

Ball Stud, Shortened, Gas

Spring 7/16 x 9/16 Compr.

Handle, 6". Alum

Mylar frame outer assy

Bracket right angle

Frame mylar outer front

1 EA

2 EA

2 EA

2 EA

2 EA

2 EA

1 EA

1 EA

4 EA

1 EA

12 EA

12 EA

24 EA

1 EA

4 EA

2 EA

2 EA

1 RL

10.5 FT

1 EA

16-5

52FUH04

54PWR01

56FUS15

62D1047

55SW26

64VS409-HA

62D1048

64MV407V03

62CL54-480

11D0932A02

16D0277A00

16D1045A00

16D1585

32BAL01

33RLY02

33RLY04

39BLO23

44LEG03

44RUB11

51WRN07

Part Number

12D4474A76

12D4475A76

81TAP25

62PUM01

11D1633A02

13D2170

16D2741A00

39VAP05

62CL54

11D0932A02

16D0277A00

16D1045A00

16D1585

32BAL01

32TRC01

33RLY02

33RLY04

39BLO23

16-6

Description

Frame mylar outer rear

Frame mylar outer side

Tape blue.015"x.50"x10'Rl

Assy, Pump, 220V 60Hz

Plate Pump

Rubber Washer

Cable, Vac Pump

Vacuum Pump 230V~ 60 Hz

Qty. per unit

1 EA

2 EA

10.5 FT

2 EA

1 EA

4 EA

1 EA

1 EA

5kW 208/240V~ 60Hz Power Supply 1 EA

Cover, AL54 1 EA

Harness, 5K Power Supply

Harness, Beau Plug

1 EA

1 EA

Interlock Harness

Ballast

Autoformer 208-240V~

Contactor, 2 pole,NO,30Amp

Relay, Sealed

Blower, mdl ball bearing

1 EA

4 EA

1 EA

1 EA

2 EA

1 EA

Fuse Holder, 3AG/3AB

Power Cable for AL53

Fuse, 3A 250V 3AG Slow Blow

Voltage Selector 60Hz

Switch, 3PDT, 250V, 10A

Voltage Selection Board

Capacitor Assembly 60 Hz

Assy UV Lt Ctrl 5K 60Hz

5kW 480V~ 60Hz Power Supply

Cover, AL54

Harness, 5K Power Supply

Harness, Beau Plug OEM

Interlock Harness

Ballast

Contactor, 2 pole,NO,30

Relay, Sealed

Blower, mdl ball bearing

Leveling Glide, Non-Skid-Sw

Grommet,Continuous .085

NSI Wire crimp nut

1 EA

1 EA

1 EA

4 EA

1 EA

2 EA

1 EA

4 EA

1.250 FT

6 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

94MS36 Rev. F2 S/W Ver 2.06

62D1046-64

64MV407V01

62LHSE-SW

L1261

PA91

90RF53-SW

63D0142B00

12D1361

12D1577

12D1997A99

16D0180A00

18D319

31MOT06

39BLO23

45KOB05

55SW02

55SW03

56THM01

62SASE-SW

63D3669B00

Part Number

54PWR01

54PWR05

62D3654A00

64MV407V03

62CL64

16D0277A00

16D1045A00

16D1585

32BAL03

32TRC01

33RLY02

33RLY04

39BLO23

44LEG03

44RUB11

52FUH04

54CAB10

56FUS15

94MS36 Rev. F2 S/W Ver 2.06

Description

Power Cable for AL53

Pwr Crd 18/3 SJT 12'

Assy, Capacitor AL54-480

Assy UV Lt Ctrl 5K 60Hz

5kW 220V~ 50Hz Power Supply

Harness, 5K Power Supply

Harness, Beau Plug OEM

Interlock Harness

Qty. per unit

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

Ballast

Autoformer 208-240V~

Contactor, 2 pole,NO,30

Relay, Sealed

Blower, mdl ball bearing

Leveling Glide, Non-Skid-Sw

Grommet,Continuous .085

Fuse Holder, 3AG/3AB

Cable, 3x 4.0MM2 black-rubb

Fuse, 3A 250V 3AG Slow Blow

4 EA

1 EA

1 EA

2 EA

1 EA

4 EA

1.250 FT

1 EA

8 FT

1 EA

Capacitor Assembly 50Hz

Assy UV Lt Ctrl 5K 50Hz

Lamphead 5kW SE-SW

Lamp L1261

PA91 photocell assembly

Reflector

Lamp Support Assy

Shutter Chain

Spring, Idler-5K Shutter

Sprocket, Shutter Motor

K-Harness, Lamphead 5 K 1 EA

Glass, Frosted Diffuser for Photocell 1 EA

Motor, AC Gear Positive

Blower, mdl ball bearing

1 EA

2 EA

Knob, Glass. Carriage

Switch, Shutter Timing

Switch, GlassInterlock

Thermostat, model K

5K Supper Wide Shutter

Idler arm ass'y

2 EA

1 EA

1 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

2 EA

2 EA

1 EA

1 EA

1 EA

16-7

52FUH04

56FUS15

62D1047

55SW26

64VS409-HA

62D2652A00

64MV407V24

62CL84-480

16D1045A00

16D1585

16D2617A00

16D2629A00

32BAL01

33RLY02

33RLY04

39BLO23

44LEG03

44RUB11

52FUH04

54PWR05

Part Number

11D3605A62|0

12D700

41-06NHX

41-06SBL.62

41B10WFR

43BLB15

64TR408V00

62CL84

16D1045A00

16D1585

16D2617A00

16D2629A00

32BAL01

32TRC08

33RLY02

33RLY04

39BLO23

44RUB11

16-8

Description

Bracket Idler-Shutter Ay

Sprocket 10 Tooth .250

NSI 6-32 Hex Nut Zinc

Qty. per unit

1 EA

1 EA

1 EA

NSI 6-32x5/8 Shoulder Bolt

NSI #10 Flat Washer Black

Bearing, Flanged .187 I.D

PCB Trigger

1 EA

1 EA

2 EA

1 EA

8kW 60Hz 208/240V~ Power Supply 2 EA

Harness, Beau Plug OEM

Interlock Harness

Power Cable, AL54-8K P/S

Harness, 8K-B P/S - MAIN

Ballast

Autoformer 208/225/240V~

Contactor, 2 pole,NO,30

Relay, Sealed

Blower, mdl ball bearing

Grommet,Continuous .085

1 EA

1 EA

1 EA

1 EA

4 EA

1 EA

1 EA

2 EA

1 EA

1.25 FT

Fuse Holder, 3AG/3AB

Fuse, 3A 250V 3AG Slow Blow

Voltage Selector 60 Hz AL

Switch, 3PDT, 250V, 10A

Voltage Selection Board

Assembly, Capacitor

Prnt Light Ctrl PCB w/Min

8kW 60Hz 480V~ Power Supply

Harness, Beau Plug OEM

Interlock Harness

Power Cable, 8K P/S

Harness, 8K-B P/S - MAIN

Ballast

Contactor, 2 pole,NO,30

Relay, Sealed

Blower, mdl ball bearing

Leveling Glide, Non-Skid-Sw

Grommet,Continuous .085

Fuse Holder, 3AG/3AB

Pwr Crd 18/3 SJT 12'

1 EA

1 EA

4 EA

1 EA

2 EA

1 EA

4 EA

1.25 FT

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

2 EA

1 EA

1 EA

94MS36 Rev. F2 S/W Ver 2.06

Part Number

56FUS15

62D3533A00

64MV407V24

62CL94

16D1045A00

16D1585

16D2617A00

16D2629A00

32BAL01

32TRC08

33RLY02

33RLY04

39BLO23

44RUB11

52FUH04

56FUS23

62D2723A00

64MV407V22

Description Qty. per unit

Fuse, 3A 250V 3AG Slow Blow 1 EA

Assy, Capacitor 60H,480V

Prnt Light Ctrl PCB w/Min

1 EA

1 EA

8kW 50Hz 220V~ Power Supply

Harness, Beau Plug OEM

Interlock Harness

Power Cable, 8K P/S

Harness, 8K-B P/S - MAIN

2 EA

1 EA

1 EA

1 EA

1 EA

Ballast

Autoformer 208/225/240V~

Contactor, 2 pole,NO,30

Relay, Sealed

Blower, mdl ball bearing

Grommet,Continuous .085

Fuse Holder, 3AG/3AB

Fuse, 4 Amp 250V Slo-BLo

Assembly, Capacitor

Prnt Light Ctrl PCB w/Min

4 EA

1 EA

1 EA

2 EA

1 EA

1.25 FT

1 EA

1 EA

1 EA

1 EA

94MS36 Rev. F2 S/W Ver 2.06

16-9

16-10 94MS36 Rev. F2 S/W Ver 2.06

17. Warranty

OLEC

Limited Warranty

OLEC equipment is warranted against defects in material for ONE (1) Year from date of purchase. Faulty parts will be repaired, replaced, or purchase price refunded at OLEC's option, for the original Buyer, provided the parts have been replaced by authorized personnel and are returned prepaid to the OLEC factory in Irvine, CA. Shipment must be accompanied by proof of purchase and the Dealer/Distributor name.

This Warranty applies only to equipment which was installed and used according to instructions and in the way it was intended to be used by the manufacturer. Unauthorized repairs, use of non-OLEC parts and lamps, modification, or Serial Numbers that have been removed or defaced, void this Warranty. Glass parts are not included in this

Warranty. Lamps are covered according to the Warranty below.

The OLEC Corporation and/or the Seller shall not be liable for any loss, damage or injury arising out of the improper use of, the failure of, or the inability to use the equipment. It is the Buyer's responsibility to ascertain the suitability of the equipment for the application. The Buyer assumes all risk and responsibility for the proper installation, for reading the Instruction Manual and retaining it with the equipment for the safe use of the OLEC product. All operators must be made familiar with the proper use and safe operation upon installation and periodically thereafter.

No one is authorized to assume any obligation, either on behalf of the OLEC Corporation or the Seller, which is not in accordance with the above.

Lamp Warranty

Should any original OLITE Lamp fail prematurely when used in OLEC lights, it should be returned promptly to OLEC, prepaid. It should be accompanied by proof of purchase, explanation of the type of failure incurred, and the approximate useful life of the lamp prior to failure. If it is determined by OLEC that the failure or shortened life has been caused by faulty material or workmanship, full or partial replacement will be extended to the Buyer.

IMPORTANT: The use of any lamp, other than those purchased or approved by OLEC will void this Warranty.

All Warranty Service should be handled through the Distributor through whom the equipment was purchased.

94MS36 Rev. F2 17-1

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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