EUROPEAN CUREMASTER
Contents
1. RLT FILTER gt CASSETTE UNIT SWI GE 01 SW2 1 3 3 4 PS gt P GO LP1 u SW3 mc 3 Ee 4 Ne 2 4 gt 1 1 Eegen A RL2 E oth tw rt e rd 45 T 7 d k 4 2 sz 5 Al A2 X LP2 GL 2 2 ER Ref Part No Description SE ie Di 50241 DIODE p 4 LP1 3 50182 INDICATOR RED 0 82 50182 NDICATOR AMBER 1 1 2 58068 CONTACTOR EU SW1 50161 CIRCUIT BREAKER 2 SW2 4 60185 SWITCH Q0 sp 181 801730 TERMINAL BLOCK 20 AMP Ee 0 FIL1 321 02 FILTER T1 2 50228 50Hz Ri N A FACTORY FITTED APPENDIX 4b ELECTRICAL CIRCUIT DIAGRAM ETS3 53 20 CON 1 D1 1 4 D2 2 ort 5 D3 CASSETTE UNIT 2 N u MCB1 CON 2 sw 400V W H lt 10 3 PHASE 74 Yi 8 Mb 11 50Hz am eg N 16 i ge m T2 a1 A1 FLASH OFF FULL BAKE TIMER T1 TIMER T2 55 ai Ref PartNo Description _ D1 50241 DIODE L2 A1 LP1 3 S0182 INDICATOR RED ie ka LP2 50182 INDICATOR AMBER RL1 2 5806862. amp LP2 09 LP2 BA 11 FLASH OFF ER TIMER 1 j a Ref Part No Description NE D1 3 50241 DIODE LP1 3 50182 INDIGATOR RED lb vi LP2 50182 NDICATOR AMBER EEE RL1 4 58068 SW1 50163 CIRCUIT BREAKER ISW2 3 50185 SWITCH 501736 TERMINAL BLOCK 20 T1 2 50228 TIMER 50 Hz FIL1 321 02 FILTER FM 72 Page 63 of 64 TRISK FM 72 ISSUE 6 O Edwin Trisk 2004 EDWIN TRISK LTD PALLION INDUSTRIAL ESTATE SUNDERLAND TYNE AND WEAR SR4 6SN ENGLAND TEL 44 0 191 510 0992 FAX 44 0 191 510 0689 E mail infrared trisk co uk Web www trisk co uk
3. tae ts 14 3 1 4 CASSETTE BACKBAR ASSEMBLY 16 3 1 5 I R CASSETTE ASSEMBLY CENTRBE Gites dancing 18 3 1 6 I R CASSETTE ASSEMBLY OUTER Gere 18 3 2 CUREMASTER ULTRA ETS3 S3 20 SJ 20 3 2 BSES ae Seed 21 3 2 2 UPRIGHT ARM ASSEMBLY mare aan 22 3 2 3 G ONTROLBOXASSEMBLY 26 3 2 4 CASSETTE BACKBAR ASSEMBLY 28 3 2 5 ER CASSETTE ASSEMBLY CENTRE iii fa e etos e ceti tios 30 3 2 6 I R CASSETTE ASSEMBLY OUTER a ene 30 3 3 GUREMASTER SUPER TWIN ETS5 55 20 55 21 re a 32 Jd BSE A S 33 3 3 2 UPRIGHT ARM ASSEMBLY ae a 34 3 3 3 CONTROL BOX ASSEMBLY e are 38 3 3 4 I R CASSETTE BAGKBAR ASSEMBLY n ste 40 3 3 5 I R CASSETTE ASSEMBLY CENTRE eee vate teet ekke 42 3 3 6 I R CASSETTE ASSEMBLY OUTER tat 42 3 3 7 DOUBLE UNIT BRACKETIT 44 4 FAULT FINDING GUDE ae 45 S REPAIR PROGEDURES ament re 48 5 1 REMOVAL OF CONTROL BOX FROM UPRIGHT 48 5 2 MAINS CABLE REPLACEMENT orte tht ete rn ee c 49 5 3 CASSETTE CORD e ek rte eerte 49 5 4 CONT
4. 10 TYPE B 20 N A THIS ITEM IS FACTORY FITTED 21 58028 SCREW COUNTERSUNK SOCKET HEAD M10 x 4 20 22 50294A LOCKNUT M12 2 23 PDDO12X COVER SIDE 1 24 PDDO12V COVER FRONT 1 25 PDDO42 TOP CAP UPRIGHT 1 26 S8040 BOLT M8 x 30 1 27 S0312 WASHER M8 2 28 50292 LOCKNUT 8 1 29 PDDO11 PIVOT BRACKET 1 30 PDD033 PIN 1 31 50112 GAS STRUT 800N 1 HALF NUT 32 50117 LEVER GAS STRUT 1 50118 LEVER END 1 33 50116 END GAS STRUT 1 34 177 01 CAPPED STARLOCK 5 16 2 35 194 01 SPACER 2 36 D320 03 36 STRUT ARM PIN 1 37 PDD043 COLUMN TOP BRACKET 1 38 50077 NUT CAP M8 1 39 PDD087 SHROUD TERMINAL BLOCK 1 40 PDDO71 BRACKET TERMINAL BLOCK 1 41 50173 TERMINAL BLOCK 204 3 WAY 1 42 50294 HALF 12 1 43 50257 SCREW COUNTERSUNK HEAD No8 x 1 2 4 TYPE B FM 72 Page 11 0164 ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 44 50512 STRAIN RELIEF GLAND SPIRAL M20 1 45 50513 CONCLAMP TYPE B M20 1 46 50269 SCREW HEX HEAD M5 x 16 1 47 0291 NUT M5 1 48 50308 WASHER M5 1 49 50308 WASHER SHAKEPROOF 5 1 50 50250 SCREW NYLON M3 x 25 2 51 50298 NUT NYLON M3 2 52 50307 WASHER NYLON M3 4 53 50220A CABLE TIE SNAP IN 1 54 370 16 CABLE MAINS INPUT 6m 55 PDD139 SIDE COVER STRIP LOWER 1 56 PDD140 SIDE COVER STRIP UPPER 1 57 PDD141 CABLE HANGER 1 ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS A PRE PREPARED PART FM 72 Page 12 o
5. br 50163 CIRCUIT BREAKER SW1 3 50185 SWITCH 62 LP2 QOLP3 TB1 S0173C TERMINAL BLOCK 20 1 2 50228 50 Hz FM 72 Page 61 of 64 APPENDIX 4c 400V an N 50 2 4100W ELECTRICAL CIRCUIT DIAGRAM ETS3 53 21 01 z 02 03 i CASSETTE UNIT MCB1 FIL1 fa CON2 am a ee re Y1 MARK2 SW3 81 Case QQLPI _ E vds FLASH OFF FULL BAKE TIMER T1 TIMER T2 e Ret PartNo Description D1 3 60241 DIODE LP1 3 50182 INDICATOR RED LP2 S0182A INDICATOR AMBER RL1 2 S8068C Loos MCB1 50163 CIRCUIT BREAKER Swi 3 60185 SWITCH 1 501736 TERMINAL BLOCK 20 1 2 60228 50 Hz FILI 821 02 FILTER FM 72 Page 62 of 64 APPENDIX 4d ELECTRICAL CIRCUIT DIAGRAM ETS5 PGA 004 UNIT FILTER m 0 FILI Bones d B LI 67 og 2 1 8 Fi 2 7 l 9 13 9 z 8 14 p3 20 L3 2 8 EE Gigs e
6. 1 PDD127 LABEL POWER MCB 1 2 PDD049 SIDE SHEET RIGHT HAND LONG 1 50352 POLYESTER INSULATING TAPE 2 1m 3 PDD050 SIDE SHEET LEFT HAND LONG 1 50352 POLYESTER INSULATING TAPE 2 1m 4 PDDO51 BASE LONG 1 PDD073 DIN RAIL 2 50328 RIVET 93 2 8 4 50355 211 1 2 5 PDD057 HEAT SINK 3 6 PDD056 HEAT SINK SPAGER SHORT 3 7 321 02 FILTER S3 21 1 8 PDD080 HEAT SINK GRILLE LONG 1 9 50185 SWITCH 3 10 50163 CIRCUIT BREAKER 1 11 580680 CONTACTOR 2 12 50228 TIMER 50H2 2 13 50241 DIODE 3 14 50173 TERMINAL BLOCK 204 3 WAY 1 15 50182 INDIGATOR RED 2 16 50182A INDIGATOR AMBER 1 17 50340B POP RIVET 5 x 12 NYLON 6 18 50349 RETAINING PIN 2 19 50328 RIVET 3 2 x 6 28 20 N A N A 21 50227 TIMER KNOB 2 22 50340 P CLIP 12 5 CABLE 2 23 50330 POP RIVET 4 8 x 15 ALUMINIUM 3 24 50311 SCREW PAN HEAD M4 x 4 4 25 N A THIS ITEM IS FACTORY FITTED ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS PRE PREPARED PART FM 72 Page 27 of 64 3 2 4 CASSETTE BACKBAR ASSEMBLY IR CASSETTE BACKBAR ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 360 06 BACKBAR LONG 1 2 5320 05 02 I R CASSETTE ASSEMBLY CENTRE 53 20 1 5321 05 02 I R CASSETTE ASSEMBLY CENTRE 53 21 1 3 5320 05 01 I R CASSETTE ASSEMBLY OUTER 53 20 2 5321 05 01 I R CASSETTE ASSEMBLY
7. 5 I R CASSETTE CENTRE 6 CASSETTE OUTER FM 72 Page 8 of 64 3 1 1 BASE BASE COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 5360 01 1 2 58031 WASHER M10 4 3 502934 LOCKNUT M10 NYLOC 4 4 50075D ENDCAP PLASTIC 4 5 S0065 BRAKED CASTOR 2 6 50064 UNBRAKED CASTOR 2 FM 72 Page 9 of 64 3 1 2 UPRIGHT ARM ASSEMBLY FM 72 Page 10 of 64 UPRIGHT ARM ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDDOO1 UPRIGHT COLUMN 1 2 PDD002X SUPPORT ARM 1 PDD023 LABEL CUREMASTER SUPER 2 PDD195 LABEL CAUTION THIS ARM EXTENDS 2 3 PDD002Y CONTROL ARM 1 4 PDDOO3X U CHANNEL COLUMN 1 5 PDDOO3Y U CHANNEL SOCKET 1 50078 GROMMET STRIP 2 x127mm 50275 BOLT M12 x 90 1 6 58027 ROLL PIN 210 x 50 2 7 58032 BOLT M10 x 60 2 8 58031 WASHER M10 4 9 S0293A LOCKNUT M10 2 10 8030 NUT CAP M10 4 11 021 HOUSING 1 12 372 03 IEC SOCKET 3 13 PDDO40Y TOP END CAP SOCKET HOUSING 1 14 PDD040X BOTTOM END SOCKET HOUSING 1 15 T1033 LOCKNUT M12 BINX 1 16 50076 NUT CAP 12 1 17 50314 WASHER M12 3 18 PDDO36W SPACER 1 19 50251 SCREW SELF TAPPING POZI HEAD No8 1 2
8. ARMS 42 Remove the M12 half nut and carefully slide the metal plate from M12 stud This will reveal a terminal block UPRIGHT ARMS 41 that connects the mains cable UPRIGHT ARMS 54 to the control box input cable Removal of the mains cable involves disconnecting the mains input wires from the mains input terminal block UPRIGHT Arms 41 The mains input cable HOSWF3 1 5mm cores for models ETS2 and HOSWF5 1 5mm cores for models 55 is retained by a strain relief gland UPRIGHT ARMS 44 and may be removed by slackening the external hexagonal locking collar When the new cable is fitted to the upright the cable sheath must pass at least 5mm through the terminal block side of the spiral gland Refer to Figuresia and 1b for terminal block connections The unit is now ready for re assembly 5 3 CASSETTE CORD REPLACEMENT Cassette Cord is usually supplied as part of a spares package complete with Strain Relief Plate and associated components The following procedure details the steps of replacing just the Cassette Cord itself 1 2 Ensure that the unit is disconnected from the mains supply Disconnect the cassette cords I R CASSETTE CENTRE OUTER 8 from IEC sockets UPRIGHT ARMS 12 Remove the affected Infrared cassette assembly from the end of the arm by removing the M12 binx style locknut UPRIGHT ARMS 15 from the M12 X 90 bolt UPRIGHT ARMS 5 Carefully support the Infrared ca
9. OUTER 93 21 2 4 PDD014X SIDE BRACKET LONG 2 5 PDDO14Y SIDE BRACKET SHORT 4 6 PDD036X SPACER 4 7 S8051 SCREW COUNTERSUNK SOCKET HEAD M8 x 35 4 8 PDD034X SPRING RIGHT HAND SIDE BRACKET 2 9 S0321A WASHER SHAKEPROOF M8 12 10 S8054 NUT M8 6 11 S0087B RATCHET LEVER FEMALE 2 12 S0312 WASHER M8 20 13 S0087A WING KNOB FEMALE 4 14 S8053 WASHER CAPPED STARLOCK M3 8 15 S8052 SCREW COUNTERSUNK SOCKET HEAD M8 x 45 4 16 PDD034Y SPRING LEFT HAND SIDE BRACKET 2 17 PDD131 PIVOT BOLT 1 18 T1011 RATCHET LEVER FEMALE M12 1 3 2 5 I R CASSETTE ASSEMBLY CENTRE 3 2 6 I R CASSETTE ASSEMBLY OUTER CASSETTE ASSEMBLY CENTRE COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD072 END CAP 2 2 50251 SCREW SELF TAPPING No4 x 3 8 10 3 5330 05 24 CASSETTE SIDE V LONG 2 4 5330 05 20 CASSETTE BACK MESH V LONG 1 5 5330 05 21 BACK REFLECTOR V LONG 1 80332 RIVET 3 2 x 8 ALUMINIUM 2 6 5330 05 23 CABLE TRAY V LONG 1 7 PDD021 SIDE REFLECTOR 2 8 370 05 PLUG CORDSET 1 CM01 05 20 STRAIN RELIEF PLATE 1 350 05 STRAIN RELIEF GROMMET 1 S0173C TERMINAL BLOCK 20A 3 WAY 1 S0328A RIVET 93 2 x 8 BLACK 6 S0309 WASHER SHAKEPROOF M3 4 S0349 RETAINING PIN 1 9 380 11 I R EMITTER 1 10 5330 05 22 GRILLE 53 20 1 5320 05 20 GRILLE 93 21 1 11 58049 SCREW HEAD SET M8 x 50 2 12 58008 CABLE CLIP 2 13 50220 CABLE TIE SNAP 6 14
10. rest of the unit TIMER REPLACEMENT Remove control box as described in 5 1 Before removing faulty the timer CONTROL BOX 12 carefully mark the leads to the timer terminals and indicators to aid re assembly Pull the timer knob off to expose two retaining screws Removing these screws will allow the timer to be eased out of the control box channel after removing indicator connections Refit the timer in reverse order to dismantling taking care to fit the timers with M4 x 4mm long pan head screws if not already fitted If the terminals to the timers have not been identified reference to the Circuit Diagrams should aid re assembly Figures 4a amp 4b Re assemble unit as in 5 4 IEC SOCKET REPLACEMENT Ensure that the unit is disconnected from the mains supply Drill out the rivets that hold the plastic top and bottom caps UPRIGHT ARMS 13 14 onto the arm socket housing UPRIGHT ARMS 11 Remove caps Remove the plastic caps UPRIGHT ARMS 10 that cover the bolts that attach the socket housing to the arm U channel UPRIGHT ARMS 5 Slacken the M10 locknuts UPRIGHT ARMS 9 sufficiently to allow the socket housing to slide off and give access to the IEC sockets Do not use excessive force or the wires will be damaged Take note of the wiring connections to the damaged socket then remove the wires and unclip the socket Clip the new socket into the housing and refit the cables doubt refer t
11. 9 50185 SWITCH 2 10 50163 CIRCUIT BREAKER 1 11 580680 CONTACTOR 4 12 50228 TIMER 50H2 2 13 50241 DIODE 3 14 50173 TERMINAL BLOCK 204 3 WAY 1 15 50182 INDIGATOR RED 2 16 50182A INDIGATOR AMBER 1 17 50340B POP RIVET 5 x 12 NYLON 8 18 50349 RETAINING PIN 2 19 50328 RIVET 23 2 x 8 34 20 N A N A 21 50227 TIMER KNOB 2 22 503404 P CLIP 7 5 CABLE 2 23 50330 POP RIVET 4 8 x 15 ALUMINIUM 4 24 50311 SCREW PAN HEAD M4 x 4 4 25 N A THIS ITEM IS FACTORY FITTED ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS PRE PREPARED PART FM 72 Page 39 of 64 3 3 4 I R CASSETTE BACKBAR ASSEMBLY IR CASSETTE BACKBAR ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD170 BACKBAR LONG 1 2 009 CASSETTE ASSEMBLY CENTRE 55 20 1 PPA035 CASSETTE ASSEMBLY CENTRE 55 21 1 3 PPAOO9Y CASSETTE ASSEMBLY OUTER 55 20 2 PPA034 CASSETTE ASSEMBLY OUTER 55 21 2 4 PDDO14X SIDE BRACKET LONG 2 5 PDDO14V SIDE BRACKET SHORT 4 6 PDDOS6X SPAGER 4 7 58051 SCREW COUNTERSUNK SOCKET HEAD 8 x 35 4 8 PDDO34X SPRING RIGHT HAND SIDE BRACKET 2 9 50321 WASHER SHAKEPROOF 8 14 10 58054 NUT M8 6 11 50087B LEVER FEMALE 2 12 50312 WASHER M8 26 13 50087 WING KNOB FEMALE 4 14 8053 WASHER CAPPED STARLOCK M3 8 15 8052 SCREW COUNTERSUNK SOCKET HEA
12. ACTOR REPLACEMENTT 50 5 5 TIMER REPLACEMENT hip e te ut uo ere ep OP G a 51 5 6 JEG SOCKET REPLACEMENT Lungene me m eo are marne ted 51 5 7 GAS STRUT REPLACEMENT 52 58 R EMITTER REPEAGEMENT eee 52 6 APPENDICES uge eee enurese 54 FM 72 Page 5 of 64 1 INTRODUCTION This manual is intended to aid the servicing of the TRISK branded products listed on the cover Servicing operations should only be carried out by qualified service personnel who must use TRISK approved components Although every effort has been made to ensure that the following information is accurate it is only intended to help service personnel rather than direct them in their every step It is vitally important that any problems encountered when servicing units are referred to your importer PLEASE NOTE THAT WHEN SERVICING THE UNIT REFER TO SECTION 5 FAULT FINDING GUIDE BEFORE COMMENCING ANY REPAIR PROCEDURE 1 1 SERVICING TOOLS The following tools are the minimum required to service the range of products listed on the front cover No Required Description Round Parallel tipped 3mm Screwdriver Round Parallel tipped 5mm Screwdriver Round Supadrive No 1 Screwdriver 19mm Combination Spanners 17mm Combination Spanners Stanley Hand Drill Drill 3mm diameter Combination Pliers Wire Strippers Cutters Allen Key 6mm AF Crimp Tool for Crimping Red Blue
13. AT ALL BODY PARTS THE USRE S OR OTHERWISE ARE FREE FROM WITHIN OPERATIONAL ARES TO AVOID ENTRAPMENT THIS MANUAL ISSUE 06 IS ONLY INTENDED FOR THE ASSEMBLY AND OPERATION OR THE SERVICING OF THE MODELS MENTIONED ON THE FIRST PAGE THIS MANUAL IS AN UNCONTROLLED DOCUMENT TRISK RESERVE THE RIGHT TO UPDATE UNIT SPECIFICATIONS WITHOUT PRIOR NOTICE OR CONSULTATION PLEASE READ THE RELEVANT REPAIR PROCEDURE THOROUGHLY AT LEAST ONCE BEFORE COMMENCING ANY SERVICING OPERATION SERVICING OPERATIONS SHOULD ONLY BE CARRIED OUT BY QUALIFIED SERVICE PERSONNEL WHO MUST USE TRISK APPROVED COMPONENTS IF INANY DOUBT ABOUT ASSEMBLY OR OPERATION OF THE UNIT PLEASE DO NOT HESITATE TO CONTACT YOUR DISTRIBUTOR OR THE TRISK SERVICE DEPARTMENT FM 72 Page 3 of 64 THIS PAGE IS LEFT BLANK INTENTIONALLY FM 72 Page 4 of 64 CONTENTS 1 INTRODUCTION iii 6 9 6 2 TECHNICAL SPECIFICATIONS dende 7 1 CUREMASTER SUPER ETS2 82 21 ne tme AE 7 2 2 GUREMASTER ULTRA ETS3 83 20 S3 21 vasse 7 2 3 CUREMASTER SUPER TWIN ETS5 55 20 55 21 7 3 EE DEEN EE 8 CUREMASTER SUPER ETS2 S2 21 ed 8 le BASE sarte 9 3 1 2 UPRIGHT ARM ASSEMBLY 10 3 1 3 CONTROL BOX ASSEMBLY
14. B 44 50512 STRAIN RELIEF GLAND SPIRAL M20 1 45 50513 CONCLAMP M20 1 46 50269 SCREW HEX HEAD M5 x 15 1 47 0291 NUT M5 1 48 50308 WASHER M5 1 49 50308 WASHER SHAKEPROOF 5 1 50 50250 SCREW NYLON M3 x 25 2 51 50298 NUT NYLON M3 2 52 50307 WASHER NYLON M3 4 53 50220A CABLE TIE SNAP IN 1 54 50198 CABLE MAINS INPUT 6m 55 PDD139 SIDE COVER STRIP LOWER 1 56 PDD140 SIDE COVER STRIP UPPER 1 57 PDD142 CABLE HANGER 1 ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS PRE PREPARED PART FM 72 Page 36 of 64 THIS PAGE IS LEFT BLANK INTENTIONALLY FM 72 Page 37 of 64 3 3 3 CONTROL BOX ASSEMBLY FM 72 Page 38 of 64 CONTROL BOX ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD047 FASCIA PANEL 1 PDD062X LABEL FLASH OFF 50 2 1 PDDO62Y LABEL FULL BAKE 50Hz 1 PDD067X LABEL SWITCHES 1 2 5420 03 22 SIDE SHEET RIGHT HAND V LONG 1 50352 POLYESTER INSULATING TAPE 2 1m 3 420 03 21 SIDE SHEET LEFT HAND V LONG 1 50352 POLYESTER INSULATING TAPE 2 1m 4 420 03 20 BASE V LONG 1 PDD073 DIN RAIL BRAGKET 4 50328 RIVET 93 2 x 8 4 50355 GROMMET 11 1 2 5 PDD057 HEAT SINK 3 6 PDD056 HEAT SINK SPAGER SHORT 3 7 321 02 FILTER S3 21 1 8 PDD080 HEAT SINK GRILLE LONG 1
15. D 8 x 45 4 16 PDDO34V SPRING LEFT HAND SIDE BRACKET 2 NOTE THE ABOVE QUANTITIES ARE PER CASSETTE BANK SO DOUBLE EACH QUANTITY FOR PER UNIT 3 3 5 CASSETTE ASSEMBLY CENTRE 3 3 6 CASSETTE ASSEMBLY OUTER 2 NA 10 CASSETTE ASSEMBLY CENTRE COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD072 END CAP 2 2 50251 SCREW SELF TAPPING No4 x 3 8 8 3 PDDOO6Y CASSETTE SIDE LONG 2 4 PDDOO6W CASSETTE BACK MESH LONG OUTER 1 PDD267 CASSETTE BACK MESH LONG CENTRE 1 5 PDDOO7X BACK REFLECTOR LONG 1 50332 RIVET 3 2 x 8 ALUMINIUM 3 6 PDD082 CABLE TRAY 1 7 PDDO 1 SIDE REFLECTOR 2 8 370 20 PLUG CORDSET 1 CM01 05 20 STRAIN RELIEF PLATE 1 350 05 STRAIN RELIEF GROMMET 1 50173 TERMINAL 20A 3 WAY 1 50328 RIVET 03 2 x 8 BLACK 6 50309 WASHER SHAKEPROOF M3 4 50349 RETAINING PIN 1 9 380 08 EMITTER 1 10 PDDOOSX GRILLE S5 20 1 PDDO161 GRILLE 55 21 1 11 58049 SCREW CAP HEAD SET 8 x 50 2 12 58008 CABLE 2 13 50220A CABLE TIE SNAP IN 4 14 N A THIS ITEM IS FACTORY FITTED ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS PRE PREPARED PART CASSETTE ASSEMBLY OUTER COMPONENTS AS ABOVE BUT WITHOUT ITEM NUMBER 11 3 3 7 DOUBLE UNIT BRACKET DOUBLE UNIT BRACKET COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUA
16. EDURE 3 REFERS Examine socket housing at the end of the arm If any IEC sockets have been damaged REPLACE DAMAGED SOCKET PROCEDURE 6 REFERS FM 72 Page 46 of 64 PROBLEM INDICATOR STATUS ACTION 5 ARM WILL NOT RAISE OR LOWER N A Gas strut locknut upright Arms 31 may be slack causing unit to jam reset rotate gas strut shaft one half turn clockwise and check operation with release arm Continue this operation until a position is obtained which allows the arm to move freely up and down when the gas strut lever is depressed Tighten locknut If examination of the gas strut reveals damage to the unit e g bent shaft refer to GAS STRUT REPLACEMENT PROCEDURE 7 6 INFRA RED EMITTER IN CASSETTE WILL NOT ILLUMINATE Mains indicator lamp is on one timer light is on and emitter switches are on Check cassette plugs I R CASSETTE CENTRE OUTER 8 are securely plugged into their IEC sockets UPRIGHT ARMS 12 and that the cassette cords have not been damaged If other Infrared emitters operate correctly substitute plug of faulty emitter unit into another socket If emitter does not operate it needs replacing I R EMITTER REPLACEMENT PROCEDURE 8 REFERS FM 72 Page 47 of 64 5 REPAIR PROCEDURES 5 1 REMOVAL OF CONTROL BOX FROM UPRIGHT 10 11 Ensure that the unit is disconnected from the mains supply Remove the Infrared cassette f
17. ER PROCEDURE 4 REFERS Check that the supply voltage is within operating range of unit FM 72 Page 45 of 64 PROBLEM INDICATOR STATUS ACTION 3 INFRARED EMITTERS TURN ON IMMEDIATELY THE MAIN POWER SWITCH IS TURNED ON Indicator lamps on both timers should be off If both timer indicator lamps are off contactor CONTROL BOX 11 is sticking REPLACE CONTACTOR PROCEDURE 4 REFERS One of the timer indicator lamps is on Wait for timing sequence to finish If timer does not turn off in reasonable time turn off manually and check main infrared emitters turn off If emitters need to be turned off manually the timer CONTROL BOX 12 is sticking REPLACE TIMER PROCEDURE 5 REFERS 4 INFRA RED EMITTERS FLICKER Mains indicator lamp flickers Check wiring to mains plug for a poor connection Lightly tug mains cable UPRIGHT ARMS 54 at base of upright If lights are affected by this action then the problem is with the mains cable or mains input terminal block UPRIGHT ARMS 41 Examine Mains Cable for a poor connection REPLACE MAINS CABLE IF REQUIRED PROCEDURE 4 REFERS Mains indicator lamp steady illumination Ensure cassette plugs CASSETTE CENTRE OUTER 8 are securely plugged into their IEC sockets UPRIGHT ARMS 12 and that the cassette cords have not been damaged If the cord is damaged REPLACE CASSETTE CORD PROC
18. FITTED CANNOT BE ORDERED AS PRE PREPARED PART FM 72 Page 15 of 64 3 1 4 CASSETTE BACKBAR ASSEMBLY a 5 e We MON W NOG H De G3 0 EG KC AR JO De S g m 5 72 16 of 64 IR CASSETTE BACKBAR ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD132 BACKBAR LONG 1 2 PPAO17 IR CASSETTE ASSEMBLY CENTRE 1 3 016 CASSETTE ASSEMBLY OUTER 2 4 PDDO14X SIDE BRACKET LONG 2 5 PDDO14Y SIDE BRAGKET SHORT 4 6 PDD036X SPACER 4 7 8051 SCREW COUNTERSUNK SOCKET HEAD 8 x 35 4 8 PDDO34X SPRING RIGHT HAND SIDE BRACKET 2 9 50321 WASHER SHAKEPROOF 8 14 10 58054 NUT M8 6 11 50087B LEVER FEMALE 2 12 50312 WASHER M8 26 13 50087 WING FEMALE 4 14 58053 WASHER CAPPED STARLOCK 8 15 8052 SCREW COUNTERSUNK SOCKET HEAD 8 x 45 4 16 PDDO34V SPRING LEFT HAND SIDE BRACKET 2 3 1 5 I R CASSETTE ASSEMBLY CENTRE 3 1 6 I R CASSETTE ASSEMBLY OUTER CASSETTE ASSEMBLY CENTRE COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD072 END CAP 2 2 50251 SCREW SELF TAPPING No4 x 3 8 10 3 PDDOO6Y CASSETTE SIDE LONG 2 4 PDDOO6W CASSETTE BACK MESH LONG 1 5 PDDOO7X BACK REFLECTOR LONG 1 S0332 RIVET 93 2 x 8 10 6 PDDO82 CABLE TRAY L
19. N A THIS ITEM IS FACTORY FITTED ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS A PRE PREPARED PART CASSETTE ASSEMBLY OUTER COMPONENTS AS ABOVE BUT WITHOUT ITEM NUMBER 11 3 3 CUREMASTER SUPER TWIN ETS5 55 20 55 21 BASE UPRIGHT ARMS CONTROL BOX CASSETTE BACK BAR ASSEMBLY I R CASSETTE CENTRE I R CASSETTE OUTER DOUBLE UNIT BRACKET FM 72 Page 32 of 64 3 3 1 BASE BASE COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD190 BASE 1 2 58031 WASHER M10 4 3 S0293A LOCKNUT M10 NYLOC 4 4 50075D ENDCAP PLASTIC 4 5 S0065 BRAKED CASTOR 2 6 50064 UNBRAKED CASTOR 2 FM 72 Page 33 of 64 3 3 2 UPRIGHT ARM ASSEMBLY FM 72 Page 34 of 64 UPRIGHT ARM ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDDOO1 UPRIGHT COLUMN 1 2 PDD002X SUPPORT ARM 1 T1040 HANDLE LARGE 1 50330 POP RIVET 4 8 x 15 ALUMINIUM 2 PDD025 LABEL CUREMASTER SUPER TWIN 2 PDD085 LABEL CAUTION THIS ARM EXTENDS 2 3 PDD002Y CONTROL ARM 1 4 PDDOO3X U CHANNEL COLUMN 1 S0078 GROMMET STRIP 127mm 5 01 04 08 COMPACT TWIN ARM U CHANNEL 1 50078 GR
20. NTITY 1 PDD172 DOUBLE UNIT 1 SUPPLIED WITH THE FOLLOWING ITEMS 2 50276 BOLT M12 x 110 2 3 50314 WASHER M12 6 4 50294A LOCKNUT M12 BINX 2 5 50076 NUT CAP 12 4 6 PDD045 END CAP 2 FM 72 Page 44 of 64 4 FAULT FINDING GUIDE PROBLEM INDICATOR STATUS ACTION 1 INFRA RED Timer indicator lamp Timer CONTROL BOX 12 may EMITTERS WILL NOT does not turn off at end be sticking Manually turn timer TURN OFF of pre set time off and check that the indicator lamp turns off REPLACE TIMER PROCEDURE 5 REFERS Timer indicator lamp Manually turn timer on and off and turns off at end of timing listen for contactor relay sequence CONTROL BOX 11 opening and closing contactor may be sticking Tap side of upright to see if contactor will open Re check operation If problem persists REPLACE CONTACTOR PROCEDURE 4 REFERS 2 INFRA RED Timer indicator lamp Check that cassette cords I R EMITTERS WILL NOT showing timer on CASSETTE CENTRE OUTER TURN ON 8 are securely plugged into their IEC sockets UPRIGHT ARMS 12 Manually turn Timer on and off and listen for Contactor CONTROL BOX 11 opening and closing Listen for buzzing sound of contactor trying to operate REPLACE CONTACTOR PROCEDURE 4 REFERS Check operation of other timer CONTROL BOX 12 manually and see if the infrared emitters will turn on If operating correctly REPLACE CONTACTOR ON ORIGINAL TIM
21. NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD253 UPRIGHT COLUMN 1 2 PDD002X SUPPORT ARM 1 T1040 HANDLE LARGE 1 50330 POP RIVET 4 8 x 15 ALUMINIUM 2 5330 02 20 LABEL CUREMASTER ULTRA 2 PDD085 LABEL CAUTION THIS ARM EXTENDS 2 3 PDD002Y CONTROL ARM 1 4 PDDOO3X U CHANNEL COLUMN 1 S0078 GROMMET STRIP 127mm 5 PDDOO3Y U CHANNEL SOCKET 1 50078 GROMMET STRIP 127mm 50275 BOLT M12 x 90 1 6 58027 ROLL PIN 210 x 50 2 7 58032 BOLT M10 x 60 2 8 58031 WASHER M10 4 9 S0293A LOCKNUT M10 2 10 58030 NUT CAP M10 2 11 PPA021 HOUSING 1 12 372 03 IEC SOCKET 3 13 PDDO40Y TOP END CAP SOCKET HOUSING 1 14 PDD040X BOTTOM END SOCKET HOUSING 1 15 11033 LOCKNUT M12 BINX 1 16 50076 NUT CAP 12 1 17 50314 WASHER M12 4 18 PDDO36W SPACER 1 19 50251 SCREW SELF TAPPING HEAD No8 x 1 2 10 TYPE B 20 N A THIS ITEM IS FACTORY FITTED 21 58028 SCREW COUNTERSUNK SOCKET HEAD M10 x 4 20 22 50294A LOCKNUT M12 2 23 PDDO12X COVER SIDE 1 24 PDDO12V COVER FRONT 1 25 PDD042 TOP CAP UPRIGHT 1 26 58040 BOLT M8 x 30 1 27 50312 WASHER M8 2 28 50292A LOCKNUT M8 1 29 PDDO11 PIVOT BRACKET 1 30 PDD033 PIN 1 31 550 03 GAS STRUT 1200N 1 HALF NUT 32 50117 LEVER GAS STRUT 1 50118 LEVER END 1 33 50116 END GAS STRUT 1 34 177 01 CAPPED STARLOCK 5 16 2 35 194 01 SPACER 2 36 D320 03 36 STRUT ARM PIN 1 37 PDD043 COLUMN TOP BRACKET 1 38 50077 NUT CAP M8 1 39 PDD087 SHROUD TERMINAL BL
22. OCK 1 PDD088 LABEL PHASE TERMINAL BLOCK 1 40 PDDO71 BRACKET TERMINAL BLOCK 1 FM 72 Page 23 of 64 ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 41 50173 TERMINAL 204 5 WAY 1 42 50294 HALF 12 1 43 50257 SCREW COUNTERSUNK HEAD No8 x 1 2 4 TYPE B 44 350 01 STRAIN RELIEF GLAND SPIRAL PG16 1 45 351 01 GLAND NUT PG16 1 46 50269 SCREW HEX HEAD M5 x 16 1 47 50291 NUT M5 1 48 50308 WASHER M5 1 49 50308 WASHER SHAKEPROOF 5 1 50 50250 SCREW NYLON M3x25 2 51 50298 NUT NYLON M3 2 52 50307 WASHER NYLON M3 4 53 50220A CABLE TIE SNAP 1 54 300 13 CABLE MAINS INPUT 6m 55 PDD139 SIDE COVER STRIP LOWER 1 56 PDD140 SIDE COVER STRIP UPPER 1 57 PDD142 CABLE HANGER 1 T1050A PLUG MAINS S3 21 1 ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS PRE PREPARED PART FM 72 Page 24 of 64 THIS PAGE IS LEFT BLANK INTENTIONALLY FM 72 Page 25 of 64 3 2 3 CONTROL BOX ASSEMBLY 72 26 of 64 CONTROL BOX ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD128 FASCIA PANEL 1 PDD062X LABEL FLASH OFF 50 2 1 PDDO62Y LABEL FULL BAKE 50Hz
23. OMMET STRIP 127mm 50283 BOLT M12 x 100 1 6 58027 ROLL PIN 410 x 50 2 7 58032 BOLT M12 x 60 2 8 58031 WASHER M10 4 9 S0293A LOCKNUT M10 2 10 8030 NUT CAP M10 4 11 TM01 02 13 HOUSING 1 12 372 03 IEC SOCKET 6 13 PDDO40Y TOP END CAP SOCKET HOUSING 1 14 01 04 07 COVER BOTTOM COMPACT TWIN 1 15 11033 LOCKNUT M12 BINX 1 16 50076 NUT CAP 12 1 17 50314 WASHER M12 4 18 PDDO36W SPACER 1 19 50251 SCREW SELF TAPPING HEAD No8 x 1 2 10 TYPE B 20 N A THIS ITEM IS FACTORY FITTED 21 58028 SCREW COUNTERSUNK SOCKET HEAD M10 x 4 20 22 50294A LOCKNUT M12 2 23 PDDO12X COVER SIDE 1 24 PDDO12V COVER FRONT 1 25 PDD042 TOP CAP UPRIGHT 1 26 58040 BOLT M8 x 30 1 27 50312 WASHER M8 2 28 50292A LOCKNUT M8 1 29 PDDOTI PIVOT BRACKET 1 30 PDD033 PIN 1 31 50115 GAS STRUT 1500N 1 HALF NUT 32 50117 LEVER GAS STRUT 1 50118 LEVER END 1 33 50116 END GAS STRUT 1 34 177 01 CAPPED STARLOCK 5 16 2 35 194 01 SPACE 2 36 D320 03 36 STRUT ARM PIN 1 37 PDD043 COLUMN BRACKET 1 38 50077 8 1 39 PDD087 SHROUD TERMINAL BLOCK 1 PDD088 LABEL PHASE TERMINAL BLOCK 1 40 PDDO71 BRACKET TERMINAL BLOCK 1 FM 72 Page 35 of 64 ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 41 50173 TERMINAL 204 5 WAY 1 42 50294 HALF 12 2 43 50257 SCREW COUNTERSUNK HEAD x 1 2 4 TYPE
24. ONG 1 7 PDD021 SIDE REFLECTOR 2 8 370 05 PLUG CORDSET 1 CM01 05 20 STRAIN RELIEF PLATE 1 350 05 STRAIN RELIEF GROMMET 1 50173 TERMINAL 20A 3 WAY 1 50349 RETAINING PIN 1 9 380 08 EMITTER 1 10 PDD161 GRILLE 1 11 58049 SCREW CAP HEAD SET 8 x 50 2 12 58008 CABLE 2 13 50220A CABLE TIE SNAP IN 4 14 N A THIS ITEM IS FACTORY FITTED ITEMS THAT ARE FACTORY FITTED CANNOT BE ORDERED AS PRE PREPARED PART CASSETTE ASSEMBLY OUTER COMPONENTS AS ABOVE BUT WITHOUT ITEM NUMBER 11 FN 0 3 2 CUREMASTER ULTRA ETS3 53 20 53 21 a 1 BASE 2 UPRIGHT ARMS 3 CONTROL BOX 4 I R CASSETTE BACKBAR ASSEMBLY 5 I R CASSETTE CENTRE 6 I R CASSETTE OUTER FM 72 Page 20 of 64 3 2 1 BASE BASE COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 5360 01 01 BASE 53 20 1 PDD190 BASE 83 21 1 2 58031 WASHER M10 4 3 S0293A LOCKNUT M10 NYLOC 4 4 S0075D ENDCAP PLASTIC 4 5 S0065 BRAKED CASTOR 2 6 S0064 UNBRAKED CASTOR 2 FM 72 Page 21 of 64 3 2 2 UPRIGHT ARM ASSEMBLY FM 72 Page 22 of 64 UPRIGHT ARM ASSEMBLY COMPONENTS ITEM
25. TRISK EUROPEAN CUREMASTER SERVICE MANUAL ETS2 ETS3 amp ETS5 PGAO001 52 21 53 20 53 21 PGA004 55 20 55 21 FORM 72 ISSUE 6 VALID FROM 22 09 04 O Edwin Trisk Ltd 2004 IMPORTANT PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE COMMENCING ASSEMBLY OR OPERATION OF THE UNIT FAILURE TO DO SO COULD RESULT IN DAMAGE OR INJURY FOR WHICH EDWIN TRISK LIMITED WILL ACCEPT NO RESPONSIBILITY OR LIABILITY THIS EQUIPMENT MUST BE EARTHED REMOVE ALL PACKING PIECES FROM EACH CASSETTE HEAD BEFORE USE THIS UNIT MUST NOT BE USED IN A SPRAY BOOTH WHERE THERE IS A POTENTIALLY FLAMMABLE ATMOSPHERE UNTIL EXTRACTION OF ANY FLAMMABLE VAPOUR IS COMPLETE WE ALSO ADVISE CONTINUED EXTRACTION DURING CURE DO NOT MOVE THE UNIT AROUND USING THE MAINS CABLE DO NOT MOVE THIS UNIT DURING OPERATION AS THIS MAY LEAD TO PREMATURE EMITTER FAILURE ALLOW UNIT TO COOL FIRST A SUITABLY RATED FUSE MUST BE USED TO PROTECT THE UNIT THIS UNIT SHOULD ONLY BE USED TO CURE PAINT AND PRIMER APPLIED TO METALLIC PANELS DO NOT POINT THE UNIT AT ANY LIVING BEING DO NOT POINT THE UNIT AT ANY EASILY FLAMMABLE SUBSTANCES ISOLATE MAINS SUPPLY BEFORE REMOVING COVERS THE SUPPORT ARM EXTENDS FIERCELY WHEN CASSETTE ASSEMBLY IS NOT FITTED FM 72 Page 2 of 64 IN CASE OF DAMAGE TO THE SUPPLY CORD THE USER MUST REPLACE IT INSTEAD QUALIFIED PERSONNEL SHOULD BE TAKE CAUTION WHEN OPERATING MECHANICAL COMPONENTS ENSURE TH
26. TS3 amp 5 Socket Connections ETS2 amp 3 Socket Connections ETS5 Electrical Circuit Diagram Electrical Circuit Diagram Electrical Circuit Diagram Electrical Circuit Diagram ETS2 ETS3 53 20 ETS3 53 21 ETS5 72 54 0164 APPENDIX 1 3 WAY TERMINAL BLOCK CONNECTIONS BASE OF UPRIGHT ETS2 MAINS CABLE CABLE TO CONTROL BOX BROWN L OH BROWN BLUE N 4 BLUE GREEN GREEN YELLOW ef E CE YELLOW OR MAINS CABLE CABLE TO CONTROL BOX BROWN L OH BLACK 1 BLUE N C gt BLACK 2 GREEN GREEN YELLOW ef E a YELLOW FM 72 Page 55 of 64 APPENDIX 1b 5 WAY TERMINAL BLOCK CONNECTIONS BASE OF UPRIGHT ETS3 4 5 CABLE TO CONTROL BOX BLACK BROWN BLACK BLUE GREEN YELLOW BLACK BROWN BLACK BLUE GREEN YELLOW MAINS CABLE CES L2 OH L3 N O EE Ex MAINS CABLE OR BLACK 1 BLACK 2 BLACK 3 BLACK 4 GREEN YELLOW CABLE TO CONTROL BOX ET on 592 L3 N O o o Eu BLACK BROWN BLACK BLUE GREEN YELLOW FM 72 Page 56 of 64 APPENDIX 2a CONNECTIONS AT TOP OF UPRIGHT ETS2 Cable to Control Box RED OR BROWN MARKED 1 YELLOW OR BROWN MARKED 2 BLUE OR BROWN MARKED 3 BLUE GREEN YELLOW Terminated with blue shrouded r
27. and Yellow Insulated Crimp Connections 1 Hand Rivet Gun with nozzle for 3mm rivets 1 Heyco Hand pliers lt sch M sch FM 72 Page 6 of 64 2 TECHNICAL SPECIFICATIONS 2 1 CUREMASTER SUPER ETS2 52 21 Rated Voltage Power Consumption nominal Heating elements Area of cover Dimensions Weight 230V 50Hz 1 Phase 3 emitters full power 3300W 3 quartz tungsten filament ruby sleeved Infra Red Emitters 100cm x 80cm Width 66cm Height 164cm Length 150cm 50Kg 2 2 CUREMASTER ULTRA ETS3 63 20 53 21 Rated Voltage Power Consumption nominal Heating elements Area of cover Dimensions Weight 230V 50Hz 1 Phase 3 emitters full power 4500W 3 quartz tungsten filament ruby sleeved Infra Red Emitters 100cm x 120cm Width 66cm Height 164cm Length 150cm 50Kg 2 3 CUREMASTER SUPER TWIN ETS5 55 20 55 21 Rated Voltage Power Consumption nominal Heating elements Area of cover Dimensions Weight 400V 50 2 3 Phase 6 emitters full power 6600W 6 quartz tungsten filament ruby sleeved Infra Red Emitters 100cm x 180cm Width 66cm Height 164cm Length 150cm 70Kg FM 72 Page 7 of 64 3 UNIT BREAKDOWN 3 1 CUREMASTER SUPER ETS2 52 21 2 TA ES D A 2 d KU p 1 BASE 2 UPRIGHT ARMS 3 CONTROL BOX 4 I R CASSETTE BACKBAR ASSEMBLY
28. eceptacles Cable to Arms and Sockets BLACK MARKED 1 BROWN MARKED 2 BLACK MARKED 3 BLUE GREEN YELLOW Terminated with blue male couplers APPENDIX 2b CONNECTIONS AT TOP OF UPRIGHT ETS3 amp 5 Cable to Control Box Red MARKED1 YELLOW MARKED 1 BLUE MARKED 1 RED MARKED 2 YELLOW MARKED 2 BLUE MARKED 2 BLACK BLACK GREEN YELLOW GREEN YELLOW Terminated with blue shrouded receptacles Cable to Arms and Sockets BLACK MARKED 1 BROWN MARKED 2 BLACK MARKED 3 BLACK MARKED 11 BROWN MARKED 22 BLACK MARKED 33 BLUE BLUE GREEN YELLOW GREEN YELLOW Terminated with blue male couplers FM 72 Page 57 of 64 APPENDIX 3a SOCKET CONNECTIONS ETS2 amp 3 GREEN YELLOW l E SOCKET 1 Id BLACK 1 T E SOCKET 2 BROWN 2 f E N SOCKET 3 BLACK 3 BLUE FM 72 Page 58 of 64 APPENDIX 3b SOCKET CONNECTIONS ETS5 PGA 004 GREEN VELLOW 0 IQ SOCKET 1 BLACK 1 mes E SOCKET 2 CABLE 1 L N BROWN 2 SOCKET 3 BLACK 3 BLUE GREEN YELLOW SOCKET 4 BLACK 1 SOCKET 5 CABLE 2 BROWN2 SOCKET 6 BLACK 3 BLUE FM 72 Page 59 of 64 APPENDIX 4a ELECTRICAL CIRCUIT DIAGRAM ETS2
29. f 64 THIS PAGE IS LEFT BLANK INTENTIONALLY FM 72 Page 13 of 64 3 1 3 CONTROL BOX ASSEMBLY FM 72 Page 14 of 64 CONTROL BOX ASSEMBLY COMPONENTS ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 1 PDD048 FASCIA PANEL 1 PDD062X LABEL FLASH OFF 50 2 1 PDD062Y LABEL FULL BAKE 50Hz 1 PDDO66X LABEL SWITCHES 1 2 PDD049 SIDE SHEET RIGHT HAND LONG 1 50352 POLYESTER INSULATING TAPE 1 5m 3 PDD050 SIDE SHEET LEFT HAND LONG 1 50352 POLYESTER INSULATING TAPE 1 5m 4 PDDO51 BASE LONG 1 PDD073 DIN RAIL 2 50328 RIVET 93 2 x6 18 50355 GROMMET 11 1 2 5 PDD057 HEAT SINK 1 6 PDD056 HEAT SINK SPAGER SHORT 1 7 321 01 FILTER 1 8 PDD058 CONTACTOR SHORTING LINK 4 9 PDD080 HEAT SINK GRILLE LONG 1 10 50185 SWITCH 3 11 50161 CIRCUIT BREAKER 1 12 580680 CONTACTOR 2 13 50228 50H2 2 14 50241 DIODE 1 15 501730 TERMINAL 204 3 WAY 1 16 50182 INDIGATOR RED 2 17 50182A INDIGATOR AMBER 1 18 50340B POP RIVET 4 8 x 12 NYLON 4 19 50349 RETAINING PIN 2 20 50328 RIVET 23 2 x 8 20 21 50256 SCREW DRIVE HEAD TAPTITE M3 x 8 1 22 50227 TIMER KNOB 2 23 50340 P CLIP 07 5 CABLE 2 24 S0330 POP RIVET 04 8 15 ALUMINIUM 3 25 50311 SCREW PAN HEAD 4 4 26 N A THIS ITEM IS FACTORY FITTED ITEMS THAT ARE FACTORY
30. h bolt Refer to Figures 1a and 1b for terminal block connections Slide the metal plate back onto the upright retaining stud and place the upright back onto the base assembly For safety refit M12 locknuts Remove the self tapping screws that secure the column top bracket UPRIGHT ARMS 37 at the top of the upright Carefully remove the column top bracket from the top of the upright Within the upright are a number of in line connectors Separate the required in line connectors to allow the control box to be slid upwards and slightly outwards and to be removed from the upright FM 72 Page 48 of 64 5 2 MAINS CABLE REPLACEMENT Ensure that the unit is disconnected from the mains supply Remove the Infrared cassette from the end of the arm by removing the M12 binx style locknut UPRIGHT ARMS 15 from the M12 x 90 bolt UPRIGHT ARMS 5 Carefully support the Infrared cassette and slide this unit off the bolt being careful not to lose the fittings For double units ETS5 at least 2 people are recommended to remove assembly With the extended backbar it may be easier to remove each set of three cassettes and the backbar separately Remove 2 x M12 locknuts UPRIGHT ARMS 22 and fittings from beneath the base that hold the upright to the base assembly Lift the upright from the base and lay it on it s side Examination of the bottom of the upright will expose metal plate UPRIGHT ARMS 40 retained by a half nut UPRIGHT
31. he front of the Infrared cassette CASSETTE CENTRE OUTER 10 Remove the self tapping screws I R CASSETTE INNER OUTER 2 that hold the side reflectors CASSETTE OUTER 7 into cassette A small flat bladed screwdriver will be necessary to lift the side reflector from the cassette FM 72 Page 52 of 64 10 11 When the side reflectors are removed take note of the cable positions before removing the old emitter The in line connectors can be separated by hand but better solution 15 to use two pairs of pliers one to hold each connector when separating the wires Fit the new Infrared emitter to the sockets in the cassette Try to avoid touching the ruby sleeve with bare hands by using tissue paper to handle the emitter Reconnect the Infrared emitter to the cassette wiring taking care to replace the wires in the original positions Fit the side reflectors then clean ruby sleeve and reflectors with IPA or Methylated Spirits Refit the grille Allow 15 minutes for the solvent to dissipate before switching on FM 72 Page 53 of 64 Appendix 1a Appendix 1b Appendix 2a Appendix 2b Appendix 3a Appendix 3b Appendix 4a Appendix 4b Appendix 4c Appendix 4d 6 APPENDICES 3 way Terminal Block Connections base of upright ETS2 5 way Terminal Block Connections base of upright ETS3 amp 5 Connections at Top of Upright ETS2 Connection at Top of Upright E
32. o Figures 3a and 3b Socket Connections Refit the socket housing to arm FM 72 Page 51 of 64 5 7 GAS STRUT REPLACEMENT 10 11 12 Ensure that the unit is disconnected from the mains supply Check that the rating of replacement gas strut is correct if in doubt check rating on old gas strut Remove the self tapping screws which secure the plastic cap UPRIGHT ARMS 25 on the top of upright Remove the 2 plastic covers UPRIGHT ARMS 23 from the side of the upright Carefully support the cassette assembly on a stand or bench Remove the split pin UPRIGHT ARMS 36 from the collar assembly which fastens the gas strut to the support arm being careful not to lose the components Push out the lower gas strut pivot pin UPRIGHT ARMS 30 Rotate the gas strut and remove from the upright Replace with a TRISK pre prepared gas strut Replace the lower gas strut pivot pin Adjust the arm height to suit the new gas strut setting Reassemble the holding collar arrangement and fix in place with a new split pin CAUTION Once fitted Gas Strut should only be tested with I R Cassettes in place 13 Check that gas strut operation is satisfactory 5 8 I R EMITTER REPLACEMENT 1 Check that the replacement emitter has the correct voltage and wattage ratings Check the old emitter end caps if in doubt Ensure that the unit is disconnected from the mains supply Remove the wire grille from t
33. orm the end of the arm by removing the M12 binx style locknut UPRIGHT ARMS 15 from the M12 x 90 bolt UPRIGHT ARMS 5 Carefully support the Infrared cassette and slide this unit off the bolt being careful not to lose the fittings For double units ETS5 at least 2 people are recommended to remove the assembly With the extended backbar it may be easier to remove each set of three cassettes and the backbar separately Remove the self tapping screws holding the top cap UPRIGHT ARMS 25 onto the top of the upright Remove the 2 plastic covers UPRIGHT ARMS 23 from the sides of the upright This will expose 4 x M10 countersunk socket head screws UPRIGHT ARMS 21 which retain the main arm U channel UPRIGHT ARMS 4 Slacken these screws one turn to aid in the removal of the control box Remove 2 x M12 locknuts UPRIGHT ARMS 22 and fittings from beneath the base that hold the upright to the base assembly Lift the upright from the base and lay it on it s side Examination of the bottom of the upright will expose metal plate UPRIGHT ARMS 40 retained by a half nut UPRIGHT ARMS 42 Remove the M12 half nut and carefully slide the metal plate from M12 stud This will reveal terminal block UPRIGHT ARMS 41 that connects the mains cable UPRIGHT ARMS 54 to the control box input cable Disconnect the wires that connect Control Box to Terminal Block NOTE The earth terminal may be retained by M5 eart
34. rminals on the replacement Contactors can have their cables changed over one at a time or reference can be made to the Circuit Diagrams Figures 4a amp 4b When the wires have been changed over from the old contactor to its replacement remove the faulty contactor from the DIN rail and replace with the new contactor Carefully reposition the harness into a tidy condition so that when the base plate is riveted back to the side sheets wires are not trapped and damaged The control box should then be inspected for any damage before refitting to the upright The control box may be replaced in the upright and the in line connections at the top of the upright re made Refer to Figures 2a amp 2b Connections at Top of Upright for further details Refit the column top bracket UPRIGHT ARMS 37 using fittings To complete re assembly of unit lift the upright from the base assembly and lay it on it s side to gain access to the bottom terminal block bracket Slide the terminal block bracket off the column mounting studs and connect the control box leads to the terminal block Refer to Figuresta amp 1b for terminal block connections FM 72 Page 50 of 64 5 5 Carefully refit the terminal block bracket to the stud and retain it with the M12 half nut UPRIGHT ARMS 42 taking care not to trap any cables in this operation Refit the upright to the base and refit the plastic top cap to the upright with self tapping screws and re assemble the
35. ssette assembly and slide this unit off the bolt being careful not to lose the fittings FM 72 Page 49 of 64 Examination of the rear of the affected Infrared cassette will show the cord entering the unit via a spiral gland mounted on strain relief plate CASSETTE CENTER OUTER 4 Drill out the four rivets which hold the strain relief plate to the back mesh CASSETTE CENTRE OUTER 4 and the central rivet that holds the earth terminal to the strain relief plate record should be made of the connections to the terminal block before removing old cable of Heyco hand pliers is usually required for removing and fitting the spiral gland but normal hand pliers can be used if necessary Fit the new cord CASSETTE 8 Re attach the cassette earth terminal Rivet the strain relief plate onto the back mesh CASSETTE CENTRE OUTER 4 The unit is now ready for re assembly CONTACTOR REPLACEMENT Remove the control box as described in 5 1 The first operation involves drilling out the rivets which hold the control box base metal plate CONTROL BOX 4 to the two side sheets CONTROL BOX2 8 3 This will allow the base to be sprung out of the two side sheets leaving the fascia plate still riveted A replacement contactor will be supplied Check that the replacement contactor has the same specifications as the faulty contactor The cables attached to the old contactor should be transferred to the equivalent te
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