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AP42CL 8000 Closed Loop High Resolution Printer Service Manual O

1. RED 22 GA 16D3794A00 XMR p BLACK 22 G j NNOS e 240 RED 18 GA 16D3793A00 T RED 22 GA BLACK 18 GAY e BLACK 22 GAY gt 16D2621B00 GRAY 5 COND 16 1003 15 LACK 5 COND Se 120 C 16D1003A06 Lack 5 COND pu 09 BLUE 18 GA f Ha BLUE 18 GA e lov 85 16D1003A10 BLACK 5 COND m gt BLOWER c4 a 16D1003A09 BLACK 5 COND Qaov gg TERMINAL ai UPPER RIGHT 16D1003A10 BLACK 5 COND STRIP N 3 WHITE 18 GA eet Soc 2 WHITE 18 1 5 n P2 J n P2 16D3810A00
2. INPUT 480 VAC 60HZ INPUT e Toward front of unit 2T Safety Interlock 277 9 PER LER i pet 8 ERN YA X X X X Y x Y Y Power Relay Ballast Ballast 3 EN X EY Y S ae 7 Din Socket 10u FT 1Opf uf 12uf 2 12 m eu p2 11 3 10 btu Madi edium 9 Relay 8 4 7 e bk w 6 R 5 wht E 3 4 Power wht 5 X Supply 3 N Blower No 22 2 L R 2 r R O 12 gry 1 M A le I R 11 pre N D 10 bra 9 0 8 red wht 5 7 o rg wht R PI 6 brn wht 9 L 5 Biu wht cleai 4 red 3 blu 2 wht
3. b H 56FUS15 3Amp 250V Slow Blow Fuse hi 623533400 ogangan haa Capacitor a jm le CH Assembly Sobooo l 4 1 d 1 5 0 s Safety uu Interlock diii 64MV407 83 39BLO03 S2FUH04 32BALOI Control Board Blower Fuse Holder Ballast ge n m m mm m m mmm M M M M M M M OJejelejejejejejoejeojojojojojojojo jojo o 18 Terminal Strip 1 Power Output S Power _ u Input ER El nom 120 VAC Coil Voltage UHU 33RLY04 33RLY02 Sealed Relays Power Relay d 56FUS15 3Amp 250V 3AG Slow Blow Fuse 32TRCOS EEE z Autoformer m 1 62D2723A00 zu it Capacitor Assembly ji 5 0 Safe
4. 220 VAC 50HZ INPUT Tap Switch Voltage Toward Selection front of unit 2400 203 240 208 T1 Board Safety Interlock 208 ee 3 18 OEA AA AX Toke Ballast Ballast Hower Relay V Y nud au 39 25 EN Y CY Y Y X Y X 120 0 I ae Din e 3 Socket Slow Blo 2225 lon f Wf Iyf Fuse 46 12 11 e 10 bu Medi edium 9 Relay P 8 S 14 o 7 blk Y 6 e e R 5 Lm 13 S 4 Power ht Supply ii D 3 r4 Blower P 2 L Y T pos E R 12 bry M I org 10 9 10 8 7 drghwht R 6 L 3b a 4 red 3 blu 2 wht 8 1 bik brn d org 6 red 12 11 n C 10 9 4 wht 8 7 3 pur Interconnecting 6 5 Beau Plug 2 Connector yel 4 3 1 grn yel 2 1 Towar center of unit 13 24 94MS42 Rev S W Ver 2 06 AL 84 480 Power Supply 60Hz 120 VAC 60HZ
5. P2 fe FL fe cee coe 22 I MU Kl 8 a e Ve a 8 9 EE Front View of Control Board ora zn vorn 9995 999 Mi e nt zd Triacs amp Relay E n Unit Power TR10 2 r nit Power ae n ab 6 Le TRIO1 Shutter Motor E d 2 TR102 High Relay ziel Vm IH TRI03 Medium Relay EE TRios lt ua N TR104 Main Contactor E 5 h E h wo TRIOS Lamp head fans hm gt LEP 15 2 94MS42 Rev B1 S W Ver 2 06 Drive Motor Fault Tree Manually position both frames in a mid position Turn unit on Does upper frame move into unit Does lower frame move Wait 20 seconds Does integrator
6. Yes No Check Safety Glass No Are any LED s and Lever Good lit on the PC Board Good Reinstall safety glass Be Test 1 Is power relay pulling in No Go to test 1 Go to test 2 after checking PC Board fuse Yes Test 2 Check wires and Lamp Lamp vlotages on 12 red amp 14 Repair or old new black 200 245 VAC to top No good replace of power relay wires Replace Go to lamp test 3 Good Still Check for 0 VAC No strike between 4 white amp 10 black on Test 3 terminal strip Thermostats 500 VAC on safety switch or 2 yellow amp 3 associated wiring pruple No Yes could be faulty Check for 120 VAC Yes 500 VAC on PCB power No between 3 connector pins 2 Possible purple on white amp 8 red faulty terminal Check PCB fuse lamp or strip to Yes 7 N trigger orange com board on cap pac Good No good Check the wires x from 2 amp 8 to power relay Replace PC Replace Yes No Board fuse Check wiring from ballasts and voltage set switch to terminal switch and cap pac Go to test 2 after checking wires on voltage set switch 94MS42 Rev B1 S W Ver 2 06 15 1 Shutter Rotation Fault Tree
7. REN EN a20v XMR if N NOSE 2 P66 a2 7 7 16D3793A00 en s 16D3794A00 22 BLRS NOSE BLACK 22 GA BLACK 22 GA gt BROWN 18 GA 16D2621B00 GRAY 5 COND BROWN 18 GA 16D1003A15 _ BLACK 5 COND BLUE 18 GA 16D1003A06 _ BLACK 5 COND BLUE 18 GA e lov 1601003 10 BLACK 5 COND TERMINAL ge ES 16D1003A10 BLACK 5 COND STRIP 5 3 So 16D1003A09 BLACK 5 COND 18 GA gt SN 5 NIS gt BLOWER BLOWER gt Li 18 GA 1 2 16D1003A10 _ BLACK 5 COND UPPER LEFT UPPER RIGHT WHITE 18 GA VS de NZ pi sg al a el 2 WHITE 18 GA 2 BM pn n n P2 5 P2 CTRUTEME RED 18 GA SENS C WORK LIGHTS BLACK 18 GA SENSOR BOARD 120V 3 64A X508V00 18 GA RED 18 GA 13 b WHITE 18GA 5 BLACK 18 GA n n 4 TEMPERATURE MONITOR D 16D3810A00 WHITE 18 GA e ASI 14 WHITE 18 GA 5 gt 18 MAIN BOARD 64 1441 REMOTE BOARD 64MI441E BLACK 18 GA gt RED 18 GA 16D4173A24 20 VAC TEMP BOARD 16D1003A06__ BLACK 5 COND 64 503 00 72 2 P67 y BLOWER BLACK
8. 3 BRACKET 9 2 TRANS FORMER 5 48 LOWER GTOOL POWER E VACUU SUPPLY LL ple PUMP lo PS1 ral vAC3 os Pe 2 4 XMRI _1 La gt J LOWER FRONT LAMPHEAD UPPER Ie LOWER UPPER 9 POWER VACUUM VACUUM SUPPLY VAC2 PS2 Disconnect the in line electrical pump connection located approx 6 from the motor end of the pump Remove the four 20 nuts that secure the pump mounting plate to the isolation mounts Then lift the pump out of the unit e Remove the mounting plate from the defective pump Install it to the new pump Note the wire positions and remove the electrical harness from the defective pump Install it on the new pump Install the new pump in reverse order of removal and verify the correct operation and rotation 94MS42 Rev S W Ver 2 06 8 3 8 4 Tubing Fitting Replacement If a vacuum line or connection is cracked loose leaking or broken replace it as soon as possible faulty vacuum line or connection will greatly increase the vacuum drawdown time required if not eliminate full vacuum altogether vacuum lines are separated
9. TT LON T a9 9 Wa a Tiu 3SVHd HAM dSVHd S d A08 IM 6 4 IN VLA ISVHA E A 08 A 08 WAAL ONTMIA OV HLIHA quiso 4 NOLLVAAdO 4 xL HSVCl Sd ANIM Tad tno M Jovia XTddN 4 ino aaa Ws AOTT M AUHM Wood Net AOZT gt lt 5 021 9 j Y9 goza HITS IHNI so ANT AONVUO 8 TO es TATOIA m zo UNAX aay MOTTAA IV sys w ATANWASSV AVUB OY i nt SHHOLIAS NOLLOATAS Xov18 IS UNITYAOLON gt HOVITOA o asve aaa cs i __ Old HLIHA S in 1 asvs 0 84 A a in 3 gt lt TL 945 3IOLOIN 4 IONO 1 AONVUO py 5 91 1 gt lt LL AOLVAOAVAA Nyda gt lt AYTAN A9014 NOLLNITALSIA SdWnd WANDVA nad 29 gt lt Sid an a MOTTHA a N uit SL au L NMOUG ar LHIOIA 734 9 qmi zu TAI o ANNATIONLNOI Rose A
10. ACIN BLK _ 6 GA z m 18 T2 CONTACTOR ORANGE TO CAP PACK 12 CAP COM BALLAST 240 1208 BALLAST 1 08 240 BALLAST 240 PALLASE M 208 4 208 240 COM GAB 5 M YELLOW TO AUTOFORMER RED TO FUSE ip 4 e AUTOFORMER 240 VOLT VOLTAGE SELECTOR SWITCH 94MS42 Rev B1 S W Ver 2 06 13 3 13 4 AL 84 480 Ballast Wiring TERMINAL STRIP 18 17 16 15 14 13 12 111109 8 7 6 5 4 3 2 1 NO 29 VIOLET AC IN BLK 6GA P TI T2 CONTACTOR NO 20 ORANGE TO CAP PACK Ll L2 3 B oa CAP COM BALLAST BALLAST 2 M 277 277 CAP CAP COM BALLAST BALLAST 3 4 277 I 277 COM CAP 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 fu
11. the control box 94MS42 Rev B1 S W Ver 2 06 into unit display an error message No Yes No Yes Ss Motor speed controller uu u eck for outpu A t E cras N wires Al 2 reversed Try a blank tray on pins 1 and 5 T E check against wiring cycle Do rames 79 on back of control switch position in the service diagram box PCB 64CT464 manual Also check the fuse Yes No No Yes Perform a diagnostic Poe test to ensure frame Check for Replace 64CT464 LEDs change MM Refer to 120 VAC board in control on control box 7 MER Diagnostic section in input on 2 the service manual motor speed controller pins L1 amp L2 Yes No No Yes Check wires Replace Check oss Probable bad relay from 31MSC01 31MSC01 from switch to on 64CT464 to the step down motor speed control box Replace board transformer in control board 15 3 15 4 94 542 Rev B1 S W Ver 2 06 16 Parts List Part Number Description Qty per unit 62AP42CL Base Kit AccuPrint Closed Loop 1 39 5 Vacuum Pump 230 60 HZ 2 55SW45 6 Button white GO 1 55SW45 7 Button white STOP 1 62D3542A00 Assembly Rail Cover OV45 1 62D3705A00 Base Assembly AP 4
12. follows 15 Density Scale 05 Density Scale Step Correction Step Correction 2 00 0 50 2 00 0 79 1 75 0 55 1 75 0 82 1 50 0 60 1 50 0 84 1 25 0 65 1 25 0 87 1 00 0 71 1 00 0 89 0 75 0 77 0 75 0 92 0 50 0 84 0 50 0 94 0 25 0 92 0 25 0 97 0 00 1 00 0 00 1 00 0 25 1 09 0 25 1 03 0 50 1 19 0 50 1 06 0 75 1 30 0 75 1 09 1 00 1 41 1 00 1 12 1 25 1 54 1 25 1 15 1 50 1 68 1 50 1 19 1 75 1 83 1 75 1 22 2 00 2 00 2 00 1 26 Press 1 2 3 then 4 Jon the numerical keypad The Vacuum window will read _ 7 This places you in select mode Then press the 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 27 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 Press 11 21 2 then 4 Jon the numerical keypad The Vacuum window will read 22 This places you in select mode Then press the key and the exposure window will show previous calibration number for example 4 4 3 Press the 2 key the memory window will dim and you will be able to enter the new ca
13. 2 8 ee Front View of Control Board on SSS SSH 22735 Buc i ee Ld it 99 E 96 244 96 Triacs amp Rela ii C e HHH 2i HHH e naes amp SY E rR103 IL 7 H y K1 Unit Power Im 42 R9 lt amp ls Ak lae TR101 Shutter Motor dx qd 7 TR102 High Relay og alg TR103 Medium Relay lt Rm E D _ 5 3 104 Contactor lt 2 LG db 3 dus TR105 Lamp head fans O ri 3 Vo a RS j Power Connector P2 Switch Connector LED s 1 AC Hot 7 Unit Fan 1 AC Hot 7 High Switch D18 Lamp head fans 2 AC Common 8 Power Relay 2 AC Common 8 Low Med Switch D13 Power Supply Fan 3 Lamp Fans 9 Not Connected 3 Not Connected 9 Manual Expose D17 Shutter Motor 4 Shutter Motor 10 Aux Terminal 4 Aux Terminal 10 Interlock 015 High Relay 5 High Relay 11 DC Common 5 DC Com Ground 11 Not Connected D16 Medium Relay 6 Medium Relay 12 Position 6 Power Switch 12 12 VDC D14 Power Relay Check Idle Voltage on Board or on Terminal Strip Lugs 2 and 3 N Switch Connector Power Connector a a HE ooooo b Ea EE EERE g g g g J S ROO s amete ee ete N tuU z J feb a
14. 13 26 Interconnect Gabler as a ea 13 27 Printing Light Check List Check List for Printing Light Troubleshooting and Service 14 1 Fault Trees ING Strike Fault Tree aan 15 1 Shutter Rotation Fault Tree 15 2 Drive Motor Fault Treeni onde qanapi assia 15 3 Parts List Darts a tuis E 16 1 Warranty Warrants 17 1 VV ALT ATE Rei 17 1 94MS42 Rev B1 S W Ver 2 06 1 Specifications 99 lt i Upper Tray 96 Lower Tray E 51 58 ei 66 61 Crated Dimensions Length Width Height 130 78 85 330cm 198cm 216cm Shipping Weight Crated 2 400 Ibs 1089kg Uncrated 2 000 Ibs 907kg Actual Dimensions Cabinet welded heavy gauge steel construction with access doors on both sides Length Width Height 110 61 99 279cm 155cm 251cm Note The AP42CL can be disassembled see Base Assembly Diagram into 4 pieces if required to pass through most doorways or hallways Please make sure there is adequate room for its passage 94MS42 Rev B1 S W Ver 2 06 1 1 Effective Exposure Frame Area
15. 74 1 NSI 8 FLAT WASHER 41BO8WFR 73 1 5 16 SPLIT LOCK WASHER 41F2WLS 72 1 SOCKET HEAD FLAT 5 16 18 X 62 41BF2SHF 62 71 1 INSULATION PAD AL13 14 15D725 70 1 COVER DRIVE CHAIN LOWERLD 11D2799B08 69 1 COVER DRIVE CHAIN UPPER 11D2799A08 68 4 NSI 6 32 X 3 8 PHIL FLAT 41 06PFO 37 67 1 NSI 3 8 X A3 4 SOC SHLD 41BF3SHC1 7 44 1 3 8 6 NYLON LOCK NUT OV45 41 F3NLN 43 1 THREADED ROD 12D1751A00 42 2 5 16 18 X 3 4 HEX BOLT BLK 41BF2BHX 75 41 1 TENSIONER BUSHING 12D1755A00 40 1 NSI 1 4 20 X 1 3 4 HEX BOLT BLK 41B40BHX1 75 39 6 NSI 8 32 5 8 FLAT HEAD 82 41 08 2 62 38 19 NSI 10 FLAT WASHER BLACK 41B10WFR 37 24 NSI 8 LOCK WASHER SPLIT 41 08WLS 36 24 NSI 8 32 X 1 2 SOC HD CAP SCR 41 085 50 35 4 NSI 1 4 20 LOCKNUT NYLON INS 41B40NLN 34 8 NSI 1 4 SAE FLAT WASHER 41 FOWLS 33 3 WASHER SPLIT LOC 1 4 41 40WFR 32 4 1 4 20 X 3 4 HEX HEAD BOLT 41 FOBHX 75 31 4 NSI 6 32 X 3 4 PPMS ZINC 41 06PPS 75 30 4 4 40 X 5 8 PHIL FLAT MS 41 04PFO 62 29 2 NSI 6 32 X 5 8 PPMS ZINC 41 06PPS 62 28 2 NSI 4 40 KEP NUT 41 04NKP 27 6 NSI 4 40 FLEXLOCK METAL 41 04NLM 21 1 OVERTORQUE SAFETY DEVICE 4305 01 18 5 NSI 10 31HEX KEP NUT 52 28 17 1 DEFLECTOR AIR 11D3395A17 16 1 CHAIN 35 RLR 10 FT 43CHA05 15 10 BLOCK MOUNT AC TRACK 12D1635A62 14 1 HARNESS MOTOR POS SWT 16D2319A00 13 4 SWITCH TIMING ROLLER 555W02 12 2 CHAIN YOKE 12D1757A62 11 1 TENSIONER SPROCKET 12D1996A00 10 1 SPRING CHAIN TENSIONER 43SPR14 9
16. 94MS42 Rev B1 S W Ver 2 06 Continued on next page 2 6 Closed Loop Cooling Assembly cont QU G8 94MS42 Rev B1 S W Ver 2 06 DETAIL A DETAIL G 7 REF _DETAIL N 3 PLACES 16 PLACES 2 PLACES Q 8 44 12 1 4 20 X 75 HD BOLT 41 FOBHX 75 EE 43 1 BRACKET ELECTR 11D3857A17 55 4 42 1 BOX ELECTR COOLING MOD 11D3984A17 41 4 FOAM CLOSED CELL 72FOM43 40 8 5 16 SPLIT LOCK WASHER 41 F2WLS 39 8 5 16 FLAT WASHER 41 FIOWFR 38 8 5 16 18 HEX NUT 41BF2NHX sj DETAIL B 37 8 5 16 18 X 75 HEX BOLT 41BF2BHX 75 REF 8 PLACES 36 1 BRACKET UPPER 11D3920A17 x 9 9 35 1 STAND PAN WELDMENT 11D3983A17 1 REE y 34 ADHESIVE SPRAY 82ADHIS py 33 4 FOAM SHEET 1 0 X 24 X 60 0 72FOM42 7 N 32 4 6 32 WASHER SPLIT LOCK 41 60WLS X 3 4 36 32 WASHER FLAT 41 06WFR
17. 4 4PL 18 3 1 WELDMENT COOLING COMPARTMENT 11123751 00 30 2 DOOR PANEL CENTER 11D3717A00 DETAIL G 29 12 SCREW 10 32 X 1 2 SOC BUTN HD 41B12SHB 50 PT 7 28 12 SCREW 10 32 X 3 8 PH PAN HD 41BI2PPS 37 27 18 ft GASKET TRIM LOCK 48TRMO2 26 4 LEVEL LEG 12D2904A00 ep 25 1 PALLET SHIPPING 19D2896A00 BS 24 15 WASHER SPLIT LOCK 1 4 41 FOWLS 23 24 WASHER FLAT 10 41BIOWFR N 22 24 WASHER SPLIT LOCK 10 41 I0WLS 21 BRACKET SHIPPING 11D2870A63 20 BOLT HEX 1 4 20x4 5 41 FOBHX4 5 19 SCREW PH FLT HD 1 4 20x 75 41 40SF0 75 18 27 NUT HEX LOCK 1 4 20 41B40NLN H i 17 60 WASHER FLAT 1 4 41 40WFR 16 36 BOLT HEX 1 4 20x 75 41 FOBHX 75 Is 4 WASHER FLAT 5 16 41 FIOWFR DETAIL H E 14 4 LAG BOLT 5 16x 2 5 41 FIOLAB2 5 e 13 48 SCREW 6 32x 38 PH FLAT HD 41 06PF0 37 12 784 GASKET FOAM 1 4 W x 1 4 THK 44GKT12 24 STRIKE PLATE MAGNET 200 43 05 10 24 200 43MAG04 9 1 COVER TOP 11D3691A00 8 12 HOOK DOOR UPPER 11D2230A62 7 4 DOOR 11D2158A00 6 1 WELDMENT INSERT SECTION 11D3754A00 5 1 11D2163B00 4 1 COVER RAIL L H 11D2163A00 3 1 WELDMENT 11123748400 _ 2 1 WELDMENT RAIL CENTER 11D3750A00 2 D 1 1 WELDMENT LOWER 11D3690A00 REF REF QTY DESCRIPTION PART NO 94MS42 Rev B1 S W Ver 2 06 12 5 12 6 94MS42 Rev B1 S W Ver 2 06 Unit Cabling Diagram
18. 3 3 Operator Control Panel serien 3 4 Table Showing the 12 Calibration Positions 3 4 Calibration Procedures voted 3 5 Changing the Calibration Number 3 6 Matching Exposure Surfaces 3 7 En 3 8 Matching with a meter 3 8 4 Integrator Program Set Up To Enter Select Mode 4 1 Lock Level Feature nu 4 1 Lock Level Description and Operation 4 2 Setting or Changing your Lock Code feature 4 3 To Clear Lamp Statistics 4 3 To Clear Memory and Exposure Statistics 4 3 Two Value Exposure Mode 4 4 Split Exposure Mode ete tesa anna 4 4 single Surface Mode sungen als 4 5 Board Count Display Mode 4 5 Frame Control Interface Mode 4 6 Automatic Vacuum Mode 20 042 2 4 6 Auto Step 4 7 Set Default Vacuum 1 eode eer deo ea eS us 4 7 Tray Mode E 4 8 94MS42 Rev B1 S W Ver 2
19. 23 4 6 FLAT WASHER 41 06WFR 2 2 6 32 X 7 16 SOC FLAT 41 065 43 2112 IDLER ARM SHUTTER 63D3530A62 20 4 6 32X 62 SCREW 100 FLAT HD 41BO6SHF 62 19 3 6 32 37 SCREW 100 FLAT HD 41 06PF0 37 IE RE 18 13 6 32 37 SCREW PHIL PN HD 21 06 37 DETAIL YN Zee es Er ES 7 8 6 32X 25 SCREW PHIL PN HD 41BOGPPS 25 M Q3 16 2 34 40 NUT HEX 41 04NHX 2 4 40X 25 SCREW 100 FLAT HD 41B04PFO25 DETAIL A DETAIL B 14 6 6 32X 687 RD SPACER 22 58779 2 PLACES ZPLACES B 2 FUSE CLIP 43CLPO2 REF REF 12 3 6 WASHER LOCK INTERNAL 41 06WLI 18 9 18 H 2 LAMP SUPPORT ASSEMBLY 6300142803 MX x gt V 6 BEARING BALL SEE BOM o 1 SPROCKET DRIVE MACHINED 12D1998A99 8 1 AIR TUBE FRONT 12D1874A62 1 2 SPRING SHUTTER AL83 12D2060A07 6 1 AIR TUBE DRIVE 12D1873A62 3 4 6 X 187 ROUND SPACER 22 58500 411 REFLECTOR INNER RF83 SW G 1121876899 3 8 SHUTTER REFLECTOR ASSY 1102216 RUS TIMING DISC LT 1 11D0210A62 1 2 SHUTTER END PHOTOCELL SLOT 11D3974A71 QTY DESCRIPTION D4358A 94 542 Rev S W Ver 2 06 13 13 13 14 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 li
20. nile dese 8 2 Pump Replacement un S u ess 8 3 Tubing Fitting Replacement 8 4 Vacuum Gauge Replacement 8 4 Vacuum Seal Replacement ns 8 5 Phototool Wiring Diagram optional 8 7 Nose Assembly Removing the Left and Right Rail Covers 9 1 Replacing the Display and Keypad PC Board 9 1 Replacing the Emergency Stop Button 9 1 Replacing the s and Buttons 9 1 Replacing the Glass Tool Vacuum Buttons 9 2 Replacing the Vacuum 9 2 Nose Section Autoformer ede tet eon EU Idae puce 9 2 Work TIPP 9 3 Nose Fans nie arte 9 3 Cleaning or Replacing Nose Filters 9 3 94MS42 Rev B1 S W Ver 2 06 Nose Assembly Drawings Be eee 9 4 10 Exposure Trays 12 Diagrams 13 Light Source Nose Assembly Left and Right Covers 9 6 Mylar Replacement 10 1 If Mylar Pulls Out of the Frame 10 1 Outer Frame Replacement usage 10 1 Tray Assembly Drawing tre
21. 128 32 4 1 765 Upper Frame In 128 32 4 8 1710 Lower Frame In Switch Table Switch Value Function 1 Upper frame in labeled frame 4 Frame switch 8 Lower frame in labeled frame 16 se key nose section 32 Door emergency switch 128 key nose section Typical values that you will see when all switches are good e Upper tray in Frame switch closed Door and Emergency switches closed The bottom display should read 4j a o When the 94MS42 Rev S W Ver 2 06 button is pushed the value should change to 55 When the button is pushed the value should change to 27 75 7 5 3 Lower tray in Frame switch closed Door and Emergency switches closed 1 n LILI The Exposure window should read Z Z Lic C CY Fi 717 When the button is pushed the value should change to Z Z LI l IL F irtrrt When the gt button is pushed the value should change to 7275 7 Typical values that you will see when a fault occurs J J Li Indicates neither frame in position magnetic frame switches closed and does not have the correct reading from either the door switches or e emergency button Indicates upper frame in position magnetic frame switches closed and does not have the correct reading from either the door sw
22. Press the key upper tray should move in the vacuum window should Press the 5 key lower tray should move in the vacuum window should 94 542 Rev B1 S W Ver 2 06 FW y I Set Volt meter for VDC and measure across pins 5 amp 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 Exit the diagnostic mode by pressing the 9 key then the 0 key Adjust the FAST pot on the control box Press and hold the STOP key then press the GO key and then release both keys to start a blank frame cycle no vacuum or exposure e Measure across pins 5 amp 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 19mm to 1 25mm from the end of the tray rod 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 adjust
23. 4 b dq Pp d d a4 L 1 4 Eq Bg Bog 806 CORR 1 ib qp AR dA do I C Idle Voltage Adjustment Back View of Control Board 94MS42 Rev S W Ver 2 06 13 19 13 20 Signal Description Power Connector V Hot Supply to board approximately 125 P2 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 P3 Lamp Fans V proportional drive output for the blowers in the lamp head P4 Shutter V output to drive the shutter motor P5 High V Output to drive the high relay which engages the high power capacitor bank during warm up and high power exposures P6 Medium V Output to drive the medium relay which engages the medium capacitor bank during warm up and both high and medium level exposures P7 Unit Fan V Output to drive the power supply blower or fans P8 Power Relay V Output to drive the main relay This provides power to the lamp circuit P9 Not currently used P10 Aux Terminal connects to the signal connector for accessories Not used in most equipment P11 DC Common Circuit common for low voltage signals from the lamp this may not be the same potential as V Common connection and should never be interchanged P12 Position Shutter switch a
24. ASYE is 19 7 L LINMIRIOLON gt cas ts 8 E 1 1 ALHA 22 AATIOA LNOD 945 YOLOW 3 L 1 FONVAO ane AOSSTAAWOI me T DL ITIOIA ot 5422 uoivsoava a eos 9 normas 9 AOPZ T e vH H Ex gevi TL WANOVA 4 nr 5 p ama 2 s MOTIHA gt 4 9 EI O0ATOFIOTO 217 Ach Th cH wovid fe EL iL MEM Q VD9I daw anta 10 H LATOA 3 a 5 5 MOVIE B 8 ana oli l HLIHA e SXoOTH NOLLNATALSIA 12 3 94MS42 Rev B1 S W Ver 2 06 Base Assembly Diagram Continued on next page 12 4 94MS42 Rev B1 S W Ver 2 06 Base Assembly Diagram cont DETAIL F 12 PL DETAIL A 26 PL DETAIL B 2PL DETAIL C 7PL DETAIL D 4PL
25. section DO NOT TOUCH THE REFLECTOR SURFACE WITH YOUR HANDS lt Bott Wa View I Remove the 2 center screws from the bottom side and the 2 screws from the top side of the lighthead Bottom Ah N ri View View i 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 View p r N Side 2 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 94MS42 Rev B1 S W Ver 2 06 13 9 13 10 Shutter Switch The switch provides shutter position inf
26. 94MS42 Rev S W Ver 2 06 Phototool Wiring Diagram 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 Vacuum Pumps and Tubing Fitting Replacement for vacuum problems 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 The glass tool vacuum pump is independent of the integrator and is used to hold the art work to the glass tool The operation of the pump and buttons are on the left front rail cover of the unit The vacuum button must be pressed to turn ON the vacuum pump Once the pump has been turned ON the button for the upper tool or lower tool can be pressed to activate the respective solenoid in order to hold the art work to the glass tool TOOL PUMP P4 GRN YEL GRN YEL 18 3 3 BLACK gt BLUE 7 NEUTRAL 1 RED 1 1 BROWN 1 2 220vac 4 RELAY 2 ORANGE 6 6 ORANGE uc swi Pero S RED T WHITE x BLACK ta 19 EUM 12VDC 6 2 RED 2 RED 2 2 WHITE i 14 CONTROL PUMP ORANGE 7 7 GREEN sw2 1 1 518 8 amp UPPEI 1 j BLACK
27. key once to exit this mode To Clear Memory and Exposure Statistics A CAUTION This step clears all information stored in the memory Note You can abort clearing the memory by pressing the key before the display counts down to 522 and you will not change any memory and exposure statistics 94MS42 Rev S W Ver 2 06 4 3 4 4 Press the key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 3 then 4 in sequence The Vacuum window will read This places you in the select mode Press the key five 5 times 9 Press 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 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 1 2 4 in sequence The Vacuum window will read This places you in th
28. lt LI IL LI Ut IN J I lt 1 SS I j EXE felis Jee Ciel GS LEQ m De 0 x cI Je Jem 2 Microprocessor controlled light integrator with LED display 40 memories battery backup single button control lamp statistics and self diagnostics The operator control panel is composed of two sections the display board and the memory board Note The number of digits in each window Memory Window Vacuum Window Exposure Window Integrator POWER Press the power button on the integrator to turn the AP 42CL on or off When the unit is off the light system blowers will run for about two minutes to cool the lamp MEMORY Pressing the memory key will advance the memory location The display will show which memory is selected VACUUM Press the vacuum key and use the numerical keypad to enter a vacuum delay time The window shows the delay in seconds 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 zdl INTENSITY Press this key to select Low Medium or High power LEDs lit will indicate the level selected ES DIFFUS
29. 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 94MS42 Rev B1 S W Ver 2 06 Te 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 m Perform daily maintenance steps plus the following 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
30. 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 Press the 1 key a second time the letters 2 will appear in the y Vacuum window The total elapsed time in hours that the unit has been ON will be displayed in the Exposure window Press the 1 key a third time The letters Z 7 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 Press the key a fourth time The letters 2 a 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 Press key a fifth time The letters 7 Vacuum window The elapsed time in hours that the lamp has been used at high power will show in the Exposure window Press key twice to exit this mode Exposure Statistics Total Exposures pry ILL 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 0 key on the integrator to power up the light the front remote switches and the exposure unit s co
31. 30 1 ASSY UPPER COLLECTOR 11D4079A17 E 29 1 DUCT INTAKE UPPR 11D3685B17 3 US ud DETAIL J 28 1 LABEL BLACK 15D509 REF TUE REF 4 4 PLACES 10 PLACES 27 6 ft FOAM TAPE 5 x 12 THK 81 18 m 26 1 CLAMP CABLE 1 2 43CLMOI Bm i 25 st GASKET 1 16 THK 44GKTO1 i 24 1 BOX ELECT HANDY 43HBX02 23 1 COVER ELECT HANDY BOX 43BXC01 22 6 8 32 HEX KEP NUT 41 08NKP 21 6 8 32x 38 PHIL HD 41 O8PPS 37 iy 20 46 10 WASHER FLAT 41 10WFR SERRE sid ae 10 WASHER SPLIT LOCK 41 1OWLS 2 PLACES 6 PLACES 18 34 10 32 HEX KEP NUT 41 12NKP 17 26 10 32x 38 PHIL PAN HD 41 12PPS 37 16 4 1 4 WASHER SPLIT LOCK 41 FOWLS 15 4 1 4 20x 62 BUTN HD SCREW 41BFOSHC 62 14 12 1 4 WASHER FLAT 41 40WFR 3 8 1 4 20 NUT HEX NYLON LOCK 41B40NLN 2 6 6 32x 38 PHIL PAN HD 41 06PPS 38 ul 2 HEAT EXCHANGER 34 39HTX01 Gf 10 4 BLOWER 495 CFM 39BLO17 I PLACES 4 PLACES 9 2 COVER REAR LOWER 11D3687A08 8 1 COVER REAR UPPER 11D3980A08 x 1 7 1 MIDWALL COOLING MOD 11D3982A17 6 4 BRACKET MOUNT 11D3371A62 5 1 MOUNTING PLATE VALVES 11D3382A62 4 1 PLATE REAR BLOWERS 11D3381A17 3 2 PANEL SIDE HEAT EXCH 11D3374A17 2 1 DUCT INTAKE LOW HEAT EXCH 11D3685A17 fae 1 1 FRAME WELDMENT 11D3981A08 14 PLACES 6PLACES item DESCRIPTION PART NO 2 8 94 542 Rev B1 S W Ver 2 06 3 Integrator Functions Features J m dil i
32. Connecting the chiller cont TO SYSTEM DX la Y Sox y 9 2 RETE RE gt m 2 PL 94MS42 1 S W Ver 2 06 7 ad ie al CEU ee DESCRIPTION OLEC PART NOTE 1 3 SOLENOID VALVE TWO WAY 31S0V09 5 2 SOLENOID 31S0V09 C240 1 2 NPT BALL VALVE BLEED VALVE 43FIT41 4 5 1 HOSE ID BARB I NPT MALE PIPE 43FIT42 5 5 1 HOSE ID BARB 3 4 NPT MALE PIPE 43FIT43 6 1 1 NPT HEX NIPPLE MALE 43FIT44 7 8 12 NPT HEX NIPPLE MALE 43FIT57 8 3 REDUCER NIPPLE MALE 3 4 1 2 43FIT46 9 2 BUSHING FEMALE TO MALE 1 1 2 43FIT58 10 1 NIPPLE FLOW METER 1 NPT 12D3466A07 1 11 2 I NPT FEMALE COUPLING 43FIT49 12 1 NIPPLE LONG 1 2 NPTx6 LONG 43FIT66 13 2 MALE FEMALE ELBOW I NPT 43FITS1 14 3 FEMALE TEE I NPT 43FITS2 15 3 12 NPTMALE BRANCH TEE 43FIT65 16 1 FEMALE CROSS 3 4 NPT 43FITS4 17 3 12 NPT BRAIDED HOSE 20 lg 49DCT38 18 2 172 NPT FEMALE FEMALE ELBOW 43FIT60 19 BRAIDED CLEAR PVC TUBING 49DCT34 2 20 6 HOSE CLAMP FOR 1 HOSE 43CLMIO
33. N 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 e 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 e 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 N 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 sluggis
34. 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 84 Capacitor Assembly CAPACITOR ASSEMBLY PART 62D2652A00 ER 5 m 1 P n Ne Ve 2 B Cs 12uf 12uf 080 2 2 T E f Es J CF NZ h 4 7 D H AL 84 480 Capacitor Assembly CAPACITOR ASSEMBLY PART 62D3533A00 EN 5 Ti 1 A T i MN T hcm u 12uf 12uf D 3 C 5 w Larry N
35. 21 3 1 2 BRAIDED HOSE 12 Ig 49DCT39 22 2 MOUNTING PLATE 11D3382A62 23 4 HOSE CLAMP 1 5 2 43CLMI3 24 FLOW METER 49FLOWOI 25 TEMPERATURE GAGE 49THERMOI 26 TAPE TEFLON 1 2 WIDTH 8ITAPI2 3 27 1 LABEL FLOW DIRECTION COLD 15D3587A00 28 LABEL FLOW DIRECTION HOT 15D3587B00 29 HOSE INSULATION 1 1 8 X 3 8 WALL 49DCT41 8 Bleed Valve CUT ITEM 29 HOSE INSUL INTO THREE SECTIONS AS STATED IN NOTE No 2 INSERT HOSE INSULATION ONTO ITEM 19 TUBING BY APPLYING LUBRICANT CUSTOMER TO SUPPLY 1 TUBING FOR CONNECTION TO COOLING MODUULE SOME FITTINGS MAY BE ORIENTATED DIFFERENTLY THEN DEPICTED IN THIS SCHEMATIC ASSEMBLE THE SOLENOID VALVE BRANCHES FIRST BEFORE CONNECTING THEM TO CROSS ITEM 1 DO NOT OVERTORQUE FITTINGS APPLY TEFLON TAPE ITEM 26 TO ALL PIPE THREAD CONNECTION CUT TUBING ITEM 19 INTO THREE SECTIONS 24 41 43 LENGTHS TO SECURE FLOW METER ITEM 24 TO NIPPLE ITEM 10 USE HOSE CLAMPS SUPPLIED WITH FLOWMETER 6 2 3 Filling the Closed Loop System CAUTION Y If the Closed Loop System is not filled properly the unit will overheat one or both lights sources will shut themselves off randomly under heavy usage and damage to the unit will be the result Hook a hose to the bleed valve and put the hose end into a bucket Turn the power on and set the te
36. 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 94MS42 Rev S W Ver 2 06 3 5 3 6 i Press the button twice This will send the frame into the unit and start the exposure After the exposure retrieve your frame by holding down the 959 button and press 2 button When the frames start to move release both buttons Record the resulting mj reading from the meter 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 we have to change the preset 500 to 600 Change to 600 as described earlier in Calibration Procedures Section Remember 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 Press 1 2 3 then 4Jon the numerical keypad The Vacuum window will read 5 7 This places you in select mode Press
37. Off Open Off Open Off Open Off Off Lamp Fans Off Off Var Slow On Slow Med On Med Fast On Fast Fast On Off Off High Relay On On Off Off Off Off Off Off On On Medium Relay On On Off Off Off Off On On On On 13 18 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 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
38. 11 10 bic Medi edium 9 Relay 8 4 o 7 NU e w w Power 2 8 Supply R R 5 wht Blower S 4 wht U 3 R E N SIRE P T 2 Ne L R 1 2 Y L T E B R 12 br y 1 M II prg N D A 10 bra L 9 0 8 red wht 5 7 1t R p 6 brn wht 5 blu wht 9 4 led cleai 3 blu 2 8 1 Uk brn 7 org 6 red 5 12 11 blu 10 9 4 wht 8 7 3 Interconnecting 6 5 Beau Plug 2 Connector yel 3 1 grn yel 2 1 Toward gt center of unit 13 26 94MS42 Rev B1 S W Ver 2 06 Interconnect Cable WHITE GREEN 2 1 Ow YELL 2 3 VIOLET 6 5 RED BLUE 8 7 BROWN ORANGE 10 9 HEAT SHRINK 15 Wed BLACK 94MS42 Rev S W Ver 2 06 WHITE GREEN 2 1 YELLOW A 6 VIOLET 5 RED 8 BLUE 7 BROWN ORANGE 10 9 HEAT SHRINK BLACK 13 27 13 28 94MS42 Rev S W Ver 2 06 14 Printing Light Check List Check List for Printing Light Troubleshooting and Service 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 cabl
39. 4 gt If ou L 2 94 542 Rev S W Ver 2 06 WIRE COLORS 1 YELLOW 2 BROWN 3 BLUE 4 BLUE WITH WHITE STRIPE 5 ORANGE WIRE COLORS 1 YELLOW 2 BROWN 3 BLUE 4 BLUE WITH WHITE STRIPE 5 ORANGE 13 7 AL 94 Capacitor Assembly WIRES 2 FROM V HARNESS CAPACITOR ASSEMBLY PART 62D2723A00 123 d FRONT gt VIEW 5 S swa PC BOARD gt 52 N SWB swc D 2 ga _ 4 WIRES TO e 2 CAPACITOR 2 2 5 b S FEN vi x ER 5 SWITCH ON CAPACITOR D x MOUNTING BRACKET d T SH E A FEN 5 I D 167 q r o gt Tar 4l 6 WIRE COLORS m qu 4 3 2 1 2 BROWN yyy REAR VIEWOR 2 BROWN C 4 BLUE WITH WHITE STRIPE LLL 5 ORANGE 13 8 94MS42 Rev S W Ver 2 06 Opening the Lamp Head Unplug the unit Remove the glass and the four screws attaching the large outer reflector
40. WHITE 18 GA BLACK 18 GA D ER WHITE 18 GA 2 swil WORK LIGHTS E 120 3 gt 6 BLACK 18 GA 18 GA ls L3 18 GA 3 Sa MAIN BOARD REMOTE BOARD 4 gt 3E 59 WHITE 18 GA m gt BLOWER lal lala 16D1003A06 BLACK 5 COND 18 5 k O gt Qav aov EE ee Ee MEMORY BOAR LOWER LEFT LOWER RIGHT BLACK 15 COND 6D3811A00 16D2656A00 BLACK 15 COND gt KS 224 L P2 N P56 aa ee HERES 1 1 rm IC Em um Kl xe 62D3476A00 z9 FEE 56 1 al to 42 262 VALVE43 VALVE THERMOSTAT P63 amp 240 Q40V 240V sss 12VDC BLACK 18 RED 18 GA i BR uu ol EVAPORATOR WHITE 18 GA BLACK 18 S VEN e P 94 2 PUSHBUTTON 240V GREEN 18 GA GRN YEL 18 GA E 2 gt Pd XK 02 STOP 3 2 i1 1 2 3 BLACK 14 Pi c 1o 16 s lale RED 14 GA S E 1603809400 PR 6203798 00 Sig 9 N zm mg 6000000009 b Ole WHITE 18 WHITE 18 GA ES 5 E E3 paariga RED 18 GA E BLACK 18 BLACK 18 GA gt 7 BLACK 18 GA DRIVE MOTOR P60 gt GREEN 18 4 GREEN 18 GA 2 bx pa RED 18 GA 90VDC WHITE 16 GA RED 16 GA gt RED 18 4 RED 18 or D
41. and it should be low less than 600V see note 2 the capacitor is not being pulled into the circuit Check the respective relay resistor and wiring for an open 11 If a reading remains low less than 600V see note 2 and it should be high 700V or more see note the capacitor is locked into the circuit Check the respective relay wiring and PC board for a short 12 If 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 94MS42 Rev B1 S W Ver 2 06 checks affect the operation and make them appear to be operating incorrectly Also check blower voltage at terminals 4 amp 5 for most lights this voltage should be a MINIMUM of 65V to 75V 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 amp 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 necess
42. gt NETIC P62 x cpm es ae P52 P53 MAGNETIC SW 64AX505V00 s ia T2 ya p E e BROWN 18 GA BROWN 18 1 BROWN 18 GA _ 2 4 BLACK 18 GA BLACK 18 GA R 3 4 5 DRAIN A Iw 46 6 oO 8 16D2970A00 swi VACUUM AND TEMPERATURE MONITOR MOTOR gt gt gt gt OMMUNICATION 2 2 gt ak OPTION E gt gt VACUUM 95 gt A 2 7 M J14 PUMPS z 0 ni 4 2 3 1 4 2 1 2 2 5 e J5 m n Z py BROWN 18 GA OBE BE 12 12VDC BROWN 18 GA BLACK 18 52 10 gt DRAIN LOWER P lo P e BLOWER 5013 5012 SOLI 16D3796A00 P 16D2970A00 LN 05 gt gt re re 6 5 2 Y a RED 18 GA BLACK 18 GA S BLACK 18 GA RED 18 GA PHOTOCELL 2 1 12VDC o 2 RED 18 BLACK 18 GA AUX ne a BLACK 18 GA RED 18 GA PEE 321 GTOOL FAST MED SLOW 6 s 4 sen T 159 COOLING CTRISBOARD 16D1003A06 BLACK 5 COND 4 opu eis RI RS R3 R6 R2 G4AXSOIV03 413 1 UPPER LAMPHEAD lt N ZEN m fon S GA L 11 10 SL 9 SREDUIRQA 16D0957 15 E Ne wW 9 a Eee ns ies S 5 E 5 ERE e 32 Pa gt UPPER Fer E NO Sei RED 18 BLUE 18 GA t 3 m gt 2 BLACK 18 GA BROWN 18 GA VACUUM PUMP gt G
43. new style
44. then remove the shutter assembly End View e Reassemble in reverse order DO NOT TOUCH THE REFLECTOR SURFACE WITH YOUR HANDS 13 12 94MS42 Rev S W Ver 2 06 8 Shutter Assembly Drawing CERE N REF REF N Y Y DETAILE DETAIL F X CORS peran G gt e 4PL REF SECTION GG f SECTION 44 DETAIL REF DETAIL 4 REF N DETAIL REED gt lt H lt swe Saad DETAIL A 2PL DETAIL DETAIL A DETAIL 313 THERMOSTAT PN APPLY LOCTITE 242 TO THREADS WHERE INDICATED pee 28 2 BUSHING IDLER ARM 1203550 62 ONO 27 4 8 WASHER SPLIT LOCK 41 08WLS 10 22 25 18 26 4 8 32X 25 SCREW PHIL PN HD 21 08 5 25 7 i 25 21 6 WASHER SPLIT LOCK 41 06WLS 24 4 36 32 NUT FLEX LOCK 4106NLM
45. 1 IDLER BUSHING 12D1754A00 8 1 IDLER SPROCKET 12D1753A00 7 1 SLIDER 12D1752A62 6 1 SLIDE 12D1750A62 9 2 SWITCH MOUNT 45 11D2111B62 4 1 MOTOR DRIVE ASS Y 62D3798A00 3 191 TAPE GLIDE BLACK UHMW 81TAP17 2 2 SHAFT ACCUTRACK 12D2150A99 1 1 WELDMENT OV45 TOP RAIL amp LOW 11D3750A00 ITEM QTY DESCRIPTION PART NO 11 2 94MS42 Rev B1 S W Ver 2 06 Tray Transport System The printer has two aluminum exposure tray assemblies Vacuum for frame evacuation is drawn through two ports in the glass one at each of the rear corners The top Mylar frame is hinged in the back with a gas strut on each side that holds the Mylar frame open The exposure frame transport system is powered by hp PMDC Permanent Magnet Direct Current gear motor It is controlled and operated by the control panel through the rail cover 29 and switches Pressing the 29 switch once will start a vacuum cycle The second time 5252 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 259 switch before pressing the 2 switch and then releasing both The frames move at two speeds a fast speed initially then 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 preven
46. 2 SWITCH INTERLOCK 5559 46 50 2 MOUNT SPRING LT BLK AP30 11D1660A99 4 2 NYLON IDLER PULLY 49PULOI 48 2 BRACKET WHEEL MOUNT OV45 11D1659A99 47 1 LIGHT BLOCK UPPER OV45 11D2148A17 46 1 HINGE LIGHT BLOCK OV45 12D1653B62 45 1 SPACER HINGE OV45 11D2202B02 38 19 NSI 10 FLAT WASHER BLACK 41BIOWFR n 251 4 TAPE GLIDE BLACK UHMW 8ITAPI6 DETAT iF 62D2321A00 ITEM QTY DESCRIPTION PART NO 11 6 Continued on next page REF 7163 94MS42 Rev B1 S W Ver 2 06 Lower Light Block insert section Assembly Drawing DETAIL B 16 PL DETAIL 62D2321A00 62D2321A00 WHEEL ASS Y BOTH SIDES SEE DETAIL C So ee IGE VIEW 94 542 Rev B1 S W Ver 2 06 67 2 1 4 ID NYLON WASHER 44WFNO2 65 2 NSI 10 LOCKWASHER SPLIT 41 10WLS 59 2 BRACKET WHEEL MOUNT OV45 1D1659A99 58 2 1 2 THIN FLAT WASHER 41 FSWFT 57 2 ASS Y CONTROL DELAY BOX 62D2719A00 53 1 SPACER HINGE OV45 1D2202B02 52 2 NSI 6 32 X1 4 PPMS ZINC 41 06PPS 50 51 5 NSI 6 SPLIT WASHER 41 06WLS
47. 5 UPPER TOOL b sw P2 22 13 3 LOWER TOOL 1 1 2 2 WHITE P3 B SOLENOID VALVE UPPER SOLENOID VALVE LOWER 12VDC POWER SUPPLY g 51324 BLUE BLUE 2 Sa WHITE 0 BROWN 240V 240V PUMP OUTLET 240V OUTLETS REAR VIEW ITEM DESCRIPTION OLEC QTY PART NO 1 RELAY 12VDC CHASSIS MOUNT 33RLY20 1 2 HARNESS CNTRL BOX GTOOL 16D3208A00 1 94MS42 Rev B1 S W Ver 2 06 8 7 8 8 94MS42 Rev S W Ver 2 06 9 Nose Assembly Removing the Left and Right Rail Covers Turn unit OFF allow the unit to complete its cool down cycle and disconnect power e To remove rail covers Toremove the right rail cover While standing in front of the unit locate and disconnect all multi pin connectors and vacuum lines below the rail cover on the right side e To remove the left cover While standing in front of the unit locate and disconnect all multi pin connectors and vacuum lines below the rail cover on the left side Remove the two 20 hex bolts holding the cover to the main cabinet using a wrench see Nose Assembly Left and Right Covers Remove the two 20 hex bolts holding the cover to the drawer rails using a wrench see Nose Assemb
48. Left and Right Covers Remove the twelve 10 32 x 1 2 Soc button head screws see Base Assembly Diagram DETAIL Slide cooling compartment out to get access to the autoformer Meter input and output of the autoformer from 0 to 240V 0 to 208V and 0 to 120V If defective replace 94MS42 Rev B1 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 cover Note If the work lights are not turning ON check the rocker switch and power to the switch Note The work lights receive their power from the autoformer in the nose section change the lamps the trays must first be moved to the center position This is done by e Press and hold the button Press the 22 button Release both buttons when trays start moving Just before the trays reach the center turn the power OFF e Lift the diffusion cover off of the light assembly Twist the lamp to disengage it from the socket and remove it Install in reverse order Nose Fans Note The nose fans are controlled by a rocker switch on the underside of the right front corner of the rail cover Note If the nose fans are not turning ON check the rocker switch and power to the switch Remove the nose Disconnect the power leads to the blower s e Remove the blower s Install in reverse order Cleaning or
49. Shutter position switch 8 Not currently used 9 Shutter position switch 10 Interlock and thermostat switching 11 Not currently used 12 Incoming voltage 13 Autoformer 14 Incoming voltage 1 The ground terminal is for safety purposes and carries no current 8283 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 240 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 OV during unit warm up and when the lamp temperature 13 16 94MS42 Rev B1 S W Ver 2 06 rises it increases As the lamp reaches temperature the fans speed 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
50. cable 1 16D2629A00 Harness 8K B P S main 1 32BAL01 Ballast AL 83 4 33RLYO2 Contactor 2 pole NO 30Amp 1 33RLY04 Relay Sealed 2 39BLO03 Blower Model Ball Bearing 1 43CLM02 Cable Clamp Regal 1 43SPROS Compression Spring 44LEGO3 Leveling Glide Non Skid 4 44RUBO2 Grommet Continuous 1 25 51WRN07 NSI Wire crimp nut 6 52FUH04 Fuse Holder 3AG 3AB 1 54PWR05 Pwr Crd 18 3 SJT 12 5 15 1 56FUS15 Fuse 3A 250V 3AG Slow Blow 1 6203533 00 Assy Capacitor 60H 480V 1 64MV407V04 Assy UV Lt Ctrl 8K 60Hz 1 62LH83SE SW Lamp Head 8K Stdrd Rev SE 1 62LH83SE SW Lamp Head 8K Stdrd Rev SE 1 62LHK02 83 Roller Assembly AL 83 1 62SA83SE BASE AL 83 Shutter 1 63D0142B03 8K Lamp Support Bracket 2 L1282 Lamp 1 91 photocell assembly 1 11D0863A71 Glass Clamp 2 12D1361 Ladder Chain 18 49 1 12D1577 Spring Idler SK Shutter 1 12D1997A99 Sprocket Hub Machined 1 16D0180A00 Harness Lamp Head 5 K 1 HG 1 Safety Glass 1 18D319 Glass 5K Frosted Diffuser 1 31MOTO06 Shutter Motor 1 39BLO14 Blower 50 60 Hz 8K 2 44WFNO2 1 4 ID Nylon Washer 1 45 05 Knob Glass Carriage 2 94 542 Rev B1 S W Ver 2 06 16 7 Part Number Description Qty per unit 55S W03 Switch Glass 2 Pos Blk 1 5 01 Thermostat model K 2 62LHKO1 Switch Assembly 1 63D3669A00 Idler Arms Assy LT8 1 64MV414 T Trigger Board Tested 8K 1 16 8 94MS42 Rev B1 S W Ver 2 06 17 Warranty OLEC Limited Warranty OLEC equipment is
51. capacitors The voltage should be 700 V If voltage is lower check the power path to the tap switch and ballasts 700 V for the 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 Atidle 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 8kW light with an L1280 lamp at low intensity two capacitors will be about 370 and three capacitors will be over 700V Now when you go to medium intensity you should see three capacitors at about 395V and two capacitors at over 700 NOTE the number of capacitors at the lower voltage 1 e in the circuit and the voltage increase from the p
52. cycle the Auto Step mode ON or OFF Press the 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 72 77 turned ON or when you press the 25 button for the first time If you press the 9 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 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 3 4 in sequence The Vacuum window will read This places you in the select mode IL Press the 27 key once The Memory window will read Press and release the 2 key until the Exposure window reads 5272 Press the 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 key twice to exit this mode 94MS42 Rev B1 S W Ver 2 06 4 7 Tray Mode The default tray speed is set at the factory to 5 seconds OLEC does not recommend changing t
53. 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 94MS42 Rev S W Ver 2 06 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 below j Ifusing a razor blade or any other sharp object be careful not to damage or scratch the glass Itis VERY IMPORTANT not to stretch the seal as it is being placed onto the frame glass x r4 5 11 CUTSEALENDSFLUSH AND 9 BOND ENDS TOGETHER USING 7 N 6Y85 THIN COAT OF GASKET ar VAS AS ADHESIVE CLEAN ANY EXCESS FROM SEAL SURFACE PETN NO GAP ALLOWED RX N x I 9 SH REF TEXTURE NEARSIDE TYP 8 1 TEFLON SEALANT SITAPI2 7 251 TUBING CLEAR VINYL 49DCT24 6 2 HOSE ADAPTER 44ADTO3 13 2 STRIP CORNER 13D3006A00 5 14ft SEAL WAVE SHAPE 44GKTI3 12 TAPE TRANSFER SITAPI7 4 4 O RING 9 562 LD 44ORNGO2 it 1 GASKET ADHESIVE 82ADHII 3 2 INTAKE PORT 12D1728A62 10
54. 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 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 7121 3 in sequence The Vacuum window will read This places you in the select mode I Press the 5 key once The Memory window will read 5 Lt Press and release the e key until Fr ZZ appears the Exposure window This places you in the frame control interface mode Press the 22 key to cycle the frame control interface mode ON or OFF Press 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 525 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 lt button once when the frame has not been opened To act
55. mounting bracket Place the mandrel over the shoulder screw Place left spring over mandrel Secure washer and nut over shoulder screw Reinstall left and right side panels and reconnect power 94MS42 Rev B1 S W Ver 2 06 12 Diagrams Control Box Front View Typical FAST SLOW E SET SELECT SWITCH TO MOTOR SPEED COMMUNICATION LINE UP WITH ee LED INDICATOR LIGHT hu STOP O SLOW 12VDC 1 Red C L U aloo ool ht Red BIk t Org Wht Bik Blk Red Blk Red Blk Red CRANE MOTOR VACUUM L SWT AE ACCESSORY PUMPS SWITCH 60 O O 4 12VDC 3lo o AUX E J21 GTOOL x 3 x Z amp ra 5 ex N O O N CO N P N 24 ae EA N N 25 N R1 R5 R3 R4 R6 R2 On 480VAC printers only 94MS42 Rev B1 S W Ver 2 06 12 1 94MS42 1 S W Ver 2 06 Diagram iring Control Box W 208VAC 60Hz 380V AC 50Hz
56. of Power to the PC Board 13 4 Interlock System an 2a ae 13 4 Lamp Voltage elei 13 5 Lamp Power Pathu on dese Vd e aba S 13 5 Trigger BO san 13 6 Capacitors and Level Switching 13 6 Opening the Lamp Head 13 9 AAT Be des 13 9 Shutter SWICCh aa ser Ruten 13 10 Shutter Brake aan L g 13 10 Shutter Motor 13 10 Installme the Mott sans es ne 13 11 Sh tter R moYval iie uses 13 12 LT8 Shutter Assembly Drawing 13 13 94MS42 Rev B1 S W Ver 2 06 0 4 14 15 16 17 Sa Sa os 13 14 Lamp Head Blowers lea 13 15 Blown Fuse PC 13 15 Lamp Head Signals L n else 13 16 Eight Function Stales are 13 18 Printed Circuit Board Layout 13 19 Srenal Desenp on s ua D Sa Aes 13 20 Circuit Diagram 64MV407 60 2 13 22 Lamphead for all Lights 13 23 AL 84 Power Supply 60HZz 13 24 AL 84 480 Power Supply 60HZz 13 25 AL 94 Power Supply 50HZz
57. 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 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 94MS42 Rev B1 S W Ver 2 06 7 1 7 2 mm m 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 fra
58. the ex key once and press the key to clear then key then the key to activate the vacuum after being turned off earlier in this procedure Changing the Calibration Number Press the J key on the integrator The Memory window will read the Exposure window will show the existing calibration number for the top surface of the upper frame at the selected intensity 1 Press the 5 key to select frame surface 52 r F lt n Remember For top frame calibration use and 5 and for bottom frame calibration use and 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 key to open the program then use numerical keypad N Example To change from 500 to 650 simply press s s e Press the key to close the program Press the key twice to return to the operating mode 94MS42 Rev S W Ver 2 06 Matching Exposure Surfaces Doa 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
59. 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 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 Phillips screw driveranda VON 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 94MS42 Rev S W Ver 2 06 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 s
60. the two black retainer clips on each side of the switch from the rail cover Press together the switch retainer clips on the base of the switch and push the switch out through the top 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 rail cover Replacing the Glass Tool Vacuum Buttons Remove the left rail cover and place it on carpet or any surface that will not damage the paint see Nose Assembly Left and Right Covers 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 in two pieces and remove it from the rail cover Install the new switch in reverse order Replacing the Vacuum Gauges Remove the right rail cover and place it on carpet or any surface that will not damage the keypad overlay or the paint see Nose Assembly Drawings Remove the vacuum tubing from the gauge Remove the gauge retaining bracket and the faulty vacuum gauge Install in 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 right and left rail covers and place them on carpet or any surface that will not damage the keypad or the paint see Nose Assembly
61. 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 DJ key on the integrator to power up the light the front remote switches and the exposure unit s computer system 94MS42 Rev S W Ver 2 06 4 5 u wae u N 4 6 Press 2 then 4 in sequence The Vacuum window will read This places you in the select mode Ln Press the key once The Memory window will read Lt Press and release the e key until the Exposure window This places you in the board count option Press the key to cycle the board count ON or OFF Press the 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
62. 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 S
63. 06 0 2 Type ucc 4 8 Exposure Statistics Elapsed nennen 4 9 Exposure Statistics Total Exposures 4 9 Selecting a Memory 4 10 Ae a Aa 4 10 Entering an Exposure Time eerie od pectet ipee 4 10 Setting the Light Intensity a Re NI NER 4 11 Cx posure eier 4 11 Blank A S N 4 11 Error Handling System silber 4 12 Diagnostics Output Diagnostics eene resin e In eintreten 5 1 Output Functions Check 5 1 Functions Table 5 2 Input Diagnostics aussen ps 5 3 Typical values that you will see when all switches are good 5 3 Typical values that you will see when a fault occurs 5 4 Lamp Changing Instructions Lamp Changing Instructions 6 1 Preventive Maintenance Preventive Maintenance Dally 7 1 Preventive Maintenance Monthly 7 1 Preventive Maintenance Semi Annually 7 1 Vacuum System sun 8 1 Kluskinp the Pump 22 8 1 Pomp Disassembly 8 2 P mp SC gaa ma naa
64. 1 1 52FUH08 Fuseholder 3AG 25 Tab 2 52LUGOI Lug Connector 2 8 Wire 1 52RCP20 Receptacle 125V 20A 2 52RCP21 Receptacle 250V 15A 2 52RCP24 Receptacle 250V 50A 2 52TS19 Power Dist Block 3 pole 4 2 56 0504 Fuse 5A 250V Slow 2 56FUS13 Fuse 30 A 250 V Slow Blow 4 56FUS15 Fuse 3A 250V 3AG Slow Blow 1 56 0516 Fuse 1 2 250 3AG Slow 1 56 0528 Fuse 10 250 Slow Blow 4 62D2483A00 Blower 220V 1 62D331A Voltage Selector Assembly 1 64CT464 PCB Assembly AccuPrint 1 62AL85 L2 Printing Light with L 1282 208 240 60Hz 2 62CL85 8K CL85 Power Supply 208 240 60Hz 1 16D1045A00 Harness Beau Plug OEM 1 16D1585 Interlock Harness 1 16D2617B00 Power Cable AL85 AP42 PS 1 16D2629A00 Harness 8K B P S Main 1 32BAL01 Ballast 4 32 08 Autoformer 208 225 240 1 33RLY04 Relay Sealed 2 33RLY18 Contactors Relay 50 Amp 1 39BLO03 Blower Model Ball Bearing 1 52FUH04 Fuse Holder 3AG 3AB 1 56 0515 Fuse 3A 250V 3AG Slow Blow 1 62D1046 85 Capacitor Assembly 1 6201047 Voltage Selector 60 Hz AL 1 64MV407V04 Assy UV Lt Ctrl 8K 60Hz 1 62LH83SE SW Lamp Head 8K Stdrd Rev SE 16 6 94MS42 Rev B1 S W Ver 2 06 Part Number Description Qty per unit 62CL84 480 L2 Power Supply 480V 60Hz 8K 16D2617B00 Power Cable AL85 AP42 PS 16D1045A00 Harness Beau Plug 1 16D1585 Interlock Harness 1 16D2617A00 Power
65. 1 S W Ver 2 06 Cooling Requirements Minimum pressure and flow rate of the chilled water depends on input temperature CAUTION If water temperature and water flow do not meet the following specifications the unit will overheat one or both light sources will shut themselves off randomly under heavy usage and damage to the unit could be the result AP42CL 8000 Cooling Requirements 24 000 BTU hr at idle 65 000 BTU hr at full load Water Pressure 26 PSI 20 GPM minimum at 50 F 10 C 10 PSI 10 GPM minimum at 45 F 7 C 94MS42 Rev B1 S W Ver 2 06 1 5 1 6 94MS42 Rev B1 S W Ver 2 06 2 Cooling System Connecting the Evaporator Place the evaporator flat on the floor Connect the hose from the evaporator to the bottom of the rear panel drain LCAUTION Make sure the hose end on the evaporator is lower than the bottom of the rear panel drain or moisture will collect in the bottom of the Closed Loop System lt Feed for Evaporator Power Cord Evaporator Drain Hose to Evaporator SY Z Attach the plate to rear of cabinet Connect it to the 3 pin connector P63 marked Evaporator provided inside the unit Note The evaporator is ON when the machine is ON If the fan in the evaporator does not come ON when the machine is turned ON unplug the electrical connector P8 on the
66. 15 125 AL84 w L1282 400 430 400 430 425 500 460 530 500 75 95 90 120 115 125 115 125 AL94 w L1280 360 380 360 380 380 410 415 445 500 70 90 90 120 115 125 115 125 AL94 w L1281 400 430 400 430 425 500 460 530 500 65 90 90 120 115 125 115 125 AL94 w L1282 400 430 400 430 425 500 460 530 500 65 90 90 120 115 125 115 125 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 94MS42 Rev B1 S W Ver 2 06 13 5 13 6 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 othe
67. 15 CONDI 6D3811A00 16D2656A00 BLACK 15 COND r 62D3476A00 5 G aov p E P63 amp oZ 6 5 4 LOWER RIGHT 5 51 BLACK 18 GA RED 18 GA E UN 2 WHITE 18 GA BLACK 18 GA PA 3 1 oo 002 lt 3 3 SRD x EVAPORATOR GREEN I8 RA GRN YEL 18 GA K K 240V Alls 6 s 4 E E E amp amp BERS SOLI SOL2 SOL3 ki c 1o 5 258 3 gt 3 1 s rad trit i OR gt FJ 8 ca 1o 62D3798A00 il _ 240V 240V 240 2 TAN Go MOTI M 5 Le e ol jo i 16 128 P60 rar DRIVE MOTOR WHITE 16 GA 1 16 GA 9i s I gt P73 o SW5 SW6 VDO BLACK 16 GA RES z M z t sa 4 BLACK 18 16 GA gt WHITE 18 GA 5 99999990999 io 4 gt a BLACK 18 a RED 18 GA BLACK 16 GA a 5 a Re p GREEN 18 GA us 5 OE 3 8 GA Ege RED 18 GA gt gt ES 5 3 BLACK 18 GA 5 E 16D3808A00 LE 204 RED 18 Q5 AY Kia FAM BLACK 18 ign mL BEBERERE 16D2196A00 RED 22 GA GRN YEL gt BLACK 22 GA 18 GA z EFIE FL 2 16D4172A10 P61 WHITE Z BEES 57762 1 18 eg IRA IZ e P50 sc 2556 eoo ze UPPER TRAY 1 gt
68. 17 Divider Nose Left 1 11D3746B17 Divider Nose Right 1 16D3804A00 Harness light blower 1 18D3776A00 Bezel Worklight 1 19D1942A99 Filter Top 2 26CF4 15 4 Resistor 15Kohm 2W 5 1 32 08 Autoformer 208 225 240 V 1 35LMF06 Lamp Yellow Viewing 20 w 4 39BLO11 Blower 2 39CLF02 Light Fixture Undercabine 4 43FIT13 Reducer Tube to 2 43FIT14 Connector Tube to 1 2 49DCT27 Tubing Nylon OD 0 515118 Spade Ins 22 18Ga 8 4 52SKL13 Lampholder Bi Pin 0 527505 5 Position Terminal Strip 1 55SW01 Switch CW 2 62AP42CL TOP Assy Top Section AP42 1 11D2222A17 Side Mount 1 11D2222B17 Side Mount 1 11D2223A17 Bracket Rolling Filter 1 11D2223B17 Bracket Rolling Filter Mo 1 11D2224A17 Bracket Lamp Head Mount 1 11D2224B17 Bracket Lamp Head Mount 1 11D2260A17 Bracket Lamp Support 1 11D2266A17 Bracket Support Sml 1 11D2368A62 Bracket shipping 2 11D249 H D1 Lamp Head Heat Defl 2 45 06 Knob Lite Std 4 16 4 94MS42 Rev B1 S W Ver 2 06 Part Number Description Qty per unit 62D3476A00 Assy condensate evap CLS 1 39EVPOI Condensate Evaporator 23 1 42HHS2175 Grommet rubber 3 a 1 51TMLO03 Terminal male 14 20 AWG 3 52 08 Receptacle 3 Pin 1 68D3477A00 Instr Assy cond evap CLS 1 62D3555A00 Assy Ctrl Bx 8K CLS GT 208 240 60hZ 1 16D3208A00 Harness Cntrl Bx GTools 1 16D3448A00 Harness 8k
69. 2 STRIP RH amp LH SIDE 1352214599 2 2 VACUUM BLOCK 12DI738A71 9 2 STRIP FRONT amp REAR 13D2213D99 1 1 GLASS AP30D 18D3728A00 ITENIQTY DESCRIPTION PARTNO TEM QTY DESCRIPTION PART NO 00 A00 Continued on next page 94MS42 Rev S W Ver 2 06 8 5 8 6 Vacuum Seal Replacement cont Unless otherwise specified Dimensions are in inches Dwg ANSTY 14 5 Tolerances are Angles 5 deg X 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 Do not stretch seal Cut 90 notch see Detail B Use a seal miter cutting tool Continue pealing off paper from seal bend 90 and press seal onto transfer tape while aligning seal with outside edge of the glass CAUTION Do not stretch seal Press ABS strip items 9 amp 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 4 xe 25 DETAIL B V Nd 20 DEEP 4 1 lt SEAL MITER CUTTING TOOL 3 DETAIL DETAIL
70. 2CL 1 68D3827A00 Assy mylar frame 2 90KITCHN CVR Kit Drive Chain Cover 1 32 05 480V units only Transf 5 480 240 1 16D3503A00 480V units only harness XMR 1 62AP42CL CENTER Assy AP42 Center Section 1 11D1660A99 Mount Spring Lt Blk 2 11D2111B62 Switch Mount 2 11D2148A17 Light Block Upper 1 11D2202B02 Spacer hinge 1 11D2240A62 Mount Door Switch 2 11D3395A17 Deflector Air 1 11D4326A07 Strip right rail 2 12D1635A00 Block Mount Accu Trac 10 12D1653B62 Hinge Light Block 1 12D1750A62 Slide 1 12D1751A00 Threaded Rod 1 12D1752A62 Slider 1 12D1753A00 Idler Sprocket 1 12D1754A00 Idler Bushing 1 12D1755A00 Tensioner Bushing 1 12D1757A62 Chain Yoke 2 12D1996A00 Tensioner Sprocket 1 12D2150A99 Shaft AccuTrack OV 2 15D725 Insulation Pad AL 13 1 16D2319A00 Harness Motor POS 1 43 05 Chain 35 RLR 10 10 430SD01 Overtorque Safety De 1 435 07 Sprocket 35A22 for 1 435 14 Spring Chain Tension 1 94MS42 Rev B1 S W Ver 2 06 16 1 Part Number Description Qty per unit 435 17 Spring Tors LH 1 43SPR18 Spring Tors RH 1 44GK TOI Gasket 1 16 Thick 0 44TIE08 NSI Cable Tie UV 5 555W02 Switch Timing 4 55SW55 Pushbutton switch 2 62D2321A00 Assembly Wheel Lig 2 62D3706A00 Exposure tray Lower 1 62D3706B00 Exposure tray Upper 1 62D3707A00 Seal Glass AP42CL 2 62D3798A00 Ass y drive
71. 50 13 NSI 6 FLAT WASHER BLACK ZINC 41BO6WFR 49 8 NSI 10 32 KEP NUT ZINC 41 12NKP 48 1 HINGE LIGHTBLOCK 45 2D1653B62 47 T TAPE GLIDE BLACK UHMW 81TAP16 46 1 LIGHTBLOCK LOWER OV45 1D2147A17 45 29 NSI 6 32 KEP NUT ZINC 41 06NKP 44 2 NSI 6 32 X 3 4 PPMS ZINC 41 06PPS 75 43 2 1 2 13 HEX NUT 41 F5NHX 42 1 SPRING TORS LH 43SPR22 41 1 SPRING TORS RH LOW 43SPR21 40 2 MANDREL SPRING LOW LT BLK 2D1653B62 39 1 MOUNT SPRING LOW LT BLK LFT 1D2051B62 38 1 MOUNT SPRING LOW LT BLK RT 1D2051A62 37 2 1 2 FLAT WASHER 41 FSWFR 36 2 NSI 1 2 13 X 2 0SHCS BLK 41 55 2 0 35 16 NSI 6 32 X 312 HEX THD SPACER 42HHS9292 34 1 ACCUPRINT PCB MASTER 64MI441E APM 33 1 ACCUPRINT PCB REMOTE 64MI441E APR 32 32 NSI 36 INTERNAL LOCK WASHER 41 06WLI 31 16 NSI 6 32 X 3 16 PPMS ZINC 41 06PPS 18 30 2 NSI 10 X 24 HEX NUT ZINC 41 14NHX 29 2 NYLON IDLER PULLY 49PULOI 28 2 NSI SHOULDER SCREW 41BFSHC 37 ITEM QTY DESCRIPTION PART NO S DETAIL 11 7 Replacing Light Block Springs For the lower light block move upper exposure frame into the cabinet For the upper light block move lower exposure frame into the cabinet Disconnect main power Remove the left and right side panels Remove the left mounting bracket first Use the new mounting bracket Insert two 8 32 x 0 62 screws and secure to mounting bracket with two 8 32 kep nuts Use the 13 x 2 0 shoulder screw and large washer and insert through the hole in the
72. 50Hz Connection Wye 3 Wires Neutral Ground Terminal Block 1112 L3 N 208 240V 50Hz Connection DELTA 3 Wires Ground Terminal Block LI L2 L3 N fF MER 480V 60Hz Connection DELTA 3 Wires Ground Terminal Block X2 X3 L1 L2 L3 Z I a 480V 60Hz Connection Single Phase 2 Wires Ground Terminal Block X1 X2 X3 L1 L2 L3 1 3 Connecting power to printer 1 4 We recommend installing a circuit breaker box within easy reach of the operator Install and run the main power cord through a strain relief then into the channel on the lower right rear of the printer and up to the power control box on the left side see diagram below Connect the main leads to the 4 position or 6 position terminal block and connect the ground lead to the single ground terminal see Figures A B C D Reinstall the lower side door Feed power through here Energize the main power circuit You should hear the lamp head and power supply cooling fans go into a cool down cycle Ensure that the voltage select switch on the hinged control panel is switched to the lit LED Install the lower front and rear black trim pieces over the forklift channels using Allen wrench 94MS42 Rev B
73. 8 1 brn 7 org 6 red 5 12 11 blu 10 9 4 wht 8 7 3 pur Interconnecting 6 5 Beau Plug 2 Connector yel 4 3 1 grn yel 2 1 AN Toward E center of unit 94MS42 Rev S W Ver 2 06 13 25 AL 94 Power Supply 50Hz 220 VAC 50HZ INPUT e Toward COM COM N front of unit gt Safety Interlock 240 x 240 v 9 lm 8 MIET nn E Power Relay Ballast Ballast Ba Sab ap aie Gan can ENNY is 7 Din Socket L Slow Blo 16uf I2uf 4uf l6uf 12uf Fuse 6 Position 20 9 Le 12 nO Position 1 6 5 p2
74. AC Coil Voltage u U 33RLY04 33RLY02 Sealed Relays Power Relay S6FUS15 250 3AG Slow Blow Fuse 32 08 Autoformer 62D2652A00 Capacitor Assembly 53JKPO1 Safety Interlock 64MV407 83 39BLO03 52FUH04 Control Board 32BALOI Blower Fuse Holder Ballast 94 542 Rev S W Ver 2 06 13 1 Power Supply for AL 84 480 60Hz m 18 Terminal Strip 1 Power Output Urn ISI pal Power T TIED Input _ Tri r 120 zai IQ SPS Voltage Ur U 5 ol e 33RLY04 33RLY02 Sealed Relays Power Relay
75. ACCUPRINT AP42CL 8000 Closed Loop High Resolution Printer Service Manual 94MS42 Rev B1 S W 2 06 This manual is designed for technical personnel and should only be used by authorized Dealer service personnel This manual is written to provide an understanding of the equipment as well as a plan for troubleshooting 94MS42 Rev B1 S W Ver 2 06 0 Contents 1 Specifications 2 Cooling System Crated Dimensions ana Keane euren 1 1 Shippins a es 1 1 Actual Dimensions 1 1 Effective Exposure Frame Area 1 2 1 2 Typical Room Requirements 1 2 Electrical specifications and connections 1 2 Connecting power to printer 1 4 Cooling Requirements oot eet rte tue Messi 1 5 Connecting the Evaporator 4 1 2 2 2 1 1 2 1 0 4 60 80 2 1 Connecting the Chillers a due bet dtr oet t eae Presb e 2 2 Filling the Closed Loop System 2 4 Checking the Chiller aes are 2 4 Closed Loop Cooling Assembly 2 6 3 Integrator Functions and Features Integrator tte eie unco dete unt odes ma fasst 3 1 Feature Quick Reference
76. AM LATCH 12D2379A76 12 27 NSI 6 SPLIT LOCK WASHER 41 06WLS 2 9 CATCH 11D2392A62 1 26 16 32 X 3 8 PHIL BLK 41 06PPS 37 2 8 LATCH 12D2391A76 2 25 WAVE WASHER 10 41 12WSW 12 7 MOUNT HANDLE 12D2390A76 2 24 NSI 10 32 X 50 PHIL PAN 41B12PPS 50 2 6 BASE HANDLE LATCH 2D2389A76 2 23 NSL 10 FLAT WASHER BLK 41B10WFR 2 5 FRAME MYLAR INNER F R 9D3823A76 2 22 NSI 6 32 X 3 8 FLT BLK 41 06 37 2 4 FRAME MYLAR INNER SIDES 9D3824A76 2 21 SHCS 10 32 X 3 4 41B12SHC 75 6 FRAME MYL OUTER RH SIDE 19D3819A76 1 20 SHCS 8 32 X 3 8 41B08SHC 37 16 3 FRAME MYL OUTER LH SIDE 9D3819B76 1 19 BALL STUD SHRT 43SDB02 2 2 FRAME MYLAR OUTER FRONT 9D3817B17 1 18 NSI 8 X 250 SPACER 42HHS8521 12 1 FRAME MYLAR OUTER REAR 9D3817B76 1 DESCRIPTION OLEC P N QTY PARTS LIST 10 6 94MS42 Rev B1 S W Ver 2 06 Gas Spring Removal and Replacement Each frame assembly has two gas springs to support the top cover sheet frame when it is opened Open the frame with the spring to be replaced The glass frame assembly is heavy make sure you support it well before removing the gas spring Remove the retainer from both ends of the spring Pull the spring from the retaining ball mounts Install the new spring 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 shaft when
77. CT Closed Loo 1 16D3878A00 Harness cntrl bx suppl 1 31MSCO2 Motor speed control K B 1 32 5 01 Power Supply Open Frame 1 32 01 Autoformer 208 240 Volt 1 33RLY20 Relay 12VDC Chassis Mou 1 44CPG08 Plug plastic black 1 DIA 3 44RUBO3 Grommet Continuous 06 0 44TIE03 NSI Cable Tie 7 50 Max 10 52FUH04 Fuse Holder 3AG 3AB 4 52FUH08 Fuseholder 3AG 25 Tab 2 52LUGOI Lug Connector 2 8 Wire 1 52RCP21 Receptacle 250 15 6 1 2 52RCP24 Receptacle 250V 50A 6 5 2 52TS20 Pwr Dist Block 2 pole 2 56FUS15 Fuse 3A 250V 3AG Slow Bl 1 56 0516 Fuse 1 2 250 3AG Slow 1 56 0528 Fuse 10 250 Slow Blow 4 62D2483A00 Blower 220V 1 62D331A Voltage Selector Assembly 1 64CT464 PCB Assembly AccuPrint 1 62D3558A Assy Ctrl Bx 8K CLS GT 480 60hZ 1 15D3586A00 Label Wiring Conn 480V 1 16D3074A00 Harness Control Box Supl 1 16D3208A00 Harness Cntrl Bx GTools 1 16D3455A00 Harness CT Box Closed 1 16D3878A00 Harness cntrl bx suppl 1 31MSCO2 Motor speed control K B 1 32 5 01 Power Supply Open Frame 1 32 01 Autoformer 208 240 Volt 1 94MS42 Rev B1 S W Ver 2 06 16 5 Part Number Description Qty per unit 33RLY20 Relay 12VDC Chassis Mount 1 44RUBO3 Grommet Continuous 06 0 44TIE03 NSI Cable Tie 7 50 Max 10 515118 NSI Spade Ins 22 18 8 2 52FUH04 Fuse Holder 3AG 3AB 6 52FUH07 Fuse Block x
78. EMBLE LOWER TRAY USE 2 LOWER LIGHT BLOCK GUIDES ITEM NO 5 IN PLACE OF ITEMS NO 21 amp 22 SEE DRAWING 6 CUT TWO PIECES OF GASKET ITEM 49 NAPPLY LOCTITE 82ADH04 TO THREADS WHERE INDICATED 2 PLACE MYLAR FRAME ASSEMBLY ITEM 3 ATOP GLASS FRAME ASSEMBLY ITEM 2 AND TRAY WELDMENT ITEM 1 ASSEMBLE AS SHOWN 10 4 37 LONG AND TWO PIECES AT 43 25 ASSEMBLE AS SHOWN 5N CONNECT MAG SWITCH CABLE ITEM 46 TO SWITCH ON ITEM 1 ROUTE TOWARD REAR SECURE WITH FIVE CABLE TIES ITEM 47 AND ONE TIE WRAP ITEM 7 BE SURE HARNESS DOES NOT COME IN CONTACT WITH ANY SHARP EDGES ON WELDMENT 94MS42 Rev B1 S W Ver 2 06 Outer Frame Assembly T GLASS TRAY ASSEMBLY 7 2 PL _ 23 REF Sy M 2 ADD WASHERS IF NEEDED TO ADJUST CATCH TO LATCH ry LATCH HANDLE SN ASSEMBLY SIDE VIEW _ OUTER FRAME ASSEMBLY TOP VIEW k M lt ES SEE VIEW A DIDIT Se 7 lt gt Continued on next page 94MS42
79. ER Press this key to select the motorized diffuser option Eu FILTER Press this key to select the motorized filter option 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 94MS42 Rev S W Ver 2 06 3 1 3 2 JU MENU This key is used as the autostep indicator and for the continuous vacuum feature Note MENU Special Function The 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 1 key the memory window will read 72 and the exposure window will read 75 7 Press the key to turn auto step function ON or OFF Press the 2 key the memory window will read 7 and the exposure window will read 7 77 Press the key to turn continuous vacuum function ON or OFF MEASURE This key is used to check the lamp intensity e Le NUMERICAL KEYPAD These keys are used to enter the vacuum time exposure units and to access a particular memory location 9 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 th
80. ER 41 08WLS 13 41 8 NSI WASHER SPLIT LOCK 1 4 41 FOWLS 12 40 2 8 32 KEP NUT ZINC 41 08N 11 2 FILTER TOP AP30 190 1942 99 39 4 NSI 10 32 KEP NUT ZINC 41 12 10 2 BRACKET FILTER HOLDER 1101939862 38 2 NSI 8 32 X 3 4PPMS ZINC 41 08PPS 75 9 2 BRACKET FILTER HOLDER LFT 110 1939 62 37 4 NSI 10 32 X 1 2PPMSZINC 41 12PPS 50 8 1 BEZEL WORKLIGHT 18D 3776A 00 36 8 NSI 6 32 X 1 2BLK SELF TAP 41 06 5 50 7 1 DIVIDER NOSE 11D3746B17 35 16 8 32 X3 8PFMS 100 ZINC 41 08PFO 37 6 1 DIVIDER NOSE 11D3746A 17 34 14 NSI 6 32 X 3 8PHIL MS BLK 41 06PFO 37 5 1 AIR DIRECTOR NO 3 11D3736A 08 33 6 1 4 20X 5 8SOCKET BTN HD BLK 41BFOSH C 62 4 1 AIR DIRECTOR NO 2 11D 3735A 08 32 3 1 AIRDIRECTORNO 1 11D3734A 08 31 2 1 REFLECTOR WORK LIGHT 11D3733A 07 30 zz 1 1 WELDMENT COOLING 11D3751A 00 ITEM QTY DESCRIPTION PART NO ITEM QTY DESCRIPTION PART NO Continued on next page 94MS42 Rev B1 S W Ver 2 06 Nose Assembly Drawings cont 4 1 44 gt l
81. Is the lamp lit Does shutter Yes ii No rotate at any No Hiper Is LED 217 li S t The shutter will on PC Board i for Ya not open for an exposure w o Yes I the lamp being Does shutter seem lit Go to the i 1 When LED 017 is lit check fi to bind during en AA No Strike Fault rotation 120VAC on 4 white and 6 red on the terminal strip when shutter should be rotating Yes No No Yes No Chain most Check set screw likely too tight or on shutter motor If LED D17 is bearing surface gear and the lit check for sufficiently shutter position Check for 120VAC at pins worn switch 2 and 4 at power shutter motor connector on PC Board Yes No IR SES Yes No Possible faulty Adjust shutter Replace shutter motor motor and or shutter Repair or replace m t replace bearings wiring from Replace and air tubes terminal strip to PC Board shutter motor Repair or replace wiring from PC Board to terminal strip Front View of Control Board
82. KEP NUT ZINC 41 06NKP 18 20 NSI 6 INTERLOCK LOCK WASHER 41 06WLI 17 10 6 32 312 HEX THD SPACER 44HHS9292 16 44 TUBING NYLON 1 4 OD 0 126 49DCT27 15 8 TAPE TEFLON SAELANT 1 2 81TAPI2 14 2 CONNECTOR TUBE 3 8 TO 1 4 OD 43FIT14 13 2 VACUUM GAUGE 0 30 HG 1 1 2 49VAGO2 12 1 OVERLAY CONTROL PANEL 15D2270A00 11 1 HARNESS MERGENCY SWITCH 16D2412A00 10 1 HARNESS SW OPERATOR OV45 16D2196A00 9 1 CONTACT BLOCK 555 48 1 8 1 EMERGENCY PUSHBOTTON 55SW53 7 1 BUTTON YELLOW STOP 55SW45 2 6 1 BUTTON GREEN GO 55SWAS 1 5 2 SWITCH NOSE AP30 33 55SW45 4 1 ASSEMBLED SUPPLIMENTAL KEYBOARD 64 1477 3 1 KEYBOARD FOR OV45 64 1478 2 1 COVER RAIL LEFT 45 11D2163A08 1 1 COVER RAIL RIGHT OV45 11D2163B08 ITEM QTY DESCRIPTION PART NO 94MS42 Rev B1 S W Ver 2 06 10 Exposure Trays Mylar Replacement Close the Mylar frame and open the twelve cam latches Remove the inner Mylar frame and position a pre cut Mylar sheet into the frame Make sure that the Mylar is overlapping on all sides 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 sur
83. LK ZINC 41BF2NHX 35 2 NSI 1 4 20 X 1 SKT HD CAP 41BOSHC1 0 34 9 1 4 20 X 5 8 SKT BTN HD SCREW 41BFOSHC 62 33 8 NSI 6 SPLIT LOCK WASHER 41 06WLS 32 28 NSI 46 FLAT WASHER BLACK ZINC 41BO6WFR 31 6 NSI 6 32 X 3 8 PHIL PAN MS BLK 41 06 5 37 30 13 NSI 10 32 5 8 SOC HD CAP BLK 41B12SHC 62 29 2 NSI 6 32 1 4 PHIL PAN MS BLK 41BO6PPS 25 DETAIL B 28 1 NSI 8 32 X 3 16 PPMS BLK ZINC 41BO8PPS 18 52 2 2 44 9 WASHER 380 ID 625 ALWFRO3 26 2 NSI SOCKET SHOULDER BOLT 41BF2BHX 75 25 2 WASHER NYLON 3 8 X3 4 X1 16 41HHS2679 24 1 PIVOT BAR OV45 12D1727B99 23 1 BRACKET VACUUM HOSE OV45 11D1696A02 22 1 GUIDE LT BLOCK 65SEAL R 11D2709B62 21 1 GUIDE LT BLOCK 65SEAL L 11D2709A62 20 2 WHEEL 43BLB17 19 2 LINEAR BEARING 1 2 DIA 43BLB12 18 1 MOUNT LIGHT BLOCK GIUDE 12D1737A62 17 1 SWITCH MAGNETIC INTE 55SW50 B 16 6 BALL STUD MODIFIED 43SDB03 DETAIL C 15 2 GAS SPRING 60 LBS 43SPR25 14 2 BALL STUD MOUNT PLATE 43SDB03 13 4 HINGE BLOCK 19D3825A76 12 3 END PIVOT BLOCK 12D1895A99 11 1 FRONT WHEEL BLOCK 12D1731A71 10 1 REAR WHEEL BLOCK 12D1733A00 9 1 FRONT BEARING BLOCK 12D1730A71 8 1 REAR BEARING BLOCK 12D1732A71 7 1 TIE WRAP ADHESIVE MOUNT BASE 44PAD03 6 2 HANDLE 6 ALUM BLACK 44HDLOS 5 2 GIUDE LIGHT BLOCK LOWER 11D2145A62 4 4 SOCKET HEAD CAP SCREW SEE BOM DETAIL D 3 1 MYLAR FRAME ASSEMBLY 91MYLFRM AP42 2 1 GLASS FRAME ASSEMBLY 91GLFRM 42 1 1 WELDMENT TRAY OV42 19D3826A02 QTY DESCRIPTION PART NO IN TO ASS
84. OWOI Flow meter 1 43 02 Handy Box 1 44GKTO1 Gasket Thick 49DCT24 Tubing LD x O D 4 49DCT34 Braid clear tubing PVC 30 49DCT38 Hose braided NPT x 20 L 3 49DCT39 Hose braided NPT x 12 L 3 49DCT41 Hose insulation 30 49THERMOI Thermometer 1 6803765 00 Assy inst plumb cool mdl 72FOM42 Foam close loop 1 thk 72FOM43 Foam closed cell polyethe 11D4326A07 Strip right rail 81TAP17 Transfer tape 3 4 18 90KITSTRIP OV45 Retrofit kit for drawer rail tape 1 62AP42CL INSERT Ass y insert sectiion 1 11D2051A62 Mount Spring Low Lt BIk R 1 11D2051B62 Mount Spring Low Lt Blk L 1 11D2147A17 Lightblock Lower 1 11D2273A17 Cover Power Terminal 1 11D3395A17 Deflector Air Clds Loop 1 11D3869A08 Cover plate switch 1 1201653862 Hinge Light Block 1 12D2053A62 Mandrel Spring Low Lt B 2 15D1852 Label Connectors Ctl Box 1 43SPR21 Spring tors LH 1 43SPR22 Spring tors RH 1 44GKTO1 Gasket Thick W 0 94MS42 Rev B1 S W Ver 2 06 16 3 Part Number Description Qty per unit 49VAV01 Valve Vacuum Relief 2 62D2321A00 Assembly Wheel Light 2 62AP42CL NSA Assy Nose Fan Work Light 1 11D1939A62 Bracket Filter Holder 2 1101939 62 Bracket Filter Holder 2 11D3733A07 Reflector Worklight 1 11D3734A08 Air Director No 1 1 11D3735A08 Air Director No 2 1 11D3736A08 Air Director No 3 1 11D3746A
85. PUMP 9 UPPER POWER SUPPLY Sek 00 RED 18 GA 240V a Z gt gt jo N O Ws BLACK 18 GA ee gt ERE gt GRN YED GRN YEL 18 5 ESO gt agGay 2 eror e RED 18GA 16D2741A00 s 32 CONTROL BOX B5 ELA 2 gt gt T LOWER g UPPER swe PHOTOCELL 7 nia RIGHT DOOR a s VACUUM LL s ge ge GET DOOR MOTOR RED 18 GA 240V 3 2 BLACK 18 GA a EMERGENCY GRN YEL 84 GRN YEL 18 E 8 E SWITCH 8 3 _ _ 5 z 9 3 16D2741A00 2 LOWER LAMPHEAD No fo LOWER sws RIGHT DOOR SWITCH UPPER LOWER CONTROL SECHS ne LOWER POWER SUFPLY E NO 18G 7 NO RED 18GA A RED 18GA sw O 12 8 94MS42 1 S W Ver 2 06 13 Light Source Component Layout Lamphead for AL 84 and AL 94 50 60Hz 55 02 64MV414 62SA83 11280 111281 or L1282 63D0142 39BLO14 Shutter Position Switch Trigger Board Shutter Assembly Replacement Lamp Lamp Support Assembly Blower gt Interconnect Cable Power Supply Si lt PES 91 39BLO14 555 03 45KOB05 9ORF83 C Reflector 31MOT06 Photocell Blower Safety Interlock Switch Knob for AL 84 AL 94 Shutter Motor Power Supply for AL 84 60Hz Power 18 Terminal Strip 1 Output nn Power ux Input nn 120 V
86. RN YEL GRN YEL 18 GA 240V 3 UPPER S E 18 P RIGHT DOOR CONTROL e CONTROL BOX 16D2741A00 5 SWITCH 5 19 UPPER POWER SUPPLY L 16D4249A12 E CM 5 ic 3 949 gt QNe E s 9 9 3 VAC2 8 P65 2 PHOTOCELL RED 18 GA BROWN 18 GA LOWER en 5 5 9 No BLACK 18 GA BLUE 18 GA M PI a Go DOOR MOTOR GRN YEL GRN YEL 18 GA Q40V E z TOWER 10 EMERGENCY SW7 RENT 16D2741A00 RIGHT DOOR 59 18 SWITCH SWITCH LOWER LAMPHEAD M 16D0957 5 LOWER LEFT DOOR SWITCH NO RED I8GA z RED 18 GA O Q CM Swan o CONTROL LOWER POWER SUPPLY 94MS42 1 S W Ver 2 06 12 7 Unit Cabling Diagram old style
87. 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 94MS42 Rev B1 S W Ver 2 06 9 3 9 4 Nose Assembly Drawings BOTTOM VIEW 58 29 1 HARNESS SW OPERATOR 45 16D2196A 00 57 28 200 pm 0000000000000 m 56 2 27 55 a Ceras 7 2 Oana 26 54 4 41 08PPS 37 25 53 ar 24 52 0000000 rete 23 51 4 NSI 10 FLAT WASHER SAE 41 10WFR 22 zt 50 8 NSI 6 32 X 3 8PHIL PAN MSBLK 41BO6PPS 37 21 LLL 49 3 NSI CABLE TIE 4 18MAX 44TIEO2 20 m 48 3 TIE WRAP ADHESIVE MOUNT BASE 44 19 49DCT27 47 2 1 4 20LOCKNUT NYLON 41B40N LN 18 1 5 POSITION TERMINAL STRIP OV24 521505 46 16 NSI FLAT WASHER SAE 41 06WF 17 2 LIGHT FIXTURE UNDERCABIN ET 24 39CLFO2 45 6 NSI 8 FLAT WASHER SAE 41 08WFR 16 2 BLOWER 39BLO11 44 8 NSI 1 4SAE FLAT WASHER 41 40WFR 15 2 LAMP YELLOW VIEWING 20 WATT 35LM F06 43 16 NSI 6 SPLIT LOCK WASHER 41 06WLS 14 1 AUTOFORM ER 120 208 240V50 60Hz 32TRCO8 42 6 NSI Z8SPLIT LOCK WASH
88. Rev B1 S W Ver 2 06 10 5 Inner Frame Assembly gt X gt s CP 15 2 129 EN CUT TO LENGTH AND T APPLY AS SHOWN a REFERENCE VIEW B v 6 PL 2 _ 16 12 PL zd S Ze 225 12 PL 18 NE EN 12 PL 10 25 12 1 gt X 5 Rel DN N i NAS 03 15 94 PL lt lt 00 4 4 1 2PL P 2PL _ INNER FRAME ASSEMBLY 26 27 34 BOTTOM VIEW E E n IN 2 PL Ts RAN NH u 28 22 20 5 2 lt 2 gt PL 2 PL FARSIDEY a 7 a 2 A SEE VIEW 17 SCREW SHLDR 9 187 X 1 25 41 08SBL1 25 2 34 NSI 6 FLAT WASHER BLK 41BO6WFR 2 16 NSI 8 X 5 SLOTTED BNDG SEE 12 33 5118 FLAT WASHER 41 08WFR 12 15 GASKET 1 16 W X 1 2 81 21 32 NSI 6 32 X 25 PPMS BLK 41BO6PPS 25 38 14 SPRING 7 16 X 9 16 COMP 43SPR12 2 31 LOWER LEDGE SIDES 19D3822A76 2 13 SWITCH MAGNETIC INTE 55SW50 B 1 30 LOWER LEDGE FRT amp RR 19D3821A76 2 12 HANDLE 6 INCH 44HDLOS 1 29 MYLAR SHEEET 13D3901A00 1 11 MOUNT MAGNETIC SWITCH 11D2971A71 1 28 NSI 6 32 FLEXLOCK NUT 41 06NLM 2 10 C
89. SutlooO dweq m IV 10 md ng L IoN a OVA 9 JON T S Q POS JON 5 Ih Ajddng A TI XAV m xny i 2 4 za 8081 due OV AN VS I OVA OII 94MS42 Rev B1 S W Ver 2 06 13 22 Lamphead for all Lights Thermostat Thermostat Shutter Position Switch N Br 5 KON v e SM 11 12 Safety Glass Switch rn Shutter Motor e ION 7 8 5 6 3 4 1 2 Ti N mA Trigger Board e e 94MS42 Rev S W Ver 2 06 13 23 gt muzo v AL 84 Power Supply 60Hz
90. Width 42 107cm Depth 34 86cm Intensity AP42CL 8000 Lamps can be operated at 8 kW 5 kW and 2 kW Typical Room Requirements TOP VIEW Circuit 36 Breaker ze Dee Front Electrical specifications and connections 3 phase Wye See Figure A 3 wires neutral ground 380 415V 50 Hz 24 amp 3 phase Delta See Figure B 3 wires ground 208 240V 60 Hz 44 amp 3 phase Delta See Figure C 3 wires ground 480V 60 Hz 18 amp Single phase See Figure D 2 wires ground 480V 60Hz 35 amp 1 2 94MS42 Rev B1 S W Ver 2 06 LI 380 415V OLITE Power Supply N Blowers Vacuum Pumps Electronics Drives Etc E arth Ground Figure A L3 L1 208 12 o _ _ OLITE 9 Power Supply 1 l 208V OLITE Power Drives Supply 1 N 7 Figure x Ground T L3 LI 480V L2 OLITE Power Supply 1 480V OLITE Power Supply 2 Blowers N Vacuum Pumps N Electronics N 4 Earth Drives Etc N Groun d Va Figure C 480V OLITE Power Supply 1 11 12 480V OLITE Power Supply 2 H2 Hl xix Earth Ground Blowers Vacuum Pumps Electronics Drives Etc Figure D 94MS42 Rev B1 S W Ver 2 06 12 380 415V
91. ary A 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 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 amp 6 If there i
92. ctive signal from the lamp head Low voltage when the shutter is open and 12VDC when closed Switch Connection 51 V Hot Output V supply for internal accessories 52 V Common Output V common for internal Accessories 53 Not currently used S4 Aux Terminal connects to the power connector for accessories Not used in most equipment 55 DC common DC circuit common for switches Not the same as V Common S6 Power Switch Switch to turn on power Low OV 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 94MS42 Rev B1 S W Ver 2 06 Switch Connection cont 57 High Switch Switch to select high power level Low OV for high 58 Low Med Switch Switch to select power level when high switch is off Low OV for medium power High 12VDC for low power S9 Manual Switch Manual expose switch Low OV to cause exposure 510 Interlock External interlock outlet Line must be connected to DC common to allow an exposure Outlet is normally shorted when plug in not inserted S11 Not currently used 12 12V Output for internal accessories Not used in most equipment DIN Connection Expose High expose when connected to a compatible integrator High D1 Medium Low expose depending on t
93. e 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 A 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 208V and you have 240V coming in the p c board and the blowers are usually the two items to get damaged Over voltage
94. e light the front remote switches and the exposure unit s computer system Press 1 2 3 4 in sequence The Vacuum window will read SEL This places you in the select mode Press the key once the Exposure window will read L Press the 22 key once If the Lock Level is set at or 1 the Memory and Exposure windows will 94MS42 Rev B1 S W Ver 2 06 4 P N dim Enter the lock level desired Press the 27 key to set entry If the Lock Level is set for 2 3 or 4 the Exposure window will read Enter your 3 digit code Press the 22 key Press the key Press the 22 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 Lock Level Description and Operation Lock Level 0 The Vacuum window will read Lock Level 1 The Vacuum window will 7 777 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 key the Memory window will read and the Exposure window will read oct Press the key to turn the lock for this memory ON or OFF then press the key When the lock is tu
95. e lower through 3 key that corresponds to the most commonly used applications 94MS42 Rev B1 S W Ver 2 06 jm o ee T b gt ms J D x J k w gt 2 ILLI Bcc EJ J Lt In d D T J Y gt J J w w L X gt ku a x J ku 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 Level Feature Lock Code Feature 2 two Value Exposure Feature Motorized Filter Feature Single Surface Exposure Feature Exposure Count Feature Frame Control Switch Feature Automatic Vacuum Feature Auto Step Feature Vacuum Delay Feature Frame Speed Feature System Type Setting Feature 94MS42 Rev B1 S W Ver 2 06 3 3 3 4 Operator Control Panel The AP 30 heavy duty exposure system has a power key on the integrator Press the key to turn on the unit Press the key again after use and the system will run through a 2 minute cool down cycle and then turn off all blowers STOP Button Press the button once Frame movement will sto
96. e select mode Li Press the 5 key once The Memory window will read 5 Lt HAL Press and release the A key until 22 72 is displayed in the Exposure window Press the key to cycle mode ON or OFF Press 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 Note The two value mode MUST be selected ON for the split exposure mode to function Press the key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 1 2 3 4 in sequence The Vacuum window will read This places you in the select mode 5 I Press the key once The Memory window will read 94MS42 Rev S W Ver 2 06 9 J gt 1 yd L LEN L Press and release the e key until appears in the Exposure window IL This places you in the split exposure o
97. e tetra reet ere qu ra prend eue 10 3 Outer Frame Assembly uses nie 10 5 Inner Frame Assembly 10 6 Gas Spring Removal and Replacement 10 7 Replacing the Linear Bearings 2 10 7 Frame Glass Replacement 10 8 11 Center Drive Assembly Center Drive Assembly Diagram 11 1 Tray Transport System neigen 11 3 Tray Drive Motor Replacement 11 3 Tray Drive Clutch Adjustment 2 22 2221 11 11 3 Tray Speed Adjustment 11 4 Light Block Assembly 11 6 Lower Light Block insert section Assembly Drawinsg 11 7 Replacing Light Block Springs 11 8 Control Box Front View 12 1 Control Box Wiring Diagram 12 2 Base Assembly Diagram 12 4 Unit Cabling Diagram new style 12 7 Unit Cabling Diagram old style 12 8 Component Layout aaa ea ee 13 1 Ballast Tap Switch Wiring 13 3 Path
98. e the Mylar is not cut too small The Mylar must overlap on all sides so that it comes up between the inner and outer frames Mark on the Mylar where the cam latches are and cut a small slit in the mylar to allow the cam latches to lock down Then trimmed off once the inner frame has all the cam latches in the closed position Make sure the inner and outer frames are not bent or damaged if so replace them Outer Frame Replacement Remove the inner frame 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 2 Allen screws from each of the four hinges in the back of the frame and lift the frame off Note The frame MUST be squared when it is reinstalled 94MS42 Rev B1 S W Ver 2 06 10 1 10 2 Place the new frame flat on the tray Line up and insert the Allen head screws through the hinge into the frame Make sure the frame 1 to above the top of the hinge to avoid the possibility of damaging the glass then tighten them down Reinstall the inner frame without the Mylar and close all cams 1 32 to 1 16 Allen Screw H Frame ATN Hinge Bar 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 d
99. ear 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 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 Lamp Voltage Terminals 2 amp 3 Lamp Fan Voltage Terminals 4 amp 5 Model Idle Low Med High Trig Idle Low Med High Trig AL84 w L1280 360 380 360 380 380 410 415 445 500 75 95 90 120 115 125 115 125 AL84 w L1281 400 430 400 430 425 500 460 530 500 75 95 90 120 115 125 1
100. eat Exchanger Solenoids 2 Blower On Off HIIS 3 Upper Vacuum Pump On Off 4 Lower Vacuum Pump On Off 5 Work Light and Nose Section Fans On Off LU ih s Motor Direction Control ETA 7 Frame Motor On Off e Motor Fast Slow U B s All controls off LU Return to Select mode SEL Heat Exchanger Viewing Lights 6 Motor Direction e Blowers Motor Power C J O Motor Speed Top Vacuum Pump Bottom Vacuum Pump Heat Exchanger 94MS42 Rev S W Ver 2 06 Input Diagnostics Switch Check The switch check can be done while in the Select mode Press the 0 key on the integrator to power up the light the front remote switches and the exposure unit s rr 5 L computer system Press 1 2 3 then 4 in sequence The Vacuum window will read This places you in select mode e Press the 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 the lower integrator display should read frame in the display should read 72 key pressed on the nose section RSA 7 t 55 With the lower 7177 DOOR FRAME SWITCH FRAME NUMBER DISPLAYED
101. eller 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 OL EC 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 OL ECC will void this Warranty All Warranty Service should be handled through the Distributor through whom the equipment was purchased 94MS42 Rev S W Ver 2 06 17 1 Corporation 17112 Armstrong Avenue Irvine Ca U S A 92614 U S A 949 399 6500 Fax 949 399 6501
102. en 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 Check Q If the pump does not activate when the 2 Diagnostics section then button is pressed see the Ensure that the exposure frame is in its full outward position Check for 52 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 94MS42 Rev B1 S W Ver 2 06 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 Pump Replacement Vacuum pump replacement is straightforward The front pump controls the upper frame the rear pump controls the lower frame Front and rear as viewed by the operator Remove the right side lower cabinet panel Disconnect the vacuum tubing from the pump Push the outer ring on the connector and pull the vacuum tubing out
103. es 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 Not used 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 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 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 Communication error Remote board is not communicating with the master board Possible causes are no power to remote board bad or disconnected communication cable Remote board has reset or temporarily lost power After clearing the error normal function should continue At least one lamp intensity frame surface has not been calibrated Solution Ensure the unit has been completely calibrated 94MS42 Rev S W Ver 2 06 5 Diagnostics Output Diagnostic
104. evaporator and check with a voltage meter the P8 connector between pins amp 2 for 240V If voltage is present and the blower is not running replace the blower If voltage is not present go to the control box and unplug the J12 connector and measure for 240V between pins 3 amp 4 on the board If voltage is present there is a break in the cable from the board to the evaporator and it needs to be replaced If there is no voltage replace the 64CT464 PCB in the Control Box 94MS42 Rev B1 S W Ver 2 06 2 1 2 2 Connecting the chiller Mount the Flow Meter and Temperature Gauge assembly on a wall in a horizontal position j The Flow Meter and Temperature Gauge assembly must be mounted horizontal or the Flow Meter will not function properly e Connect the hose from the Water in from Chiller to the flow meter Bleed Valve 1 2 NPT E internal taper thread amp Wut Mount L J Assembly Overflow on wall Bucket Return d m to chiller m 9 1 ID SO a Y Flow From meter chiller guage for 1 ID hose Connect another hose from the temperature gauge to the Closed Loop In Connect the hose from the Closed Loop Out to the Water out to Chiller Continued on next page 94MS42 Rev B1 S W Ver 2 06 Wows DRAIN TO
105. following procedure to set the clutch at the minimum setting for operation Remove the left side center panel on the printer and locate the clutch at the left rear corner 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 Replace the left side panels removed above Tray 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 left hand corner of the Control Box The frame speed adjustments will be made from these pots Activate the Diagnostics Mode through the keypad Press the 2 3 then 4 keys the center display will read 5 Press the 6 key this will activate the diagnostic mode Press the key this will reset the vacuum window to 17272727 Press the 7 key to set motor drive the vacuum window should read
106. ght 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 mar
107. h or may even break Flushing the pump should remove these materials There are two options for flushing the pump 94MS42 Rev S W Ver 2 06 8 1 Flushing Option 1 This option requires two pipe nipples at least 4 102 mm long with gt 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 Prying with a screwdriver will damage the gasket This will allow access to the intake and exhaust ports 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 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 loos
108. he power supply there is nothing you can do in the power supply to correct bad voltage from the wall Check input voltage to the PC board with the power off at pins amp 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 94MS42 Rev B1 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
109. he unit switches when connected to an older style integrator or other manufacturer s equipment D2 DC Common Common for all signals D3 Low Exp Low expose input D4 Power Signal from integrator to turn on the power D5 Medium Exp Medium 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 94MS42 Rev B1 S W Ver 2 06 13 21 64 407 60 Diagram ait osodxq MOT uonisoq Joynys ER ie mimo 3 psodxq ene u JA 11 3 od C 9 edAL indng mo 5 ER S uo mod T sodx ys H I poj2euuo ION 6 feos TOMOd 8 10 91307 A susyu pue Joynys uey Ajddng Ue HUN L Jamo 10 nding 3 71 AUF B C yX so ora EPA umpa 104 mdino Kep y un poW 8 9 POSITION ae v osia kepa yH g Dm Or PST ION IQON 1214 y rn 6 JON 1 nnus 20 nding suey 5 a SAYASA z 8 Pest 10N J semog 21807
110. his setting without consulting the OLEC factory Damage to the transport can occur Press the key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 3 then 4 in sequence The Vacuum window will read This places you in the select mode Ln Press the 27 key once The Memory window will read Lt Press the 4 key until appears in the Exposure window Press the key once The Vacuum window will read and the Exposure window will read a z 1 If lock mode was turned ON enter your code now then press the 77 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 and then press the key again the Memory window and Exposure window will return to normal brightness Press the key twice to exit this mode Type Mode 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 0 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 1112 3 then in sequence The Vacuum window will read S L This places you in the se
111. iagram 2 per corner Tighten the inner frame Allen head screws in the order shown in the diagram 2 per corner AX 4 Lift the frame and push the gas shocks back onto the ball joints Reinstall the safety clips into the ends of the gas shocks 94MS42 Rev B1 S W Ver 2 06 Tray Assembly Drawing N SIE gt N 1 ve 13937 38 4 eee 22 87 2PL 4PL VIEW AA Continued on next page 94MS42 Rev B1 S W Ver 2 06 10 3 Tray Assembly Drawing cont 50 2 GAS SPRING 80 LBS 43SPR24 49 161 ADHESIVE RUBBER GASKET SEE BOM 48 2 HINGE BLOCK CLAMP 19D3815A02 47 5 NSI CABLE TIE UV 4 44TIE08 46 1 CABLE MAGNETIC TRAY SWITCH 16D2970A99 45 12 NSI 6 32 X 1 2 PHIL PAN BLK 41BO6PPS 50 44 10 NSI 6 KEP NUT ZINC 41 06NKP 43 1 RAMP SWITCHES AP30 OV33 11D2112A62 42 1 1 4 20 X 3 8 BOTTON HEAD 41 FOSHB 37 41 6 NSI 10 32 X 3 8 PPMS BLK 41B12PPS 37 40 2 NSI LOCKWASHER SPLIT 1 4 41 FOWLS 39 8 10 32 X 3 4 SHCS 41B12SHC 75 38 18 NSI 10 FLAT WASHER BLACK 41B10WFR 37 18 NSI 10 LOCKWASHER SPLIT 41 10WLS 36 2 5 16 18 HEX NUTS B
112. igh 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 Press the 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 e Press the integrator 27 key to select the desired light level to be calibrated always start at Low Intensity For 8kW Low 2000 W Medium 5000 W High 8000 W Inorder to prevent possible damage to the high resolution printers Mylar while calibrating we recommend you set the no vacuum feature Press the key on the keypad the Memory and Exposure windows will dim Press the key three times Press the 72 key once This will prevent vacuum while calibrating The Vacuum window will read 7 The high resolution printer s calibration has been set at the factory Upper frame top surface Upper frame bottom surface Ji M Lower frame top surface Lower frame bottom surface m
113. 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 94MS42 Rev B1 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 64MV407V24 Control Board layout 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
114. itches or emergency button Indicates lower frame in position magnetic frame switches closed and does not have the correct reading from either the door switches or e emergency button Q button is pressed switch is bad Whatever the switch value display reads when the 2 and the value does not increase by a value of 128 the Whatever the switch value display reads when the switch is pressed and the value does not increase by a value of 16 the 2 switch is bad Q 4 94MS42 Rev S W Ver 2 06 6 Lamp Changing Instructions The lamps 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
115. ivate this option Press the key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 then 4 in sequence The Vacuum window will read This places you in the select mode Lh Press the 27 key once The Memory window will read 94MS42 Rev S W Ver 2 06 Press and release the e key until 2 777 appears in the Exposure window This places you in the automatic vacuum option Press the 22 key to cycle the automatic vacuum mode ON or OFF Press the key twice to exit this mode Auto Step Mode 1 IN Lr N Note This feature allows you to series of exposures sequence Note If Auto Step is selected the LED over the 8 key will indicate if the feature is ON or OFF If ON press the key to turn it OFF Press the 0 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 3 then 4 in sequence The Vacuum window will read L This places you in the select mode I Press the 27 key once The Memory window will read Lt Press and release the key until 5 appears in the Exposure window This places you in the autostep option Press the 27 key to
116. k 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 94MS42 Rev B1 S W Ver 2 06 Lamp Head Blowers The lamp head blowers are contro
117. lamp one end at a time out of the holders and remove the lamp from the lamp head gt Shutter Clean the reflector with a mild solvent such as denatured alcohol and clean soft cloth Use glass cleaner to clean the safety glass Dirty 94MS42 Rev S W Ver 2 06 6 1 6 2 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
118. lect mode Li Lt Press the 5 key once The Memory window will read 5 Press the key untill in the exposure window This places you in the System Type option Press the key once The Vacuum window will read and the Exposure window will read ic a z 1 If lock mode was turned ON enter your code now then press the key If the lock code has never been changed the default code is 000 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 key twice to exit this mode 94MS42 Rev S W Ver 2 06 Exposure Statistics Elapsed Hours 1 ku d d m IT N N Le N v m 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 0 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 then 4 in sequence The Vacuum window will read BEL This places you in the select mode Press the 1 key The letters
119. libration number by pressing the new number into the key pad 94MS42 Rev S W Ver 2 06 3 7 3 8 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 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 is 40 Ref A 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 94MS42 Rev S W Ver 2 06 4 Integrator Program Set Up To Enter the Select Mode Note This step must be followed in several of the program set ups Press the DJ key on the integrator to power up the light the front remote switches and the exposure unit s computer system I I Press 1 2 4 in seque
120. lled 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 Asymptom 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 e Toreplace the blower in the lamp head see section Opening Lamp Head Blown Fuse on PC Board If the fuse blows on the printed circuit board check if the fuse is 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 coil
121. ly Left and Right Covers Carefully slide the cover off of the structure e Reassemble in reverse order Replacing the Display and Keypad PC Board Remove the right rail cover and place it on carpet or any surface that will not damage the keypad overlay or the paint see Nose Assembly Left and Right Covers Remove the 6 nuts holding the Display Keypad and the 4 nuts from the Quick Memory Keypad along with all the plug in connectors Cut any tie straps holding wiring harnesses soldered to the boards in order to remove them Install the new pc boards in reverse order and reassemble the nose Replacing the Emergency Stop Button Remove the left rail cover and place it on carpet or any surface that will not damage the paint see Nose Assembly Left and Right Covers 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 in two pieces and remove it from the rail cover Install the new switch in reverse order Q Buttons Replacing the 25 and Remove the right rail cover and place it on carpet or any surface that will not damage the keypad overlay or the paint see Nose Assembly Left and Right Covers 94MS42 Rev B1 S W Ver 2 06 9 1 9 2 Use small screw driver inserted between the switch and the sheet metal to break the glue holding
122. me 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 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 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 94MS42 Rev S W Ver 2 06 8 Vacuum System Vacuum Pumps Description The printer uses two hp oilless rotary vane vacuum pumps one for each exposure frame Pressing the 252 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
123. ment 94MS42 1 S W Ver 2 06 11 5 Light Block Assembly Upper Light Block center section Assembly Drawing wy DR ese Deh zu 63 Go i x O M 3 BOTH SIDES B isi y 1 z z J I S PL T TORS SPRING ASSY RH SIDE a DETAIL 6202321400 WHEEL ASS Y Per ez NSI 3 8 X A3 4 SOC SHLD 41BF3SHC1 7 55 2 1 4 ID NYLON WASHER 44WENO2 65 16 NSI 10 LOCK WASHER SPLIT 41 10WLS 63 22 51 6 KEP NUT ZINC 41 06NKP TPL 2PG aN a ela NSI 6 32 X 5 16 PHIL FLAT 100 41B06PFO 31 rog 61 4 NSI 6 LOCKWASHER SPLIT 41 O6WLS JA No 60 16 NSI 6 FLAT WASHER BLACK ZINC 41B06WER J 59 4 NSI 6 32 X 3 8 PHIL PAN MS ZINC 41BO6PPS 37 mm 58 2 NSI 10 X 24 HEX NUT ZINC 41 14NHX 57 1 Bezel AP 42 65D3774A00 56 2 NSI SHOULDER SCREW AIBFSHC 37 _ 55 2 6 BRASS 6 32 THD SPACER 42HHS8779 54 1 SPRING TORS 43SPR18 53 1 SPRING TORS LH 43SPR17 52 2 MOUNT DOOR SWITCH OV45 11D2240A62 51
124. mperature level in the integrator program to 55 F to open the solenoid valves Open the outlet valve and then the inlet valve of the chiller to allow the water into the heat exchangers Slowly open the bleed valve to let the air out of the cooling system Close the bleed valve when there are no more air bubbles in the system Set the temperature in the program to appropriate level depending on application approx 70 F Note This setting can be changed in the future for different applications Once the system has been bled make sure the bleed valve is closed and remove the bleed valve handle Checking the chiller if the Closed Loop System is getting to hot or shut ting itself down 2 4 Make sure temperature and pressure in the system meets those in section Cooling Requirements Make sure the air in the system is properly bled as described in Filling the Closed Loop System Make sure the four blowers in the back of the unit are all spinning Turn the unit off and wait for the cool down cycle to finish Remove the upper and lower rear panels see DETAILS A and K in section Electrical Connections Remove the rear plate item 4 in section Closed Loop Cooling Assembly drawing and turn the unit on to inspect the blowers Check the 3 flow solenoids feeding the heat exchangers to make sure they are operating Turn the unit off and wait for the cool down cycle to finish Open each side door and unplug the 5 pin din s
125. mputer system Press 1 2 3 4 in sequence The Vacuum window will read This places you in the select mode 94MS42 Rev B1 S W Ver 2 06 4 9 Lf Press the 2 key The letters H will appear in the Vacuum window JI The Exposure window will display the number of exposures made at high power Press the 2 key a second time The letters will appear in the L LI Vacuum window The Exposure window will display the number of exposures at low power Js Press the 2 key a third time The letters Z 7 will appear in the Vacuum Li window The number of exposures at medium power will be displayed in the Exposure window e Press the key twice to exit this mode Selecting a Memory Location Press and release the 2 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 then 2 on the numerical keypad then press the Y key Quick Keypad Instant access by pressing any of the memory locations from 0 to 9 Entering an Exposure Time Press the 2 key on the integrator No
126. mtr w co 1 65D3774A00 Silkscreen bezel AP 1 81TAP16 Tape Glide Black UH 0 1 81TAP17 Transfer Tape 3 4 1 62AP42CL COOL Assy Cooling Module AP42 1 11D3371A62 Bracket Mount Heat Exchanger 4 11D3374A17 Panel side Clsd Loop 2 11D3381A17 Plate Rear Blower Clsd Loop 1 11D3382A62 Mounting plate Plumbing 2 11D3685A17 Duct Intake 1 11D3685B17 Duct Intake 1 11D3687A08 Cover Rear Lower 1 11D3857A17 Bracket molex connector 1 11D4079A17 Ass y upper collector 1 12D3466A07 Nipple flow meter 1 16D3808A00 Harness valves 1 16D3810A00 Harness blowers 1 315 09 Two way solenoid valve 3 31SOV09 C240 Solenoid coil 208 240V 3 39BLO17 Blower 495 cfm 4 39HTXO1 Heat exhanger 34 wide 2 43 01 Cover Handy Box 1 43CLM10 Hose clamp 1 ID 6 43CLM13 Hose clamp 1 2 4 43FIT41 Manual ball valve 1 43FIT42 Barb male straight connec 5 43FIT43 Barb male straight connec 5 43FIT44 Hex nipple male Brass 1 16 2 94MS42 Rev B1 S W Ver 2 06 Part Number Description Qty per unit 43FIT46 Reducer nipple male 3 43FIT49 Female Conn 1 Brass 2 43FIT51 Male female elbow 2 A3FIT52 Female tee Brass 1 NPT 3 A3FIT54 Cross female 1 43FIT57 Hex nipple male 8 43FIT58 Bushing femal male 1 x 2 43FIT60 Female elbow NPT 2 43FIT65 NPT male branch T 3 43FIT66 Nipple 6 Ig NPT BRASS 1 43FL
127. n all the way 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 Check input voltage with the power off at terminals 12 amp 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 t
128. nce The Vacuum window will read ALL BEL 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 e 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 amp 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 0 key on the integrator to power up th
129. o I e la ee BLACK 18 GA BLACK 16 GA Z PA BLACK INGAPT BLACK 16 GA 16D3808A00 16D3807A00 16D2196A00 RED 18 BLACK 16 GA BLACK 18 GA RED 18 GA r E 5 Set 16D3805A00 L3 22 Ea Be P62 es ole gy ood UPPER TRAY 1 52 53 MAGNETIC SW 2 gt E 3 61514 BROWN 18 BROWN 18 BROWN 18GA k F ls 61 1 5 om BLACK 18 BLACK 18 ud z 5 la 3 3 1 45 22 1 3 DRAIN o Rs MOTOR ee ie fe COMMUNICATION 1622970400 swi BIS 7 gt S VACUUM DISPLAY BOARD 5 PHOTOCELL JMPS SER BUMPS INPUT OUTPUT CONTRO 4 2 lol 3 2r 1 amp 3 27 1 E ee 11 z 5 gt gt E ele e gt t ee 2 CLOSED LOOP CONTROL BOARD 2 ACCESSORY gp BROWN 18 GA 5 BROWN 18 BLACK 18 GA p SN e 16D3796A00 DRAN 4 16D2970A00 LOWER TR UPPER LAMPHEAD 2 1 gt S MAGNETIC SW RED 18 GA BLACK 18 GA ei BLACK 18 GA RED 18 GA zd 16D3797A00 RED 18 GA BLACK 18 N d BLACK 18 GA RED 18 18 gt BLACK 18 GA 4 RED 18 BLACK 18 titt it l psi ki elat T elei ko E 41 3 1 3 R3 R4 sie IS x a UPPER mE 2 iz CELL 9 CONTROL Ser IN RU VACUUM
130. ocket in the front of each light source power supply then close both doors Remove the bottom rear panel in the back of the unit When looking at the back of the unit locate the 3 flow solenoids on the left side just at the bottom of the top rear panel see Closed Loop Cooling Assembly Item 5 94MS42 Rev B1 S W Ver 2 06 Pull the solenoid coils off the solenoid valve base the coils are retained by a spring clip and should pull off easily do not remove the spring clip from coils Set the thermostat on the inside of the unit to 100 F 20 C and turn the unit on The flow meter should read no flow Turn the unit off and reconnect one of the coils and turn the unit back on the flow meter should show water flowing through the unit Turn the unit off and disconnect the coil Repeat for each of the other two coils If water does not flow with any of the coils connected and you have the new style go to the connector on the 64 501 01 PCB and measure for 240V from pin 6 white to pin 3 black for valve 1 pin 6 white to pin 2 green for valve 2 and pin 6 white to pin 1 red for valve 3 If you have the old style go to the J2 connector on the 64CL489 PCB top of the control box and measure for 240V from 2 white to pin black for valve 1 pin 2 white to pin 6 green for valve 2 and pin 2 white to pin 5 red for valve 3 94MS42 Rev B1 S W Ver 2 06 2 5 Closed Loop Cooling Assembly
131. onnector from the control box position both frames near the mid travel position Remove three linear bearing retainer block screws using Allen wrench Lift up the frame assembly about 2 51 mm and slide the bearing block assembly backward off the shaft support the frame to prevent contact with the shaft Remove the bearing from the retainer block Install in reverse order Frame Glass Replacement Note Wear leather gloves and safety glasses when performing this procedure Open the frame to be changed CAUTION Y The glass frame could suddenly move up as soon as the glass weight is removed Secure the glass frame to the tray cable ties or heavy duty tape Remove the black silicone fillers in each corner on the front edge of the glass frame Push up on the glass from under the frame Hold it up about 12 305 mm off of the frame Disconnect both vacuum hoses and lift out the glass Install new glass in the reverse order 94MS42 Rev B1 S W Ver 2 06 11 Center Drive Assembly DRIVE MOTOR ASSY DETAIL A 5PL gt N SL TIMING SWITCH DETAIL E CHAIN TENSIONER MS ASSY DETAIL B 39 6 PL DETAILD Continued on next page 94MS42 Rev B1 S W Ver 2 06 11 1 Center Drive Assembly Diagram cont
132. ormation 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
133. osure If second frame has been examined press the 2 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 v button once To retrieve it press gt again or to continue with the exposure press the 2 button The frame will move in at a slower speed Blank frame cycle STOP lt gt GO Front right arm of operator control panel To change frame position with no vacuum or exposure Note 15 turned ON and you do not open the frame press the button and the frame will move in without vacuum exposure Press and hold the 9 button 5 Press the button Release both buttons when the frames start moving 94MS42 Rev B1 S W Ver 2 06 4 1 Error Handling System If an error occurs the machine displays an error code to aid in troubleshooting The error codes defined are The message 77 _ 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 Frames did not reach intended position after the maximum amount of time Solution Determine why Were the fram
134. p Press the 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 button down then pressing the lt button starts a blank cycle no vacuum or exposure GO Button Press the 25 button once to initiate vacuum drawdown on the exposure frame Press the button a second time to move the frame into the unit and start an exposure If frame switch FrZ and auto vacuum are turned on press the gt button once to move the frame into the unit and start an exposure If frame switch and auto vac are turned on press the button once without opening the upper or lower frame will start a blank frame cycle no vacuum or exposure Note If a vacuum delay zur is used the exposure will not begin until the vacuum delay time has counted down Table Showing the 12 Calibration Positions Wwe Upper Frame Top Surface lst Sth 9th Lih Upper Frame Bottom Surface 2nd 6th 10th LE Lower Frame Top Surface 3rd 7th 11th Lh Lower Frame Bottom Surface 4th 8th 12th 94MS42 Rev S W Ver 2 06 Calibration Procedures Note The AP42 h
135. procket 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 side travel and tighten the two accessible motor screws lightly 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 DO NOT light the lamp without the safety glass or when you are close to the bulb 94 542 Rev S W Ver 2 06 13 11 Shutter Removal LTS lampheads Remove the four hex nuts mounting the blowers disconnect the blower and thermostat wires Remove the four screws holding the rear reflector to the cooling tubes and remove the reflector and lamp from the lamp head 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
136. ption Press the 77 key to cycle the split exposure mode ON or OFF e Press the 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 0 key on the integrator to power up the light the front remote switches and the exposure unit s computer system J Press 1 12 then 4 in sequence The Vacuum window will read LL SEL This places you in the select mode I Lt Press the key once The Memory window will read L BER Press and release the key until appears in the Exposure window l LII This places you in the single surface mode Press the 2 key to turn the single surface option ON or OFF e Press the key twice to exit this mode Note Press the key to activate feature in operating mode so that the Memory display reads c and the Exposure display reads SUrF Press the key to select bottombat topta Jorbothba Now press the 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
137. r 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 64MV414 FOR AL 84 AL 84 480 and AL 94 M2 J 4 Lead to Lamp 3 High Temp Wire Other Lamp Lead 2 S Yellow Wire J Nac uu Lamp Current 1 Violet Wire 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 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 94MS42 Rev S W Ver 2 06
138. 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 Shutter position DC common see terminal 9 8 Not presently used 19 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 e 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 e 11 Not presently used 12 14 Incoming voltage To get load voltage meter between terminals 12 amp 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 94 542 Rev S W Ver 2 06 13 17 Light Function States Model Warm Up Idle Low Exp Med Exp High Exp Cool Down Trigger Unit Fans On On On On On On On On On On On On On On Power Relay On On On On On On On On On On Off Off Off Off Shutter Closed Off Closed Off Open
139. revious intensity 370V at low and 395 at medium e 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 e 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 94MS42 Rev B1 S W Ver 2 06 14 3 14 4 8kW with 1 1280 LAMP ORANGE YELLOW BROWN BLUE 1 BLUE 2 IDLE 700 360 700 700 700 LOW 700 360 700 700 700 MEDIUM 700 390 390 700 700 HIGH 700 425 425 425 425 8kW with L1281 LAMP ORANGE YELLOW BROWN BLUE 1 BLUE 2 IDLE 700 395 700 700 700 LOW 700 395 700 700 700 MEDIUM 700 425 425 700 700 HIGH 700 485 485 485 485 8kW with L 1282 LAMP ORANGE YELLOW BROWN BLUE 1 BLUE 2 IDLE 700 395 700 700 700 LOW 700 395 700 700 700 MEDIUM 700 430 430 700 700 HIGH 700 510 510 510 510 ti voltage readings described 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 700V or more see note 2
140. rned ON a decimal point will be displayed after each digit in the Memory window Lock Level 2 3 The Vacuum window will read WA or 1717177 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 key the Memory window will read 7 the Vacuum window will read s and the Exposure window will oc Press the 22 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 Lock Level 4 The Vacuum window will read 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 94MS42 Rev B1 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 No
141. s One of the many advancements OLEC has introduced to the field is the ability of its equipment to run a self diagnostic check All computer activated 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 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 3 then 4 in sequence The Vacuum window will read This places you in select mode Press the 5 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 Press the 9 key to reset the Diagnostics mode This turns Off all peripherals Therefore the Vacuum window will indicate a Z 7 Z 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 J key to turn off all functions Press the key twice to return to normal operation 94MS42 Rev S W Ver 2 06 5 1 5 2 Functions Table Function Value 1 H
142. s 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 Opening Lamp Head If the fuse has not blown throughout the test the power supply blower is suspect 94MS42 Rev B1 S W Ver 2 06 13 15 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 counted number 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 Description 1 Ground to lamp head 2 Lamp 3 Lamp 4 V common 5 Lamp fans 6 Shutter motor 7
143. s 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 amp 6 check the PC board output for voltage at pins 2 amp 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 94MS42 Rev B1 S W Ver 2 06 14 5 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 94MS42 Rev B1 S W Ver 2 06 15 Fault Trees No Strike Fault Tree Does shutter rotate when light turned on
144. se 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 94MS42 Rev B1 S W Ver 2 06 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 n
145. t ER gt lt 47 1 6 4 4 6 P4 bami E 2 H g o o 9 14 PL 6 PL 5 PL M pow N VEN KR 35 OY 18 38 7 ES fr NS A 2 sd S amp 8 Az a 2PL 45 407 5 55 I Ja 8 5 p N p 3 PL g EA 49 H P a as IN es A e up 4 PL 2PL J e 2 E e px e 4 IF U L u 0 5 4 P e VIEW 5 A NN 357 4PL 46 43 36 NE Se Continued on next page 94MS42 Rev B1 S W Ver 2 06 9 5 Nose Assembly Left and Right Covers D 10 PL 10X 2 PL 18 DETAIL H L DETAIL A a No EN N Z NS M COS N NG 5 AST Fal Lj VN DETAILA 2PL DETAIL STOP 9 6 22 4 BARRIER 555 45 5 21 1 45 11D2535A08 20 8 ADHESIVE SQUARE 4026 44PAD02 19 10 NSI 6 32
146. t 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 Tray Drive Motor Replacement The drive motor is in the left rear corner of the cabinet It is hp PMDC 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 See 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 panels Disconnect the motor connector from the control box Position both frames to approximately a midpoint state Disconnect the two wire connectors at the motor end of the drive motor e Remove the four 420 x LA counter sunk screws that attach the motor to the rear brace of the center section Use a open end wrench and lift out the motor Install the new motor in the reverse order Tray Drive Clutch Adjustment WARNING 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 94MS42 Rev B1 S W Ver 2 06 11 3 will be too slow and a transport error may occur Use the
147. te Lock Level must be set to 0 to program this step and reset when finished see Lock Level feature Press the key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 1 2 3 4 in sequence The Vacuum window will read This places you in the select mode Lr IL Press the 27 key once The Memory window will read Press and release the 2 key until the Exposure window reads a zc Press the key the Memory and Exposure windows will dim Enter your new 3 digit code Press the 27 key to set entry Press the key twice to exit this mode To Clear Lamp Statistics N This step clears all lamp statistics explained in sections Lamp Statistics Note You can abort clearing the lamp statistics by pressing the key before the display counts down to 3 2_ land 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 key on the integrator to power up the light the front remote switches and the exposure unit s computer system Press 2 3 then 4 in sequence The Vacuum window will read This places you in the select mode Press the 7 key five 5 times 7 Press the
148. te The Memory and Vacuum windows will dim Enter desired exposure time by depressing corresponding number on key pad For example 1 5 2 5 Press the 2 key to confirm the entry 4 10 94MS42 Rev S W Ver 2 06 Setting the Light Intensity Medium High Press the key to set intensity Press for the first time The first LED on the left indicates the intensity is set to low 2kW Press for the second time The first two LEDs light to indicate the intensity is set to medium 4kW Press key for the third time All three LEDs light to indicate the intensity is set to high 8kW Optional Press the 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 mode is OFF Making an exposure Place material in the exposure frame and close the frame If L Jand 2 77 Joptions turned ON vacuum will start automatically when the frame is closed are OFF press button to start vacuum The upper or lower vacuum gauge will indicate the vacuum level for the appropriate frame r Examine both sides of the frame to check the vacuum drawdown visually When good vacuum contact is assured press the 2 button to move the frame into the cabinet and start exp
149. the frames move in and out of the AP 42CL 8000 Check the linear bearings if frame transport becomes noisy To replace the lower frame front bearing see Tray Assembly Drawing Remove all the mounting bolts from the left rail cover and slide it forward about 3 to 4 76mm to 102mm e Remove both linear bearing retainer block screws using 7 Allen wrench Lift up the frame assembly about 2 51 mm and slide the bearing block assembly forward off the shaft support the frame to prevent contact with the shaft e Remove the bearing from the retainer block see Tray Assembly Drawing Detail B Install in reverse order e replace the upper front bearing see Tray Assembly Drawing Open the upper frame Remove the left light block rail and then close the upper frame Unplug the drive motor electrical connector from the control box and slide the top frame back about 10 254 mm Remove both of the linear bearing retainer block screws using a Allen wrench Lift up the frame assembly about 2 51 mm and slide the bearing block assembly forward off the shaft support the frame to prevent contact with the shaft Remove the bearing from the retainer block Install in reverse order To replace either of the rear bearings e Remove the left gas spring mount from the Mylar frame Remove the left side panel 94MS42 1 S W Ver 2 06 10 7 10 8 Unplug the drive motor electrical c
150. 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 94MS42 Rev S W Ver 2 06 14 1 14 2 4 5 6 7 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 NEVER operate the light source without the safety glass in place 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 i
151. ty Interlock uS H Jack 32BAL01 64MV407 95 39BLO03 Control Board Blower use Holder Ballast 13 2 94MS42 Rev B1 S W Ver 2 06 Ballast Tap Switch Wiring AL 94 Ballast Wiring TERMINAL STRIP 18 17 16 15 14 13 12 1 109 8 7 6 5 a 2 1 NO 29 VIOLET ACIN BLK 6GA amp Tl 9 CONTACTOR NO 20 ORANGE 7 TO CAP PACK LI 12 5408 amp COM BALLAST BALLAST 1 2 120 i35 COM s CAP COM BALLAST 3 4 oO 120 CAP AL 84 Ballast Tap Switch Wiring TERMINAL STRIP 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
152. v an a daa I OOVSSSEdT9 ATAINASSV I YAMOd ONIWOONI 12 2 480VAC 60Hz X d d zx A NT a WAH W IH IX x rH a LON 1 ASVOE tH D a ZI a IH 11 X a gt ATONIS a ed 408 AO08P ALIHM ld c ovia LONI OV MOVIE 1 Oct I aay EMEN Orrprd A HLIHA NOLLV IHdO SUMERET IT SVZI yov a Sd ern 2 i Yovia MNO ANAX VANS SIf I e TOT daa NOt bi WOS gt lt i EL ALIHM WOSA P lt Jovia y em wen Say 92 i 809 6 8 8 ee qasa of SIHNI t 2 8 fl SIHNI 35Nvy yo 9 9 jr ZO ANAX 4 9 a MOTTA d sam ms z NOLLOR TS S

AP42CL 8000 Closed Loop High Resolution Printer Service Manual O

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