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Accuprint AP30CL - 6000 Service Manual

Closed loop cooling high resolution printer
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AP30CL - 6000
Closed Loop Cooling
High Resolution Printer
Service Manual
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94MS41 Rev. C1 S/W Ver 2.06

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Summary of Contents for Accuprint AP30CL - 6000

  • Page 1 AP30CL - 6000 Closed Loop Cooling High Resolution Printer Service Manual 94MS41 Rev. C1 S/W Ver 2.06...
  • 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 understanding of the equipment, as well as a plan for troubleshooting. 94MS41 Rev. C1 S/W Ver 2.06...

  • Page 3: Table Of Contents

    Contents Specifications Crated Dimensions ..............1-1 Shipping Weight ................1-1 Actual Dimensions ..............1-1 Effective Exposure Frame Area........... 1-1 Intensity ..................1-2 Typical Room Requirements ............1-2 Electrical Connections ..............1-2 Electrical specifications and connections ........1-3 Cooling Requirements ..............1-4 Cooling System Connecting Power to and Checking the Evaporator ....
  • Page 4 Type Mode ................... 4-8 Exposure Statistics (Elapsed Hours)..........4-9 Exposure Statistics (Total Exposures) ......... 4-9 Selecting a Memory Location............ 4-10 Quick Keypad ................4-10 Entering an Exposure Time ............4-10 Setting the Light Intensity ............4-11 Making an exposure..............4-11 Blank frame cycle ..............
  • Page 5 10. Exposure Trays Mylar® Replacement ..............10-1 If Mylar® Pulls Out of the Frame ..........10-1 Outer Frame Replacement ............10-1 Tray Assembly Drawing ............10-3 Mylar Frame Assembly ............. 10-5 Gas Strut Removal ..............10-7 Replacing the linear bearings ............ 10-7 Frame Glass Replacement ............
  • Page 6 Blown Fuse on PC Board ............13-14 Lamp Head Signals ..............13-15 Light Function States ............... 13-17 Printed Circuit Board Layout ..........13-18 Signal Description ..............13-19 Circuit Diagram (64MV407V24) ..........13-21 Lamphead for all Lights ............13-22 AL 56 Power Supply 60Hz ............13-23 AL 56-480 Power Supply 60Hz ..........

  • Page 7: Specifications

    Specifications 72" 38" 35" 10.5" 45.5" 45" 48.5" 92.5" Crated Dimensions Length Width Height 102" 60" 80" 259 cm 152 cm 203 cm Shipping Weight Crated 1760 lbs. 800 kg. Uncrated 1450 lbs. 659 kg. Actual Dimensions Cabinet welded heavy gauge steel construction with access doors on both sides.

  • Page 8: Intensity

    Intensity Lamps can be operated at 6kW, 4kW and 2kW for the AP30CL-6000 Typical Room Requirements TOP VIEW 36" Rear 36" 36" Front TOP VIEW Electrical Connections The printer operates on 208/240V 60Hz, 3-phase, 3 wires and ground; 480V 60Hz, single-phase, 2 wires and ground; 480V 60Hz, 3-phase, 3 wires and ground;...

  • Page 9: Electrical Specifications And Connections

    • Connect the main leads to the 4 position or 6 position terminal block and connect the ground lead to the single ground terminal (see next page for hook up). • Reinstall the lower side door. • Energize the main power circuit. You should hear the lamp head and power supply cooling fans go into a cool-down cycle.

  • Page 10: Cooling Requirements

    Cooling Requirements Minimum pressure and flow rate of the chilled water depends on input temperature. For proper cooling system selection, contact OLEC. If water temperature and water flow do not meet the following specifications 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.

  • Page 11: Cooling System

    Cooling System Connecting Power to and Checking the Evaporator • Place the evaporator flat on the floor. • Connect the hose from the evaporator to the bottom of the rear panel drain. Cl 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.

  • Page 12: Connecting The Chiller

    Connecting the Chiller Connecting Chiller to Printer: • Mount the Flow Meter and Temperature Gauge assembly on a wall in the upright position. Cl The Flow Meter and Temperature Gauge assembly must be mounted level or the Flow Meter will not function properly. Bleed Valve 1/2"...
  • Page 13 Connecting Chiller to Printer (cont.) ITEM Q'TY DESCRIPTION : OLEC PART # NOTE SOLENOID VALVE, TWO WAY 31S0V09 SOLENOID COIL 31S0V09-C240 1/2" NPT BALL VALVE, MANUAL 43FIT41 1"HOSE ID.BARB-1"NPT MALE PIPE 43FIT42 1"HOSE ID.BARB-3/4"NPT MALE PIPE 43FIT43 1" NPT HEX NIPPLE - MALE 43FIT44 1/2"...

  • Page 14: Filling The Closed Loop System

    Filling the Closed Loop System Cl 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. •...

  • Page 15: Closed Loop Cooling Assembly

    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.

  • Page 16: Ms41 Rev. C1 S/W Ver

    Closed Loop Cooling Assembly (cont.) REF. REF. REF. REF. REF. DETAIL DETAIL DETAIL DETAIL REF. 8 PLACES 8 PLACES 4 PLACES 12 PLACES REF. REF. 2 PL 2 PL REF. REF. REF. REF. REF. 2 PL REF. REF. REF. REF. DETAIL DETAIL DETAIL...

  • Page 17: Integrator Functions And Features

    Integrator Functions and Features 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. [ 3 9] Memory Window [ 0 120]...
  • Page 18 MENU This key is used as the autostep indicator and for the continuous vacuum feature. Note: U MENU Special Function The U key has the optional function to be used to set auto-step and continuous vacuum per memory in normal operating mode. The frame control switch feature must be turned ON and the automatic vacuum feature must be turned OFF.

  • Page 19: Feature Quick Reference

    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. [ L ocK] Lock Level Feature [ c odE] Lock Code Feature [ 2 UAL] 2 (two) Value Exposure Feature...

  • Page 20: Operator Control Panel

    Operator Control Panel The AP 30 heavy duty exposure system has a power key on the integrator. Press the P key to turn on the unit. • Press the P key again after use, and the system will run through a 2 •...
  • Page 21 Press the P key on the integrator to power up the lights, the front • switches, and the printer's computer system. Note: Allow the printer a 5 minute warm-up period before any calibration procedures. This will allow for complete and accurate light level stabilization.

  • Page 22: Changing The Calibration Number

    Example: Let's say our 500 unit exposure gave us 600 mj. That means we got 1.2 mj per unit or a 1.2:1 ratio. The objective is to get a 1:1 ratio. To get that we would multiply our current calibration number of 500 by 1.2, 500 x 1.2 = 600. Since we are working with the Upper Tray Top Surface or [ U t] , we have •...

  • Page 23: Matching Exposure Surfaces

    Matching Exposure Surfaces • Do a test exposure in the frame being calibrated to the reference frame. • Determine the correction necessary to make each surface the same at the reference surface. If this is done with a step scale the correction is as follows.

  • Page 24: Splitting Steps

    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.

  • Page 25: Integrator Program Set Up

    Integrator Program Set Up To Enter the Select Mode Note: This step must be followed in several of the program set ups. Press the P key on the integrator to power up the light, the front remote • switches, and the exposure unit's computer system. [ S EL_] Press 1,2,3t 4 in sequence.

  • Page 26: Lock Level Description And Operation

    dim. Enter the lock level desired. Press the V key to set entry. • • If the Lock Level is set for 2, 3 or 4, the Exposure window will read [ c odE] . Enter your 3 digit code. Press the V key.

  • Page 27: Setting Or Changing Your Lock Code Feature

    Setting or Changing your Lock Code feature Note: If you are setting the code you must know the existing code. Note: Lock Level must be set to 0 to program this step and reset when finished see Lock Level feature. Press the P key on the integrator to power up the light, the front remote •...

  • Page 28: Two Value Exposure Mode

    Press the P key on the integrator to power up the light, the front remote • switches, and the exposure unit's computer system. [ S EL_] Press 1,2,3t 4 in sequence. The Vacuum window will read [ S EL_] . This places you in the select mode. Press the 9 key five (5) times.

  • Page 29: Single Surface Mode

    [ S Pgt] Press and release the e key until [ S Pgt] appears in the Exposure window. This places you in the split exposure option. Press the V key to cycle the split exposure mode ON or OFF. • Press the 0 key twice to exit this mode.

  • Page 30: Frame Control Interface Mode

    [ S EL_] Press 1,2,3t 4 in sequence. The Vacuum window will read [ S EL_] . This places you in the select mode. Press the Y key once. The Memory window will read [ S u] . • [ b cnt] Press and release the e key until [ b cnt] appears in the Exposure window.

  • Page 31: Auto Step Mode

    [ A UAC] Press and release the e key until [ A UAC] appears in the Exposure window. This places you in the automatic vacuum option. Press the V key to cycle the automatic vacuum mode ON or OFF. • Press the 0 key twice to exit this mode.

  • Page 32: Tray Mode

    Tray Mode C The default tray speed is set at the factory to 5 seconds. OLEC does not recommend changing this setting without consulting the OLEC factory. Damage to the transport can occur. Press the P key on the integrator to power up the light, the front remote •...

  • Page 33: Exposure Statistics (Elapsed Hours)

    Exposure Statistics (Elapsed Hours) Note: The exposure statistics should be reset to zero when the lamps are changed. Note: This provides the operating hours on the lamps in total and at each intensity since the last reset. This function should be used whenever the exposure lamps are replaced.

  • Page 34: Selecting A Memory Location

    [ E HI_] Press the 2 key. The letters [ E Hi_] will appear in the Vacuum window. The Exposure window will display the number of exposures made at high power. [ E Lo_] Press the 2 key a second time. The letters [ E Lo_] will appear in the Vacuum window.

  • Page 35: Setting The Light Intensity

    Setting the Light Intensity Press the I key to set intensity. Press I for the first time. The first • LED on the left indicates the intensity is set to low ( 1kW on 5kW units, 2kW on 8kW units). Medium •...

  • Page 36: Error Handling System

    Error Handling System If an error occurs, the machine displays an error code to aid in troubleshooting. The error codes defined are: [ E rr_] The message [ E rr_] will appear in the Vacuum window, and a number in the Exposure window. Look up the number below for a description of the condition.

  • Page 37: Diagnostics

    Diagnostics Output Diagnostics One of the many advancements OLEC has introduced to the field is the ability of its equipment to run a self-diagnostic check. All 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 P key on the integrator to power up the light, the front remote •...

  • Page 38: Functions Table

    Functions Table Function Value [ 0 001] Heat Exchanger Solenoids [ 0 002] Blower On/Off [ 0 004] Upper Vacuum Pump O n/Off [ 0 008] Lower Vacuum Pump On/Off [ 0 016] Work Light and Nose Section Fans O n/Off [ 0 032] Motor Direction Control [ 0 064]...

  • Page 39: Input Diagnostics

    Input Diagnostics • Switch Check The switch check can be done while in the Select mode. Press the P key on the integrator to power up the light, the front remote • switches, and the exposure unit's computer system. [ S EL_] Press 1,2,3, then 4 in sequence.
  • Page 40 • Lower tray in, Frame switch closed, Door and Emergency switches closed. [ 0 044] The Exposure window should read [ 0 044] . [ 0 172] When the G button is pushed the value should change to [ 0 172] . [ 0 060] When the S button is pushed the value should change to [ 0 060] .

  • Page 41: Lamp Changing Instructions

    Lamp Changing Instructions W The lamps and safety glass may be very hot and cause burns. Prior to changing the lamp, ensure the lamp head is turned off and allowed to complete its cooldown cycle. OLEC recomends that every year you unplug your light, remove the safety glass, and clean the glass and reflector with denatured alcohol and a soft cloth.
  • Page 42 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 •...

  • Page 43: Preventive Maintenance

    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.
  • Page 44 C Do not use silicone spray lubricants in the printer. • Lubricate frame drive chain and check tension. • Apply a light coat of machine oil to the exposure frame drive chain by rubbing an oil wetted rag along the chain. Do not wet the chain enough to cause the oil to run or drip.

  • Page 45: Vacuum System

    Vacuum System Vacuum Pumps Description: The printer uses two 1/4-hp oilless rotary vane vacuum pumps, one for each exposure frame. Pressing the G 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.

  • Page 46: Pump Disassembly

    Flushing Option #1 This option requires two pipe nipples at least 4" (102 mm) long with " NPT threads on one end. • Remove the filter elements from the front of the muffler box and screw the nipples into the same holes. •...

  • Page 47: Pump Replacement

    Pump Replacement Vacuum pump replacement is straightforward. The left-hand pump controls the lower frame; the right-hand pump controls the upper frame. (Left and right as viewed by the operator.) • Open either the left or right side cabinet door, depending on which pump is to be replaced.

  • Page 48: Vacuum Seal Replacement

    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.
  • Page 49 Vacuum Seal Replacement (cont.) • Unless otherwise specified Dimensions are in inches. Dwg. per ANSIY14.5 Tolerances are: Angles ±5 deg. .X±1 .XX±.03 .XXX±.010 .XXXX±.0030. • Clean glass perimeter. Press transfer tape onto glass. (as shown) Trim tape along edge of glass. Peel off paper. •...

  • Page 50: Glass Photo Tool (Optional)

    Glass Photo Tool (Optional) • If the unit is equipped with the Glass Photo Tool Option you will have a third vacuum pump installed in the bottom of the unit.. • See section Vacuum Pumps and section Tubing/Fitting Replacement for vacuum problems.

  • Page 51: Nose Assembly

    Nose Assembly Removing the Nose • Turn unit off, allow the unit to complete its cool down cycle and disconnect power. • While standing in front of the unit locate and disconnect all multi-pin connectors and vacuum lines below the nose on the right side. Tower Nose Remove...

  • Page 52: Replacing The S And G Buttons

    Replacing the S and G Buttons • Slide the nose out (see section Removing the Nose) but it is not necessary to completely remove it, the nose just needs to be slid out far enough to access the switches. • Use a small screw driver inserted between the switch and the sheet metal to break the glue holding the two black retainer clips on each side of the switch from the nose.

  • Page 53: Work Lights

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

  • Page 54: Nose Assembly Drawings

    Nose Assembly Drawings 4 PL 4 PL 2 PL BOTTOM VIEW NSI 6-32 KEP NUT ZINC 41-06NKP HARNESS, SW, OPERATOR OV45 16D2196A00 REMOVED REMOVED 6-32 X .312 HEX THD. SPACER 44HHS9292 SWITCH, CW 55SW01 EMERGENCY PUSHBUTTON ACTUATOR 55SW53 BARRIER 55SW45-5 3"...
  • Page 55 Nose Assembly Drawings (cont.) 3 PL 3 PL 4 PL 14 PL 6 PL 5 PL 2 PL 2 PL 45 4 PL 3 PL 4 PL 2 PL REF. 4 PL TOP VIEW 5 PL 4 PL 46 43 36 Continued on next page 94MS41 Rev.
  • Page 56 Nose Assembly Drawings (cont.) 10 PL 10 PL REF. 10 PL 4 PL DETAIL A VIEW 4 PL DETAIL B VIEW A A 2 PL 2 PL 26 2 PL 2 PL STOP DETAIL A 2 PLACES (TOP POS.) (BOT. POS.) RED BLK REF.

  • Page 57: 10. Exposure Trays

    10. Exposure Trays Mylar® Replacement • Close the Mylar® frame and open the six cam latches. • Remove the inner Mylar® frame and position the pre-cut Mylar® sheet into the frame, make sure that the Mylar® is overlapping on all side. Closed Position Open...
  • Page 58 screws through the hinge into the frame make sure the frame is " to " above the top of the hinge to avoid the possibility of damaging the glass, then tighten them down. 1/32" 1/16" Allen Outer Screw Frame Hinge End View •...

  • Page 59: Tray Assembly Drawing

    Tray Assembly Drawing 2 PL VIEW AA 2 PL 4 PL 4 PL 2 PL VIEW AA 4 PL 2 PL 2 PL REF. 2 PL VIEW AA DETAIL A 4 PL 2 PL 2 PL 2 PL 2 PL 2 PL 2 PL (BOTH SIDES)
  • Page 60 Tray Assembly Drawing (cont.) 34" SEAL "SOLID D" 44GKT07 NSI 8-32 X 1/4 PHIL PAN BLK 41B08PPS.25 TOP, HINGE, GLASS TRAY -AP30 11D2422A62 NSI CABLE TIE, UV, 4" 44TIE08 CABLE, MAGNETIC TRAY SWITCH 16D2970A00 NSI 6-32 X 1/2 PHIL PAN BLK 41BO6PPS.50 NSI #6 KEP NUT ZINC 41-06NKP...

  • Page 61: Mylar Frame Assembly

    Mylar Frame Assembly Outer Frame Assembly OUTER FRAME ASSEMBLY TOP VIEW 18 2 PL (GLASS TRAY ASSEMBLY) REF. REF. 2 PL 2 PL 2 PL 6 PL 2 PL ADD WASHERS AS NEEDED TO ADJUST CATCH TO LATCH 2 PL 2 PL LATCH / HANDLE ASSEMBLY SIDE VIEW...

  • Page 62: Inner Frame Assembly

    Inner Frame Assembly INNER FRAME ASSEMBLY 6 PL BOTTOM VIEW 6 PL CUT TO LENGTH AND APPLY AS SHOWN REFERENCE VIEW B 6 PL 16 6 PL 6 PL 30 31 6 PL 6 PL 10 6 PL 6 PL REF.

  • Page 63: Gas Strut Removal

    Gas Strut Removal Each frame assembly has two gas struts to support the top coversheet frame when it is opened. • Open the frame with the strut to be replaced. • Remove the retainer from both ends of the strut. •...

  • Page 64: Frame Glass Replacement

    Frame Glass Replacement Note: Wear leather gloves and safety glasses when performing this procedure. • Open the frame to be changed. • Remove the two glass retaining screws on the front edge of the glass frame. • Push up on the glass from under the frame. Hold it up about 12 inches (305 mm) off of the frame.

  • Page 65: 11. Center/Drive Assembly

    11. Center/Drive Assembly Center/Drive Assembly Diagram 2 PL 4 PL 4 PL DRIVE MOTOR ASSY. DETAIL A. TIMING SWITCH ASSY. 12 PL DETAIL C. 18 PL 2 PL 2 PL 4 PL CHAIN 2 PL TENSIONER 2 PL ASSY., DETAIL B. 8 PL 74"...
  • Page 66 Center/Drive Assembly Diagram (cont.) 5/16 SPLIT LOCK WASHER 41F2WLS INSUALTION PAD AL13/14 15D725 NSI 3/8 X 3/4 SOC. SHLD. 41BF2SHF.62 3/8-`6 NYLON LOCK NUT, OV45 41-F3NLN THREADED ROD 12D1751A00 5/16 - 18 X 3/4 HEX BOLT BLK. 41BF2BHX.75 TENSIONER BUSHING 12D1755A00 41B40BHX1.75 NSI 1/4-20 X 1 3/4 HEX BOLT BK...

  • Page 67: Frame Transport System

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

  • Page 68: Frame Speed Adjustment

    • Open the left side sliding door on the printer and locate the drive motor at the left rear corner of the cabinet. • Loosen the two set screws which lock the hex nut to the motor shaft. • Adjust the hex nut until the minimum setting is found that provides frame movement with no slippage.

  • Page 69: Adjust The 'Fast' Pot On The Control Box

    [ 0 096] Press the 6 key again: upper tray should move in, the Vacuum window should read [ 0 096] . • Set volt meter for VDC and measure across pins 5 & 6 on motor speed connector. Adjust the 'SLOW' pot on the control box to read 25 to 32 VDC.

  • Page 70: Light Block Assembly

    Light Block Assembly Light Block Assembly Drawing 5 PL TORSION SPRING ASSY., BOTH SIDES SEE DETAIL A 5 PL 4 PL WHEEL ASSY. BOTH SIDES SEE DETAIL C 4 PL 4 PL 8 PL WHEEL ASSY. BOTH SIDES SEE DETAIL C REF.

  • Page 71: Replacing Lower Light Block Springs

    Light Block Assembly Drawing (cont.) FRONT CABINET, AP30 11D2492A06 NSI #10 FLAT WASHER SAE 41-10WFR NSI 6-32 X 1/2 PPMS ZINC 41B06PPS.50 NSI 10-32 KEP NUT ZINC 41-12NKP NSI 1/2-13 X 2.O OSHCS-BLK 41BF5SHC2.0 NSI 8-32 KEP NUT ZINC 41-08NKP 8"...
  • Page 72 • 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 to the hole in the mounting bracket. Place the mandrel over the shoulder screw.

  • Page 73: 12. Diagrams

    12. Diagrams Control Box Front View SET SELECT SWITCH TO SLOW FAST LINE UP WITH SPEED MOTOR COMMUNICATION LED INDICATOR LIGHT 12 VDC SLOW STOP Blk Red Blk Red LINE VOLTAGE Wht Red Blk 220~ 120~ Blk Red Blk Red Wht Org Wht Blk SELECTION Blk Red Blk Red...
  • Page 74 12-2 94MS41 Rev. C1 S/W Ver 2.06...

  • Page 75: Control Box Wiring Diagram (Standard 6Kw)

    Control Box Wiring Diagram (Standard 6kW) POWER WHITE DISTRIBUTION BLUE BLOCKS BROWN BLACK GTOOL BLACK (240V) 30ASB VIOLET BLUE (RED, 16GA) BLACK BLACK (240V) YELLOW BROWN 64CT464V00 WHITE YELLOW BLUE BLUE (240V) 12VDC VACUUM PUMPS RELAY COOLING FAN (240V) (240V) EVAPORATOR YELLOW VIOLET...

  • Page 76: Unit Cabling Diagram (Old Style)

    Unit Cabling Diagram (old style) BLOWER 16D2651A00 (120V) (RED, 22 GA) BLOWER (NOSE) 240V (BLACK, 22 GA) (120V) (NOSE) 16D2621B00 (GRAY, 5 COND.) 16D1003A06 (BLACK, 5 COND.) (BROWN, 18 GA) 120V (BROWN, 18 GA) 16D1003A06 (BLACK, 5 COND.) (BLUE, 18 GA) 16D1003A09 (BLACK, 5 COND.) (BLUE, 18 GA)

  • Page 77: Unit Cabling Diagram (New Style)

    Unit Cabling Diagram (New Style) BLOWER (120V) BLOWER 16D2651A00 (NOSE) (120V) (RED, 22 GA) 240V (NOSE) (BLACK, 22 GA) BLR5 BLR6 16D2621B00 (GRAY, 5 COND.) 16D1003A06 (BLACK, 5 COND.) (BROWN, 18 GA) 120V (BROWN, 18 GA) 16D1003A06 (BLACK, 5 COND.) (BLUE, 18 GA) 16D1003A09 (BLUE, 18 GA)

  • Page 78: Unit Cabling Diagram (Ce)

    Unit Cabling Diagram (CE) TERMINAL STRIP (BLACK, 18 GA) 16D2651A00 (RED, 22 GA) (BLACK, 22 GA) 16D2621B00 (GRAY, 5 COND.) 16D1003A06 (BLACK, 5 COND.) 16D4183A04 (BLACK, 18 GA) (GRN/YEL) (18 GA) (RED, 18 GA) 16D1003A06 (BLACK, 5 COND.) LIGHT 16D1003A09 WORK LIGHTS SWITCH (BLACK, 5 COND.)

  • Page 79: Unit Wiring And Tubing Diagram

    NSI 6-32 X .312 HEX THRD SPCR 42HHS9292 CABLE, VAC. PUMP/DELAY 16D2740A00 NSI #6 INTERNAL LOCK WASHER 41-06WLS HARNRESS, PCB PWR -AP30/OV33 16D2651A00 ACCUPRINT PCB- REMOTE 64MI441E-APR HARNESS, SWITCHES -AP30 16D2487A00 NSI 4-32 X 1.0 PPMS ZINC 41-04PPS1.0 HARNESS, ACCESSORY - AP30 16D2469A00...

  • Page 80: Base Assembly Diagram

    Base Assembly Diagram 4 PL 26 4 PL 2 PL 2 PL REF. 2 PL REF. REF. REF. 4 PL DETAIL DETAIL DETAIL REF. REF. 20 PLACES 4 PLACES KNOB, 1/4-20 45KOB05 CHANNEL, HOT AIR (RH) 11D1661B17 2 PL REF. REF.

  • Page 81: 13. Light Source

    13. Light Source Component Layout Lamphead for AL 56, AL56-480 and AL 66 50/60Hz 55SW02 64MV414 62SA83 L1280, L1281 or L1282 63D0142 39BLO14 Shutter Position Switch Trigger Board Shutter Assembly Replacement Lamp Lamp Support Assembly Blower Interconnect Cable To Power Supply 90RF83-C Reflector 31MOT06 PA91...
  • Page 82 Power Supply for AL 56-480 60Hz Power Supply for AL 66 50Hz 13-2 94MS41 Rev C1 S/W Ver. 2.06...

  • Page 83: Ballast/Tap Switch Wiring

    Ballast/Tap Switch Wiring AL 56 Ballast / Tap Switch Wiring TERMINAL STRIP AC IN 10 GA CONTACTOR ORANGE TO CAP. PACK BALLAST BALLAST BALLAST BALLAST YELLOW TO AUTOFORMER RED TO FUSE AUTOFORMER 240 VOLT VOLTAGE SELECTOR SWITCH AL 56-480 Ballast Wiring TERMINAL STRIP 29 (VIOLET).

  • Page 84: Path Of Power To The Pc Board

    AL 66 Ballast Wiring TERMINAL STRIP NO. 29 (VIOLET). AC IN 6 GA. CONTACTOR NO. 20 (ORANGE TO CAP. PACK). BALLAST BALLAST BALLAST BALLAST Path of Power to the PC Board • This section is useful when there is no power reaching the PC board (no LEDs lighted).

  • Page 85: Lamp Voltage

    • 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.

  • Page 86: 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 87 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.

  • Page 88: Opening The Lamp Head

    AL 66 Capacitor Assembly CAPACITOR ASSEMBLY PART # 62D2723B00 FRONT VIEW OF PC BOARD 10µƒ 10µƒ WIRES TO CAPACITOR 4µƒ 12µƒ 16µƒ WIRE COLORS 1) YELLOW 2) BROWN 3) BLUE 4) BLUE WITH WHITE STRIPE 5) ORANGE Opening the Lamp Head •...

  • Page 89: Shutter

    Remove the 6 screws from each side of the lamphead and remove the two endcaps. On LT8 lampheads you can now access the trigger board and shutter position switch that are located at the opposite end from the shutter motor under the air plenum plate. Side View Shutter...

  • Page 90: Shutter Brake

    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.
  • Page 91 • Rotate the sprocket to tighten the other two screws and attach the wires. • The shutter can be tested with the unit open by disconnecting one of the lamp leads and holding the interlock switch. C DO NOT light the lamp without the safety glass or when you are close to the bulb.

  • Page 92: 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 93: 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. •...

  • Page 94: 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 95: 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 96 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 97: 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 98: 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. 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.

  • Page 99: 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 100 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 101: Circuit Diagram (64Mv407V24)

    Circuit Diagram (64MV407V24) 94MS41 Rev C1 S/W Ver. 2.06 13-21...

  • Page 102: Lamphead For All Lights

    Lamphead for all Lights Thermostat Thermostat Shutter Position Switch Safety Glass Switch Shutter Motor Blowers Lamp Trigger Board 13-22 94MS41 Rev C1 S/W Ver. 2.06...

  • Page 103: Al 56 Power Supply 60Hz

    AL 56 Power Supply 60Hz 208/240 VAC INPUT Voltage Tap Switch Toward Selection Board front of unit 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 104: Al 56-480 Power Supply 60Hz

    AL 56-480 Power Supply 60Hz 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...

  • Page 105: Al 66 Power Supply 50Hz

    AL 66 Power Supply 50Hz 220 VAC 50HZ INPUT Voltage Toward Selection Board front of unit Safety Interlock Power Relay Ballast Ballast 3 Amp Slow Blow Socket 16µƒ 12µƒ 10µƒ 4µƒ 10µƒ Fuse Position 2 Position 1 10 blu Medium High Relay Relay...

  • Page 106: Interconnect Cable

    Interconnect Cable WHITE GREEN YELLOW VIOLET BLUE BROWN ORANGE HEAT SHRINK BLACK WHITE GREEN YELLOW VIOLET BLUE BROWN ORANGE HEAT SHRINK BLACK 13-26 94MS41 Rev C1 S/W Ver. 2.06...

  • Page 107: 14. Printing Light Check List

    14. Printing Light Check List Check List for Printing Light Troubleshooting and Service C In order for this check list to be effective it must be followed step by step. 1) Disconnect the integrator/timer from the power supply. This will make sure that a faulty integrator or cable is not responsible for the malfunction and also eliminate a bad DIN socket on the p.c.board.
  • Page 108 • 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.
  • Page 109 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.
  • Page 110 60hZ 6kW with L1280 LAMP ORANGE YELLOW BROWN BLUE #1 BLUE #2 IDLE/LOW 700+ 360-380 700+ 700+ 700+ MEDIUM 730+ 380-410 380-410 730+ 700+ HIGH 750+ 415-445 415-445 415-445 415-445 50hZ 6kW with L1280 LAMP ORANGE YELLOW BROWN BLUE #1 BLUE #2 IDLE/LOW 700+...
  • Page 111 ‡ The voltage readings described in the following are typical of 5kW light sources see voltage chart to find high and low values for others. 10) If a reading remains high (500V~ or more see note ‡) and it should be low (less than 300V~ see note ‡), the capacitor is not being pulled into the circuit.
  • Page 112 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 113: 15. Fault Trees

    15. Fault Trees No Strike Fault Tree Does shutter rotate when light turned on? Are any LED's Check Safety Glass Good and Lever lit on the PC Board? Good Reinstall safety glass Test 1 Is power relay pulling in? Go to test 2 after Go to test 1 checking PC Board fuse...

  • Page 114: Shutter Rotation Fault Tree

    Shutter Rotation Fault Tree Is the lamp lit? Does shutter rotate at any time? Is LED #D17 lit The shutter will on PC Board not open for an exposure w/o the lamp being Does shutter seam lit. Go to the When LED #D17 is lit, check for to bind during No Strike Fault...

  • Page 115: 16. Parts List

    16. Parts List Part Number Description Qty. per unit 62APCL01 Assy Kit Base Expo AP30 1 EA 11D249 H D1 Lamphead Heat 2 EA 11D3395A17 Deflector, Air 2 EA 11D3945A62 SLM Guide lt block upper 1 EA 11D3945B62 SLM Guide lt block upper 1 EA 11D3994A07 External Reflector, AP30...
  • Page 116 55SW45-GO Button, white "GO" 1 EA 55SW45-STOP Button, white "STOP" 1 EA 56TMP01 Temperature Control 1 EA 62ATA AccuPrint Tray Assembly 2 EA 11D1726A17 Frame, glass 1 EA 11D2392A62 Catch - Latch Handle 1 EA 11D2422A62 Top, Hinge, Glass Tray...
  • Page 117 Part Number Description Qty. per unit 11D2426A17 Divider, nose AP30 Left 1 EA 11D2426B17 Divider,nose AP30 Right 1 EA 11D2427A08 Air Director No.1, Nose 1 EA 11D2433A08 Air Director No. 2 - Nose 1 EA 11D2438A08 Air Director No 3 - Nose 1 EA 11D3255A07 Reflector,Work Lt.2 Lamp...
  • Page 118 Part Number Description Qty. per unit 62D3202A00 Assy,Ctl Bx 8K 220V~ 50Hz 1 EA 16D2641A00 Harness, Cntrl Bx 1 EA 16D3208A00 Harness, Cntrl Bx -GTools 1 EA 31MSC02 Motor, speed control-KB 1 EA 32PSF01 Power Supply, Open Frame, 1 1 EA 32TRC01 Autoformer 208-240V~ 1 EA...
  • Page 119 Part Number Description Qty. per unit 52TS19 Power Dist.Block 3 pole 4 2 EA 56FUS04 Fuse, 5A/250V Slow Bl 3AG 2 EA 56FUS14 Fuse 15A 250V 2 EA 56FUS15 Fuse, 3A 250V 3AG Slow Blow 1 EA 56FUS16 Fuse, 1/2A 250V 3AG Slow Bl 1 EA 56FUS20 Fuse, 20A 250V, Slow Blow 3...
  • Page 120 Part Number Description Qty. per unit 12D2476A00 Ball Stud, Shortened, Gas 2 EA 43SPR12 Spring 7/16 x 9/16 Compr. 2 EA 44HDL03 Handle, 6". Alum 1 EA 62MFOA01 Mylar frame outer assy 1 EA 11D4306A07 Bracket right angle 4 EA 12D4473A76 Frame mylar outer front 1 EA...
  • Page 121 Part Number Description Qty. per unit 62D2726A00 Assembly, Capacitor Pack 1 EA 64MV407V24 Prnt Light Ctrl PCB w/Min 1 EA 62CL56-480 Complete 6K/480 60Hz Power Sup. 2 EA 11D0932A02 Cover, AL54/64 1 EA 11D0933A02 Divider P/S narrow body 1 EA 11D0934A02 Component Wall 1 EA...
  • Page 122 62LHK01 Switch Assembly 1 EA 63D3669A00 Idler, Arms Assy LT8 1 EA 64MV414V01 Trigger bd tested 6K 1 EA 62LHK02-83 Roller Assembly AL 83 1 EA 62SA83-B Shutter ass'y 8K SE Rev. 1 EA 16-8 94MS41 Rev. C1 S/W Ver 2.06...

  • Page 123: 17. Warranty

    17. Warranty OLEC Limited Warranty OLEC equipment is warranted against defects in material for ONE (1) Year from date of purchase. Faulty parts will be repaired, replaced, or purchase price refunded at OLEC's option, for the original Buyer, provided the parts have been replaced by authorized personnel and are returned prepaid to the OLEC factory in Irvine, CA.
  • Page 124 Corporation 17112 Armstrong Avenue, Irvine Ca U.S.A. 92614 U.S.A. (949) 399-6500 Fax (949) 399-6501...

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