Page 1 OLITE OLITE 60Hz Printing Light Service Manual 94MS20 Rev. B4...
Page 2 This manual is designed for technical personnel and should only be used by authorized dealer service personnel. This manual is written to provide an understand- ing of the equipment, as well as a plan for troubleshooting. 94MS20 Rev. B4...
Page 3: Table Of Contents
Contents Introduction Introduction ................. 1-1 Safety The Nature of UV ................ 2-1 UV, Source of Health ..............2-1 Bad UV ..................2-1 UV in Nature ................2-1 Ozone, UV“B” and UV“C” ............2-2 Safety Glass ................. 2-2 Light Leaks .................. 2-2 Overexposure to UV ..............
Page 4 General Path of Power to the PC Board ............ 5-1 Interlock System ................5-1 Lamp Voltage ................5-2 Lamp Power Path................. 5-2 Trigger Board ................5-3 Capacitors and Level Switching ..........5-4 AL 83 Capacitor Assembly ............5-4 AL 84 Capacitor Assembly ............5-5 AL 84-480 Capacitor Assembly ..........
Page 5 Wiring Diagrams Lamphead for AL 83, 84, 84-480, 85, 56, 56-480, 53, 54, 54-480, 55, 55-480, 50, 35, 25, 25-2, 23........... 7-1 Lamphead for AL 100 ..............7-2 AL 83 Power Supply ..............7-3 AL 84,85 Power Supply ............. 7-4 AL 84-480 Power Supply ............
Page 6 AL 9, AL 9 Plus Capacitor Wiring ..........9-12 AL 13 Capacitor Wiring ............9-12 Shutter ..................9-13 Shutter Switch ................9-13 Shutter Motor ................9-13 Changing Shutter Motor Brushes ..........9-13 Steps to change shutter motor brushes........9-14 Idle Setting.................
Page 7: Introduction
This manual is designed for technical personnel and is written to provide an understanding of the equipment, as well as a plan for troubleshooting. All OLEC lights respond to existing conditions. There are no fixed cycles or timers. This allows the unit to respond correctly to conditions that are not normal to operation, such as power failure or surges.
Page 8 94MS20 Rev. B4...
Page 9: Safety
Questions have been raised regarding the possible danger of exposure to UV for equipment operators using high power lights. We address this issue in terms of overall safety of such lights. OLEC lights are UL approved and meet the strictest US electrical and safety standards, including all OSHA requirements.
Page 10: Ozone, Uv"B" And Uv"C
DO NOT work under those conditions! Safety Glass Carefully selected safety glass is used on all OLITE UV lights under the reflector. It filters out nearly all the remaining UV“B” so effectively that any transmission is almost impossible to measure. This safety glass is equipped with an important electrical interlock to prevent use of the light if the glass is missing or installed improperly.
Page 11: Component Layout
Component Layout Lamphead for AL 83, 84, 84-480, 85, 56, 56-480 55SW02 64MV414 62SA83-B L1280, L1281 or L1282 63D0142B03 39BLO14 Shutter Position Switch Trigger Board Shutter Assembly Replacement Lamp Lamp Support Assembly Blower Interconnect Cable To Power Supply 90RF83-C 31MOT06 PA91 39BLO14 55SW03...
Page 12: Power Supply For Al 84
Power Supply for AL 84 Power Supply for AL 84-480 94MS20 Rev. B4...
Page 13: Power Supply For Al 85
Power Supply for AL 85 Power Supply for AL 56 94MS20 Rev. B4...
Page 14: Power Supply For Al 56-480
Power Supply for AL 56-480 Lamphead for AL 53, 54, 54-480, 55, 55-480, 35, 25, 25-2, 23 62SASE-SW 64TR408 L1250, L1252, L1261 62D142 Trigger Board Shutter Assembly Replacement Lamp Lamp Support Assembly 39BLO03 Blower 55SW02 Shutter Position Switch PA91 Photocell 45KOB05 55SW03 90RF53-SW...
Page 15: Power Supply For Al 53, Al 50
Power Supply for AL 53, AL 50 Terminal Strip CL 53 Power CL 50 Output T1 T2 Power Input 120 VAC Interconnect Cable Coil Voltage To Lamphead 33RLY04* 33RLY18 32TRC01 Autoformer Sealed Relay Power Relay 16D0334A18 * Older AL50 units Interconnect Cable used just one of these relays...
Page 16: Power Supply For Al 54-480, 55-480
Power Supply for AL 54-480, 55-480 Power Supply for AL 35 Terminal Strip CL 35 Power Output T1 T2 Power Input 120 VAC Interconnect Cable Coil Voltage To Lamphead 33RLY04 33RLY18 32TRC01 Autoformer Sealed Relay Power Relay 16D0334A18 Interconnect Cable 62D331 Voltage Selection...
Page 17: Power Supply For Al 25-2, Al 25
Power Supply for AL 25-2, AL 25 Terminal Strip CL 25-2 Power CL 25 Output T1 T2 Power Input 120 VAC Interconnect Cable Coil Voltage To Lamphead 33RLY04 33RLY18 32TRC01 Autoformer Sealed Relay Power Relay on AL 25-2 16D0334A18 units ONLY Interconnect Cable 62D331 Voltage...
Page 18: Lamphead For Al 15, 19, 20
Lamphead for AL 15, 19, 20 L1150A or L1250E Lamp for AL15 ONLY 45KOB05 63D0142B00 39BLO03-15 L1250E Lamp for AL19 /AL 20 ONLY Knob Lamp Support Assembly Blower 16D271 Interconnect Cable PA85 PA91 Photocell 62RA Reflector Assembly 55SW04 55SW02 31MOT06 64TR408-T For AL15 ONLY Safety...
Page 19: Power Supply For Al 15
Power Supply for AL 15 62BLO15 CL 15 Power Supply Fan 16D0334A18 Interconnect Cable 53JKP01-1 Safety Interlock Jack 55SW01 33RLY08 32BAL01 62D139 64MV407V03 Rocker Control Power Relay Ballast Capacitor Assembly Switches Medium Relay Board High Relay Lamphead for AL 100 Note: AL100 uses two AL53 power supplies 39BLO03 63D1437...
Page 20 3-10 94MS20 Rev. B4...
Page 21: Ballast / Tap Switch Wiring
Ballast / Tap Switch Wiring AL 83 Ballast / Tap Switch Wiring D3328A TERMINAL STRIP AC IN 6 GA. CONTACTOR ORANGE TO CAP. PACK BALLAST BALLAST BALLAST BALLAST YELLOW TO AUTOFORMER RED TO FUSE AUTOFORMER 240 VOLT VOLTAGE SELECTOR SWITCH AL 84, 85 Ballast / Tap Switch Wiring TERMINAL STRIP AC IN...
Page 22: Al84-480 Ballast Wiring
AL84-480 Ballast Wiring TERMINAL STRIP NO. 29 (VIOLET). AC IN 6 GA. CONTACTOR NO. 20 (ORANGE TO CAP. PACK). BALLAST BALLAST BALLAST BALLAST AL 56 Ballast / Tap Switch Wiring TERMINAL STRIP AC IN 10 GA CONTACTOR ORANGE TO CAP. PACK BALLAST BALLAST BALLAST...
Page 23: Al56-480 Ballast Wiring
AL56-480 Ballast Wiring TERMINAL STRIP 29 (VIOLET). AC IN 6 GA. CONTACTOR NO. 20 (ORANGE TO CAP. PACK). BALLAST BALLAST BALLAST BALLAST AL54 / AL55 Ballast / Tap Switch Wiring TERMINAL STRIP AC IN 10 GA. CONTACTOR ORANGE TO CAP. PACK BALLAST BALLAST BALLAST...
Page 24: Al54-480 / Al55-480 Ballast Wiring
AL54-480 / AL55-480 Ballast Wiring TERMINAL STRIP 18 17 15 14 13 12 11 10 9 29 (VIOLET). AC IN 6 GA. CONTACTOR NO. 20 (ORANGE TO CAP. PACK). BALLAST BALLAST BALLAST BALLAST AL53/50 Ballast / Tap Switch Wiring D3328A 18 17 15 14 13 12 11 10 9 TERMINAL STRIP...
Page 25: Al 35 Ballast / Tap Switch Wiring
AL 35 Ballast / Tap Switch Wiring D3328A TERMINAL STRIP CONTACTOR ORANGE TO CAP. PACK BALLAST BALLAST YELLOW TO AUTOFORMER RED TO FUSE AUTOFORMER 240 VOLT VOLTAGE SELECTOR SWITCH AL23 and AL20 Ballast Wiring 18 17 15 14 13 12 11 10 9 TERMINAL STRIP VIOLET AC IN...
Page 26: Al 19 And Al15 Ballast Wiring
AL 19 and AL15 Ballast Wiring 18 17 15 14 13 12 11 10 9 TERMINAL STRIP VIOLET AC IN CONTACTOR BALLAST ORANGE TO CAP. PACK 94MS20 Rev. B4...
Page 27: General
General 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. 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.
Page 28: Lamp Voltage
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 caution when using digital 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.
Page 29: Trigger Board
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.
Page 30: Capacitors And Level Switching
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 light sources are divided into two or three sections. All units have one or two idle capacitors, they are connected with a yellow wire.
Page 31: Al 84 Capacitor Assembly
AL 84 Capacitor Assembly CAPACITOR ASSEMBLY PART # 62D2652A00 12µƒ 12µƒ WIRE COLORS 1) YELLOW 2) BROWN 3) BLUE 4) BLUE WITH WHITE STRIPE 5) ORANGE 16µƒ 10µƒ AL 84-480 Capacitor Assembly CAPACITOR ASSEMBLY PART # 62D3533A00 12µƒ 12µƒ WIRE COLORS 1) YELLOW 2) BROWN 3) BLUE...
Page 32: Al 85 Capacitor Assembly
AL 85 Capacitor Assembly WIRING INSTR., CAPACITOR, 8K, 60HZ - AL85 WIRE COLOR BLUE / WHITE BLUE BROWN 12 µF 16µF 8 µF SWITCH YELLOW REMOVE ORANGE 64MV422V00 16µF 10 µF POS. 1 POS. 2 WIRES TO CAPACITORS SWITCH BOTTOM VIEW FRONT VIEW 64MV422V00 14 AWG ORANGE WIRE...
Page 33: Al 56-480 Capacitor Assembly
AL 56-480 Capacitor Assembly CAPACITOR ASSEMBLY #62D3083A00 WIRES FROM HARNESS 1 2 3 FRONT VIEW OF PC BOARD 16µƒ 16µƒ WIRES TO CAPACITOR 10µƒ 10µƒ WIRE COLORS 1) YELLOW 2) BROWN 3) BLUE 4) BLUE WITH WHITE STRIPE 5) ORANGE AL 54, AL 55 Capacitor Assembly CAPACITOR ASSEMBLY PART # 62D1048 WIRES...
Page 34: Al 54-480, Al 55-480 Capacitor Assembly
AL 54-480, AL 55-480 Capacitor Assembly CAPACITOR ASSEMBLY PART # 62D3654A00 WIRES FROM HARNESS 12µƒ 12µƒ FRONT VIEW OF PC BOARD WIRES TO 12µƒ 10µƒ CAPACITOR SWITCH ON CAPACITOR MOUNTING BRACKET WIRE COLORS 1) YELLOW 4 3 2 1 2) BROWN 3) BLUE REAR VIEW OF PC BOARD...
Page 35: Old Style Al 53, Al 50 Capacitor Assembly
Old Style AL 53, AL 50 Capacitor Assembly Old Style AL 53 Old Style AL 50 8µƒ 8µƒ 8µƒ 8µƒ 8µƒ 8µƒ 8µƒ 8µƒ Wire Colors Blue Brown Yellow Orange 8µƒ 8µƒ AL 35 Capacitor Assembly Capacitor Assembly 62D127-35 CAPACITOR SWITCH 3 2 1 YELLOW 16 µƒ...
Page 36: Al 25, Al 25-2 Capacitor Assembly
AL 25, AL 25-2 Capacitor Assembly Capacitor Assembly 62D126 Yellow Old Style (New Style) Blue Orange FRONT PCB 12µƒ 8µƒ 12µƒ Wires to Capacitors AL 23 Capacitor Assembly Capacitor Assembly 62D2753A00 D2753A BLUE BROWN YELLOW 12 µƒ 9 µƒ 3 µƒ ORANGE 12 µƒ...
Page 37: Al 20, Al 19 Capacitor Assembly
AL 20, AL 19 Capacitor Assembly ORANGE 10µƒ 10µƒ BROWN BLUE ORANGE YELLOW 3µƒ 9µƒ 10µƒ BLACK YELLOW YELLOW 55SW01 BLUE AL 15 Capacitor Assembly New Style Old Style AL 15 with L1150A Lamp AL 15 with L1150A Lamp WIRES FROM HARNESS 8µƒ...
Page 38: Opening The Lamp Head
Opening the Lamp Head • Unplug the unit. • Remove the glass and the four screws attaching the large outer reflector section. C DO NOT TOUCH THE REFLECTOR SURFACE WITH YOUR HANDS. Bottom View Remove the 2 center screws from the bottom side and the 2 screws from the top side of the lighthead.
Page 39: Shutter
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.
Page 40: Shutter Motor
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.
Page 41: Shutter Removal
Shutter Removal LT1 lampheads • Remove the 2 screws holding the air flow deflectors and remove them. Then reach through the air tube and remove the thermostat, then the high temp lamp lead (reaching through the bottom of the light a pair of needlenose pliers to remove it from the lamp support assembly makes this easier).
Page 42: Lt1 Shutter Assembly Drawing
LT1 Shutter Assembly Drawing 2 PL 4 PL 2 PL 2 PL 2 PL REF. REF. REF. REF. DETAIL DETAIL DETAIL 2 PL 2 PL 4 PL 4 PL REF. 2 PLACES REF. REF. DETAIL DETAIL DETAIL DETAIL DETAIL A DETAIL 2 PL 2 PL...
Page 43 LT8 lampheads • Remove the four hex nuts mounting the blowers, disconnect the blower and thermostat wires. View • Remove the four screws holding the rear reflector to the cooling tubes and remove the reflector and lamp from the lamp head. C DO NOT TOUCH THE REFLECTOR SURFACE WITH YOUR HANDS.
Page 44: Lt8 Shutter Assembly Drawing
LT8 Shutter Assembly Drawing 4 PL 4 PL 4 PL REF. REF. REF. DETAIL DETAIL REF. DETAIL 4 PL 4 PL REF. REF. 2 PL 17 25 SECTION 8 PL SECTION DETAIL REF. DETAIL E REF. DETAIL D DETAIL REF. DETAIL A 2 PL DETAIL...
Page 45: Idle Setting
Idle Setting The idle level occurs between exposures and low power exposures. The idle setting determines the power and temperature of the lamp, while at idle. It also allows for much lower idle power than was ever attainable before. This lower power level provides a wider light output range, low power consumption, lower heat generation, and increased lamp life.
Page 46: Lamp Head Blowers
Lamp Head Blowers The lamp head blowers are controlled by the printed circuit board to provide the correct cooling to the lamp. During warm-up, the blowers are off or run very slowly. At idle and during low exposure, the blowers vary in speed.
Page 47: Lamp Head Signals
Lamp Head Signals Signals at the Terminal Strip (Cable to the Lamp Head) A great deal of information about the operation of the lamp may be found at the terminal strip, in the power supply that connects to the lamp head. The terminals are counted number 1 at the end where the cable begins, and wire number 18 is the last wire.
Page 48 and depends on the lamp age and ambient temperature. When an exposure at high power is initiated, the lamp voltage rises to the maximum. The voltage remains there after the lamp returns to low power, until the lamp temperature again stabilizes. •...
Page 49: Light Function States
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...
Page 50: Printed Circuit Board Layout
Printed Circuit Board Layout This is a description of the signals and voltages present on the pins of the printed circuit board. 64MV407V03 Control Board layout. Used on all BUT 8kW light sources 64MV407V04 Control Board layout. Used on all 8kW light sources Note: Graphic of the new style p.c.board is shown.
Page 51: Signal Description
Signal Description Power Connector V~ Hot: Supply to board approximately 125V~. V~ Common: Common to board is the common also for relays, shutter fans, and the internal lamp head interlock. (This may not be at ground potential and should be measured with caution). Lamp Fans: V~ proportional drive output for the blowers in the lamp head.
Page 52 High Switch: Switch to select high power level. Low (0V) for high. Low/Med Switch: Switch to select power level when high switch is off. Low (0V) for medium power, High (12VDC) for low power. Manual Switch: Manual expose switch. Low (0V) to cause exposure. Interlock: External interlock outlet.
Page 53: Circuit Diagram (64Mv407 60Hz)
Circuit Diagram (64MV407 60Hz) *No Switches on Models AL55, 65, 75, 95, 96 94MS20 Rev. B4 5-27...
Page 54: Old Style (64Mv210A) Control Board Layout
Old Style (64MV210A) Control Board Layout Although there are very few old boards in the field, there are some, therefore we must address them also. To determine if you have an old board, look at the serial number. For the AL 25 the serial number is 2550 and below.
Page 55: Signal Description (64Mv210A)
Signal Description (64MV210A) Lamp Signal: V~ going to lamp. Low Expose: Input of 110V~ from timer/integrator activates a low powered exposure. Power Connector AC Hot: Supply to board. It is equal to the line voltage on 110V~ equipment, an approximately 130V~ on the 208/240V~ equipment. AC Common: Common to board, also is common for relays, shutter fans, and the internal lamp head interlock.
Page 56 5-30 94MS20 Rev. B4...
Page 57: Check List For Printing Light Troubleshooting And Service
Check List for Printing Light Troubleshooting and Service Check List for Printing Light Troubleshooting and Service C In order for this check list to be effective it must be followed step by step. 1) Disconnect the integrator/timer from the power supply. This will make sure that a faulty integrator or QC15 cable are not responsible for the malfunction and also eliminate a bad DIN socket on the board.
Page 58 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. • 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.
Page 59 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. 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.
Page 60 • SEE CHART FOR PROPER VOLTAGE READINGS (ALL VOLTAGES ARE READ TO TERMINAL 3). 1.5kW with L1150A or L1150B LAMP ORANGE YELLOW BLUE IDLE/LOW 450+ 450+ HIGH 450+ 1.5kW with L1250E LAMP ORANGE YELLOW BLUE IDLE/LOW 450+ 450+ HIGH 450+ 2kW (AL25 and AL25-2 only) with L1250 LAMP ORANGE YELLOW...
Page 61 2.3kW with L1252 LAMP ORANGE YELLOW BROWN BLUE IDLE/LOW 500+ 500+ 500+ MEDIUM 500+ 500+ HIGH 500+ 2.3kW with L1261 LAMP ORANGE YELLOW BROWN BLUE IDLE/LOW 500+ 500+ 500+ MEDIUM 500+ 500+ HIGH 500+ 3.5kW with L1250 LAMP ORANGE YELLOW BROWN BLUE IDLE/LOW...
Page 62 6kW with L1280 LAMP ORANGE YELLOW BROWN BLUE #1 BLUE #2 IDLE/LOW 500+ 360-380 500+ 500+ 500+ MEDIUM 500+ 380-410 380-410 500+ 500+ HIGH 500+ 415-445 415-445 415-445 415-445 6kW with L1281 or L1282 LAMP ORANGE YELLOW BROWN BLUE #1 BLUE #2 IDLE/LOW 500+...
Page 63 sources see voltage chart to find high and low values for others. 10) If a reading remains high (500V~ or more see note ‡) and it should be low (less than 300V~ see note ‡), the capacitor is not being pulled into the circuit.
Page 64 19) If the shutter fails to rotate at any time, then check the following: 20) When the shutter is supposed to be moving. Check for 120V~ between terminals 4 & 6. If there is voltage, go to the lamphead and check for voltage at the shutter motor then skip to step 22.
Page 65: Wiring Diagrams
Wiring Diagrams Lamphead for AL 83, 84, 84-480, 85, 56, 56-480, 53, 54, 54-480, 55, 55- 480, 50, 35, 25, 25-2, 23 Thermostat Thermostat Shutter Position Switch Safety Glass Switch Shutter Motor Blowers Lamp Trigger Board 94MS20 Rev. B5...
Page 66: Lamphead For Al 100
Lamphead for AL 100 Note: AL100 uses two AL 53 power supplies Safety Glass Switch Thermostats Thermostats Shutter Position Switch Shutter Motor Blowers Blowers Lamp Lamp Trigger Board Trigger Board 94MS20 Rev. B5...
Page 67: Al 83 Power Supply
AL 83 Power Supply 208/240 VAC INPUT Tap Switch Voltage Toward front of unit Selection Board Safety Interlock Power Power Relay Ballast Ballast High 3 Amp Socket Medium 16µƒ 12µƒ 8µƒ 16µƒ 10µƒ Slow Blow Fuse Expose 2 Position 1 Medium High Relay...
Page 68: Al 84,85 Power Supply
AL 84,85 Power Supply 220 VAC 50HZ INPUT Tap Switch Voltage Toward Selection front of unit Board Safety Interlock Power Relay Ballast Ballast 3 Amp Slow Blow Socket 10µƒ 16µƒ 12µƒ 12µƒ Fuse 10 blu Medium High Relay Relay 5 wht Power Supply Blower...
Page 69: Al 84-480 Power Supply
AL 84-480 Power Supply 120 VAC 60HZ INPUT 480 VAC 60HZ INPUT Toward front of unit Safety Interlock Power Relay Ballast Ballast Socket 10µƒ 10µƒ 12µƒ 12µƒ 10 blu Medium High Relay Relay 5 wht Power Supply Blower 12 gry 11 org 10 brn 8 red/wht...
Page 70: Al 56 Power Supply
AL 56 Power Supply 208/240 VAC INPUT Voltage Tap Switch Toward Selection front of unit Board Safety Interlock Power Relay Ballast Ballast 3 Amp Slow Blow Socket 16µƒ 16µƒ 16µƒ 10µƒ Fuse 10 blu Medium High Relay Relay 5 wht Power Supply Blower...
Page 71: Al 56-480 Power Supply
AL 56-480 Power Supply 120 VAC INPUT 480 VAC 60Hz INPUT Toward front of unit Safety Interlock Power Relay Ballast Ballast Socket 10µƒ 10µƒ 16µƒ 16µƒ 10 blu Medium High Relay Relay 5 wht Power Supply Blower 12 gry 11 org 10 brn 8 red/wht 7 org/wht...
Page 72: Al 54,55 Power Supply
AL 54,55 Power Supply 208/240 V~ INPUT Voltage Tap Switch Toward Selection Board front of unit Safety Interlock Power Relay Ballast Ballast 3 Amp Slow Blow Socket 16µƒ 12µƒ 12µƒ 16µƒ Fuse Position 2 Position 1 10 blu Medium High Relay Relay 5 wht...
Page 73: Al 54-480,55-480 Power Supply
AL 54-480,55-480 Power Supply 120 VAC INPUT 480 VAC 60Hz INPUT Toward front of unit Safety Interlock Power Relay Ballast Ballast Socket 10µƒ 10µƒ 16µƒ 16µƒ 10 blu Medium High Relay Relay 5 wht Power Supply Blower 12 gry 11 org 10 brn 8 red/wht 7 org/wht...
Page 74: Al 53 Power Supply
AL 53 Power Supply Note: AL100 uses two AL53 power supplies 208/240 VAC INPUT Voltage Toward Tap Switch front of unit Selection Board Safety Interlock Power Ballast Power Relay Ballast High 3 Amp Slow Blow Socket Medium 16µƒ 12µƒ 12µƒ 16µƒ...
Page 75: Al 50 Power Supply
AL 50 Power Supply 208/240 VAC INPUT Voltage Toward Tap Switch front of unit Selection Board Safety Interlock Power Ballast Power Relay Ballast High 3 Amp Slow Blow Socket Medium 16µƒ 12µƒ 12µƒ 16µƒ Fuse Expose 2 Position 1 High High Relay Relay...
Page 76: Al 35 Power Supply 60Hz
AL 35 Power Supply 208/240 VAC INPUT Tap Switch Voltage Toward front of unit Selection Board Safety Interlock Power Power Relay Ballast Ballast High 16µƒ 8µƒ 12µƒ 3 Amp Slow Blow Socket Medium Fuse 16µƒ Expose 2 Position 1 Medium High Relay Relay...
Page 77: Al 25-2 Power Supply
AL 25-2 Power Supply 208/240 VAC INPUT Tap Switch Voltage Toward front of unit COM COM Selection Board Safety Interlock Power Power Relay Ballast Ballast High 12µƒ 12µƒ Socket Medium Expose High Relay Power Supply Blower red/wht org/wht blu/wht clear Interconnecting Beau Plug Connector...
Page 78: Al 25 Power Supply
AL 25 Power Supply 208/240 VAC INPUT Toward front of unit Safety Interlock Power Power Relay Ballast Ballast High 12µƒ 12µƒ Socket Medium Expose High Relay Power Supply Blower red/wht org/wht blu/wht clear Interconnecting Beau Plug Connector grn/ Toward center of unit 7-14 94MS20 Rev.
Page 79: Al 23 Power Supply
AL 23 Power Supply 220 VAC INPUT Toward front of unit Safety Interlock Power Power Relay Ballast High 12µƒ 12µƒ 3µƒ 3µƒ 12µƒ 9µƒ 9µƒ 3 Amp Socket Slow Blow Medium Fuse Position Position Expose Medium High Relay Relay Power Supply red/wht org/wht...
Page 80: Al 20 Power Supply
AL 20 Power Supply 208/240 VAC INPUT Toward front of unit Safety Interlock Power Power Relay Ballast High 10µƒ 9µƒ 10µƒ 3µƒ 10µƒ 3 Amp Slow Blow Medium Socket Fuse Expose Position Medium High Relay Relay Power Supply red/wht org/wht brn/wht blu/wht clear...
Page 81: Al 19 Power Supply
AL 19 Power Supply 120 VAC INPUT Toward front of unit Safety Interlock Power Power Relay Ballast High 10µƒ 9µƒ 10µƒ 3µƒ 10µƒ Medium Socket Expose Position Medium High Relay Relay Power Supply red/wht org/wht brn/wht blu/wht clear Thermostat Safety Glass Switch Shutter Position...
Page 82: Ali 15 Power Supply
ALI 15 Power Supply Toward front of unit 120 VAC Safety Interlock INPUT Power Ballast High 16µƒ 16µƒ 16µƒ 16µƒ Power Relay Socket Jumper installed when Expose using L1150A lamp. Jumper removed when using L1150B lamp. High Relay Exposure Integrator Board Power Supply...
Page 83: Al 15 Power Supply
AL 15 Power Supply Toward front of unit 120 VAC Safety Interlock INPUT Power Ballast High 16µƒ 16µƒ 16µƒ 16µƒ Power Relay Socket Jumper installed when Expose using L1150A lamp. Jumper removed when using L1150B lamp. High Relay Power Supply red/wht org/wht brn/wht...
Page 84: Interconnect Cable For Al23, Al25, Al25-2, Al35, Al50, Al53, Al83
Interconnect Cable for AL23, AL25, AL25-2, AL35, AL50, AL53, AL83 WHITE GREEN YELLOW VIOLET BLUE BROWN ORANGE BLACK HEAT SHRINK 10 BLACK 9 HEAT SHRINK 8 BROWN 7 ORANGE 6 RED 5 BLUE 4 WHITE 3 VIOLET 2 YELLOW 1 GREEN 7-20 94MS20 Rev.
Page 85: Interconnect Cable For Al85, Al84, Al84-480, Al56, Al56-480, Al55, Al55-480, Al54, Al54-480
Interconnect Cable for AL85, AL84, AL84-480, AL56, AL56-480, AL55, AL55-480, AL54, AL54-480 WHITE GREEN YELLOW VIOLET BLUE BROWN ORANGE BLACK HEAT SHRINK WHITE GREEN YELLOW VIOLET BLUE BROWN ORANGE HEAT SHRINK BLACK 94MS20 Rev. B5 7-21...
Page 86 7-22 94MS20 Rev. B5...
Page 87: Fault Trees
Fault Trees No Strike Fault Tree No Strike Fault Tree No Strike Is there 0 VAC across pin Does shutter rotate Are there any LED's #3 purple on terminal when power is turned lit on the PC board? strip and orange com. on capacitor pack? Repair or replace wires at power...
Page 88: Shutter Rotation Fault Tree
Shutter Rotation Fault Tree Shutter Rotation Fault Tree No Shutter Rotation Does the shutter seem to Does the shutter Is the lamp lit? bind during rotation? rotate at any time? The shutter will not open for an Check the set exposure without screw on the shutter Is LED #3 lit on PC...
Page 89: Al 13 / Al
AL 13 / AL 9 AL 13 Component Layout *Capacitors for 220~ units are different values see AL 13 (220~) Wiring Diagram for values. 39BLO03 32BAL09 31MOT11 *34CAP18-S *34CAP15-S Blower Ballast Shutter Motor Capacitor Capacitor 56THM03 55SW02 64MV461V00 93MV427C2 Thermostat Safety Interlock Resistor Board Control Board...
Page 90: Al 13 Control Board (64Mv427C2)
AL 13 Control Board (64MV427C2) 14 15 16 17 18 19 10 Amp Fuse 1) AC COM 11) Incoming AC HOT DS1) POWER 2) Ballast COM 12) **Voltage Selection DS2) BLOWER 3) Lamp COM Jumpers** see NOTE A DS3) MED POWER 4) Blower COM 13) Ground DS4) HIGH POWER...
Page 91: Al 13 (120V~) Wiring Diagram
AL 13 (120V~) Wiring Diagram BALLAST 32BAL08 120V 60HZ THERM THERMOSTAT 56THM03 SW3-SW4 SWITCH,(SAFETY) 55SW12 SW1-SW2 SWITCH,(SHUTTER) 55SW02-1 MOTOR, BLOWER 39BLO03 MOTOR, DRIVE 12VDC 31MOT11 R1-R4 RESISTOR 1M Ohm 1W 26S6-10 C2,C4 CAPACITOR 20µƒ 400V 34CAP18-S C1,C3 CAPACITOR 15µƒ 400V 34CAP15-S PCBA2 RESISTOR BOARD...
Page 92: Al 13 (220V~) Wiring Diagram
AL 13 (220V~) Wiring Diagram 220~ 60HZ FUSE FUSE, 4 AMP 250V SB 56FUS23 BALLAST 32BAL09 THERM THERMOSTAT 56THM03 SW3-SW4 SWITCH,(SAFETY) 55SW12 SW1-SW2 SWITCH,(SHUTTER) 55SW02-1 MOTOR, BLOWER 62D2483A00 MOTOR, DRIVE 12VDC 31MOT11 R1-R4 RESISTOR 1Meg 1W 26S6-10 C2, C3, C4 CAPACITOR 20µF 400V 34CAP18-S CAPACITOR 15µF 400V...
Page 93: Al 9, Al 9-Plus Component Layout
AL 9, AL 9-PLUS Component Layout 39BLO03 32BAL09 31MOT11 34CAP15-S 18D718-W Blower Ballast Shutter Motor Capacitor Photocell Rod 56THM03 55SW02 64CT474-T 64MV461V00 64MV427-T for AL 9 Thermostat Safety Interlock Shutter Drive Board Resistor Board 64MV427-Plus for AL 9-Plus Switches (AL 9 Plus Only) Control Board L900 ONLY 63D0142B02...
Page 94: 64Mv427-Plus Board Layout For Al 9-Plus
64MV427-Plus Board Layout for AL 9-Plus Fuse 10 Amp 1) Ballast COM 11) Incoming AC HOT F) Photocell A(high) adjust 2) AC COM 12) Not Used G) Photocell B(low) adjust 3) Lamp COM 13) Not Used H) Photocell 4) Blower COM 14) Shutter Switch - DS1) Power 5) Blower HOT...
Page 95: Al 9-Plus Wiring Diagram
AL 9-Plus Wiring Diagram SHUTTER DRIVE BOARD 64CT474 INCOMING INCOMING AC COM AC HOT THERMOSTAT N.C. SHUTTER SHUTTER POSITION MOTOR SWITCH #2 SAFETY SAFETY INTERCONNECT GLASS GLASS CABLE SWITCH SWITCH N.O. N.O. SHUTTER N.O. POSITION SWITCH #1 64MV427 BOARD USED LAMP CHASSIS GROUND...
Page 96: 64Mv247 Board Layout For Al 9
64MV247 Board Layout for AL 9 Fuse 10 Amp 1) Ballast COM 11) Incoming AC HOT E) Overall Photocell adjust 2) AC COM 12) Shutter Motor - F) Photocell A(high) adjust 3) Lamp COM 13) Shutter Motor + G) Photocell B(low) adjust 4) Blower COM 14) Shutter Switch - H) Photocell...
Page 97: Al 9 Wiring Diagram
AL 9 Wiring Diagram INCOMING INCOMING AC COM AC HOT THERMOSTAT SAFETY SAFETY GLASS GLASS SWITCH SWITCH N.O. N.O. SHUTTER N.O. POSITION SWITCH 64MV427 BOARD LAMP CHASSIS GROUND 15µf 15µf CAPACITORS 15µf HIGH BALLAST 15µf BLOWER 94MS20 Rev. B4...
Page 98: Al 9, Al 13 Cover Removal
• Place the light on a table with the shutter flat against the table and remove the safety glass. Then remove the two screws from each of the four sides and remove the cover. OLITE AL13 Safety Glass Thumbscrews Screws Path of Power to the P.C.Board...
Page 99: Lamp Voltage
Lamp Voltage The lamp voltage measurement can provide useful information for lamp striking, lamp output and switching information. The meter used to measure can cause different results. The waveforms are not sinusoidal, so different meters may produce different results. Here is a chart with typical measurements, (see P.C. Board Layout Diagrams for the location of the test points).
Page 100: Al 9, Al 9 Plus Capacitor Wiring
AL 9, AL 9 Plus Capacitor Wiring 64MV461V00 RESISTOR BOARD BLUE BROWN 15µƒ 15µƒ 15µƒ YELLOW ORANGE 15µƒ 34CAP-AL9 34CAP-AL9 TO BALLAST AL 13 Capacitor Wiring 64MV461V00 RESISTOR BOARD BLUE BROWN 15µƒ 20µƒ 15µƒ YELLOW ORANGE 20µƒ 34CAP-AL13 34CAP-AL13 TO BALLAST C See Shrouding The Lamp before continuing.
Page 101: Shutter
voltage between the lamp lead common and the high blue (about 150V~, see diagram). Should one or more of these voltages be about 270V~, the respective capacitor is not being pulled into the circuit and the P.C. Board is most likely at fault.
Page 102: Steps To Change Shutter Motor Brushes
Place the light on its top and remove the hood and filter assembly. • Place the light on a table with the shutter flat against the table and remove the two screws from each of the four sides and remove the cover. OLITE AL13 Safety Glass Thumbscrews Screws •...
Page 103 PC Board Photocell Mount Photocell Rod Filtration layers • Locate the shutter motor and remove the orange wire from terminal No. 1 and the brown wire from terminal No. 2. Remove the two Phillips screws from the top section of the motor. Use a knife or razor blade to cut any tape or labels holding section 1 to section 2.
Page 104 • Slide brushes off the commutator. Slide new brush assembly onto commutator. Note: Center hole on brush assembly must face up. • The brush assembly has a shoulder that rests on the motor housing (section 2). The brush assembly is in position when the brushes center over the farthest outside edges of the commutator.
Page 105: Idle Setting
Idle Setting The idle level occurs when the unit is between exposures and when the unit is at 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.
Page 106: Blower
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 initiate a warm-up cycle. For these reasons, please take care when making this adjustment and check all other problems first.
Page 107: Photocell Rod Removal (Al9 Only)
Photocell Rod Removal (AL9 Only) (See Changing Shutter Motor Brushes) Shrouding The Lamp C YOU MUST SHROUD THE LAMP WHENEVER YOU OPERATE THE AL 9 / AL 13 WITHOUT THE COVER INSTALLED. Shrouding the lamp will keep you from being exposed to the harmful unfiltered UV, and will also make sure the cooling of the lamp is not effected.
Page 108 9-20 94MS20 Rev. B4...
Page 109: 10. Parts Lists
10. Parts Lists 8kW LAMPHEAD 62LH83SE-SW Lamphead 8kW Stdrd Rev SE 63D0142B03 8kW Lamp Support Bracket 90RF83-C Reflector Assembly AL 83 12D1361 Ladder Chain, # 18-49 12D1577 Spring, Idler, Shutter 16D0180A00 Harness, Lamphead 18D319 Glass, Frosted Diffusion Glass (photocell opening) 31MOT06 Motor, V~ Gear Positive Shutter 39BLO14...
Page 110 (AL 84 POWER SUPPLY 8kW 208/240V~ Cont.) 32BAL01 Ballast, AL 15-53 32TRC08 Autoformer 208/225/240V~ 33RLY02 Contactor, 2 pole,NO,30A 33RLY04 Relay, Sealed 39BLO03 Blower,Model Ball Bearing 52FUH04 Fuse Holder, 3AG/3AB 56FUS15 Fuse, 3A 250V 3AG Slow Blow 62D1047 Voltage Selector 60 Hz 55SW26 Switch, 3PDT, 250V, 10A 64VS409-HA...
Page 111 (AL 83 POWER SUPPLY 8kW 208/240V~ Cont.) 62D503-83 AL 83 Component Bracket Assembly 16D2636A00 HARNESS, 8kW P/S - MAIN 32TRC08 Autoformer 208/225/240 V~ 33RLY04 Relay, Sealed 33RLY18 Contactors Relay 50 Amp 52TS18 Terminal Strip 18 position 64MV407V04 Assy UV Lt Ctrl 8kW 60Hz 6kW LAMPHEAD 62LH83SE-SW Lamphead 8kW Stdrd Rev SE...
Page 112 AL56 POWER SUPPLY 6kW 480V~ 16D0277A00 Harness, 5K Power Supply 16D1045A00 Harness, Beau Plug OEM 16D1585 Interlock Harness 32BAL01 Ballast, AL 15-53 33RLY02 Contactor, 2 pole,NO,30A 33RLY04 Relay, Sealed 39BLO03 Blower,Model Ball Bearing 54PWR01 Power Cable for AL50/53 54PWR05 Pwr Crd 18/3 SJT 12' 5-15 62D3083A00 Assy, Capacitor Pack-6K/480V~ 34CAP10-HV...
Page 113 AL 54-480/55-480 POWER SUPPLY 5kW 480V~ 16D0277A00 Harness, 5K Power Supply 16D1045A00 Harness, Beau Plug OEM 16D1585 Interlock Harness 32BAL01 Ballast, AL 15-53 33RLY02 Contactor, 2 pole,NO,30A 33RLY04 Relay, Sealed 39BLO03 Blower,Model Ball Bearing 54PWR01 Power Cable for AL50/53 54PWR05 Pwr Crd 18/3 SJT 12' 5-15 62D3654A00 Assy, Capacitor AL54-480V~...
Page 114 (AL 35 POWER SUPPLY 3.5kW 208/240V~ Cont.) 62D331A Voltage Selector Assembly 64VS409 PCB, Voltage Selection Board 55SW26 Switch, 3PDT, 250V~, 10A 62D536 Component Brkt 2kW & 5kW 16D3171A00 Harness, Power Supply Main 32TRC01 Autoformer 208-240 V~ 33RLY02 Contactor, 2 pole,NO,30A 33RLY04 Relay, Sealed 64MV407V03...
Page 115 (AL 35 POWER SUPPLY 3.5kW 208/240V~ Cont.) 33RLY08 Relay, Power DPST-NO 62BLO15 Fan, Power Supply 62D138-6 Front Panel AL 23 16D1724 Assy, Harness, CL19 53JKP01-1 Washer Phono Jack 5kW 55SW01 Switch, CW 62D2753A00 Assembly, Capacitor Pack 34CAP12-P Cap, 12µƒ 660 V~ 34CAP20 Capacitor, Dual 9+3µƒ,660 64MV407V03...
Page 116 AL 15 POWER SUPPLY 1.5kW 120V~ 62CL15 AL 15 1.5kW Power Supply 32BAL01 Ballast, AL 15-53 44LEG03 Leveling Glide, Non-Skid 54PWR06 Pwr Crd 16/3 SJT 6' 5-15P 62D137 Center Bracket Assy AL 15 16D0633A00 Harness, Pwr AL 15 33RLY08 Relay, Power DPST-NO 62BLO15 Fan, Power Supply 62D138...
Page 117: 11. Warranty
If it is determined by OLEC that the failure or shortened life has been caused by faulty material or workmanship, full or partial replacement will be extended to the Buyer.
Page 118 Corporation 1850 East Saint Andrew Place, Santa Ana, Ca 92705 U.S.A. Tel. (714) 258-5600 Fax (714) 258-5601...

Olec OLITE Service Manual

Introduction

Safety

Component Layout

Ballast / Tap Switch Wiring

General

6 Check List for Troubleshooting and Service

Wiring Diagrams

Fault Trees

Al 13 / al

10. Parts Lists

11. Warranty

Quick Links

Need help?

Questions and answers

Summary of Contents for Olec OLITE

Table of Contents