BGK AutoCure 5000 Assembly And Operating Manual

Portable repair arm

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January 2016

AutoCure 5000 Portable Repair Arm

Assembly and Operating Manual

AC5-2116-380

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Summary of Contents for BGK AutoCure 5000

Page 1 January 2016 AutoCure 5000 Portable Repair Arm Assembly and Operating Manual AC5-2116-380...
Page 2: Table Of Contents
Contents Warnings ....................................3 Equipment Safety Guidelines ..............................4 Operating Instructions ................................5 Temperature Controller Single or Double Ramp Operation (See Figure 1) ................ 5 Lamp Installation and Replacement Instructions ........................7 Heater Position Instructions ..............................9 Maintenance ..................................12 Pivot Points ..................................
Page 3: Warnings
Warnings DANGEROUS VOLTAGES ARE PRESENT IN THIS EQUIPMENT! CONTACT WITH LIVE PARTS COULD CAUSE SERIOUS INJURY OR DEATH! CONNECTION, INSTALLATION, MAINTENANCE, ADJUSTMENT, SERVICING AND OPERATION TO BE DONE BY QUALIFIED PERSONNEL ONLY. ENSURE THAT EQUIPMENT IS COMPLETELY AND PROPERLY GROUNDED BEFORE APPLYING SUPPLY POWER AND BEFORE EQUIPMENT OPERATION.
Page 4: Equipment Safety Guidelines
Equipment Safety Guidelines (Read and understand this manual before operating equipment.) CAUTION!!  Turn power off at source before servicing equipment or attempting any interior maintenance.  If the main power switch is ON, voltage may exist at the lamps even though the lamps are not lighted. A FATAL ELECTRICAL SHOCK COULD POSSIBLY RESULT! ...
Page 5: Operating Instructions
Operating Instructions Temperature Controller Single or Double Ramp Operation (See Figure 1) Single Ramp Operation: The temperature ramps in a predetermined amount of time from ambient to a set point temperature and holds at that temperature for a required amount of time. Double Ramp Operation: The temperature ramps in a predetermined amount of time from ambient to the first set point temperature and holds at that temperature for a required amount of time, it then ramps in a predetermined amount of time to a second set point temperature and holds at that temperature for a required...
Page 6 Setting the Temperature Controller Parameters (See Figure 2) Single Ramp 1. Turn power on. 2. Turn positioning beam on and position heater. 3. Set controller parameters 4. Hold the button for 1-2 seconds a. Set rp1 (ramp time) in minutes Press b.
Page 7: Lamp Installation And Replacement Instructions
Lamp Installation and Replacement Instructions Danger!! Turn power off at source before removing end covers and servicing lamps. A fatal electrical shock could possibly result. Precautions for Handling Quartz Infrared Lamps Do not handle infrared lamps with bare hands. Remove any contaminations with alcohol and a clean, soft cloth. Contaminations on quartz tubes cause the quartz to overheat, which may lead to premature lamp failure.
Page 8 Make sure lamp sleeving is pushed all the way into Lamp Support (outer reflector) ceramic end of lamp End Cover Ensure all bare wire is Heater Power Cord contained up to terminal Ceramic terminal (trim lead if necessary) in heater head...
Page 9: Heater Position Instructions
Heater Position Instructions Important: Precautions and Instructions General Instructions (Read All) The "Positioning Beam" (red dot) is an aid for proper placement of the heat sensor. The heat Sensor reads an area of 0.8 to 1.2" diameter depending on the heater's distance from the surface.
Page 10 mirrors, door handles, interior materials, etc.) in the heating area must be masked or removed during the heating cycle. High temperature/reflective masking material approved for this type of application is required. When curing small areas, it is not recommended to use heat masking around the area except to cover heat sensitive materials.
Page 11 When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair. NOTE: These are procedures that give reliable results for most repairs. Unusual or complex repairs might need modified procedures. Contact BGK service for assistance.
Page 12: Maintenance
Maintenance The AutoCure™5000 will require some basic maintenance when used on a regular basis. Failure to do so may degrade the performance of the unit. Disconnect main power at the source before performing any maintenance procedures. Pivot Points 1. Single head units have three (3) castle nut/spring combinations and two (2) shoulder bolts with Nylock nuts. If pivot points become loose, heater positioning will not be maintained.
Page 13: Trouble Shooting Guide
Trouble Shooting Guide Heater Power Problems Problem Heater lamps come on immediately when disconnect is closed. Possible Cause and Corrective Action  With power OFF, measure the resistance from the lamp wires to ground. The measurement should be more than 100 K ohms. If it is less than 100 K, check the lamp wiring and heater head for shorts to ground. Check for a bad firing circuit board or a shorted SCR by: exchanging the firing circuit board with one from a known good control.
Page 14: Temperature Problems
Problem No output signal from temperature controller. Possible Cause and Corrective Action  Check that the set point (bottom display) is higher than the process temperature (top display).  Check the 0-5v input to the temperature controller at pins 9 & 10. If the 0-5v signal is not present, confirm that the Raytek pyrometer is functioning.
Page 15: Temperature Controller Error Codes
 Check for loose connections on the heat sensor (pyrometer) wiring.  While the heater is running at temperature, gently wiggle the pyrometer cable and have someone watch for sudden temperature changes. If this happens – replace the cable. Problem Positioning Beam does not work Possible Cause and Corrective Action Check that the power supply board is supplying approximately 3.25 vdc (TB 3).
Page 16: Service Instructions
Service Instructions Replacement of new Pyrometer Sensor 1. Open Cover for Raytek Sensor, loosen and remove wire from terminals shown below. 3. Undo wires from two wire nuts, as shown. 4. Loosen nut on pyrometer side, and remove wires from housing. 5.
Page 17: Replacement Of Pyrometer Controller
Replacement of Pyrometer Controller 1. Open Housing and loosen 4 terminals to remove pyrometer. Loosen 4 terminals to remove connection to AutoCure Arm as shown below. 2. Open New Housing, and loosen 4 terminals as shown above to remove pyrometer. 3.
Page 18 THIS PAGE INTENTIONALLY LEFT BLANK...
Page 19: Mechanical Drawings And Parts Lists
Mechanical Drawings and Parts Lists Pyrometer...
Page 21 Pyrometer Parts Listing Item Number Quantity Part No. Description 42936 SENSOR AC-65427 LASER AC-61229 PLATE, INTERMEDIATE AC-61228 INSULATOR, PYROMETER AC-61227 MOUNT, INSULATOR, PYROMETER AC-611232 HOUSING, PYROMETER AC-61230 COVER, PYROMETER AC-200099-3 SCREW, MACH, FL.HD, SLOT, 8-32 X 2.750 AC-200032 STANDOFF, HEX, 8-32 X .750 AC-13938 WASHER, LOCK, EXTERNAL TOOTH, #8 SST AC—10142...
Page 23 Pyrometer parts Listing Continued Item No. Qty. Part Number Description 2 X 2” TR-SSEM-283 SHRINK TUBING AC-200031 FEMALE CONNECTOR AC-200030 MALE WIRE CONNECTOR AC-200033 CABLE SLEEVE 28” AC-200052-1 MESH 35” AC-200077 BROWN WIRE 35” AC-200078 GREEN WIRE 72591-01 WHITE CABLE SLEEVE AC-200034 WIRE NUTS...
Page 25: Parts Listing - Pyrometer
Assembly Notes: 6. WRAP COPPER TAPE 2-3 TURNS FOR LOOSE RUNNING FIT 7. APPLY THERMAL JOINT COMPUND USING APPLICATOR AND SPREAD ACROSS ENTIRE CIRCUMFERENCE 8. CENTER PYROMETER AND LASER TO THROUGH OLES WHILE ASSEMBLING PLATES 9. STRIP BACK 5/16” MINIMUM 10.
Page 26: Heater Head Assembly (Ach5-2116)
Heater Head Assembly (ACH5-2116)
Page 27 Lamp Head Assembly Parts List Item No. Qty. Part No. Description AC-200098-1 AVK, 1ST GRIP, #8 AC-64095 PLATE,REINFORCEMENT,HANDLE AC-59449 REFLECTOR,OUTER,2 LAMP,1600 AC-13938 WASHER,LOCK,EXTERNAL TOOTH,#8,SST AC-61925 BRACKET,PIVOT,HEATER,2 LAMP 39331 LAMP,IR,1600W/240V,CER,CL,19.7OAL,16.0L AC-50869 WASHER,1.5 OD X .531 X .125 THK AC-63940 J-BOX,HEATER AC-64237 MOD,HEX BOLT,1/2-13 X 2.00 AC-54585 PIN,COTTER,1/8 X .750...
Page 28 2116 Lamp Head Assembly Parts Listing Item No. Qty. Part Number Description AC-61924 SKIN,2 LAMP,1600 AC-59445 REFLECTOR,INNER,2 LAMP,1600 AC-59463 COVER,END,2 LAMP,3" CENTER AC-200098-1 AVK, 1ST GRIP, #8 AC-61923 INSULATOR,END COVER,2 LAMP,3" CTR AC-200097 RIVET, BLACK, ALUMINUM, #43 AC-59449 REFLECTOR,OUTER,2 LAMP,1600 AC-58833 TERMINAL,3 POLE,CERAMIC,600V AC-50686-3...
Page 29 Parts List ITEM PART NUMBER DESCRIPTION AC-61924 SKIN,2 LAMP,1600 AC-59445 REFLECTOR,INNER,2 LAMP,1600 AC-59463 COVER,END,2 LAMP,3" CENTER AC-200098-1 AVK, 1ST GRIP, #8 AC-4002 10-32 AVK,1ST GRIP AC-64095 PLATE,REINFORCEMENT,HANDLE AC-4012 3/8-16 AVK,1ST GRIP AC-61923 INSULATOR,END COVER,2 LAMP,3" CTR AC-200097 RIVET, BLACK, ALUMINUM, #43 AC-59449 REFLECTOR,OUTER,2 LAMP,1600 AC-58833...
Page 30: Ac5 Stand
AC5 Stand 49 42 18 72 58 25...
Page 31 CLIP, SAFETY TO GAS SPRING AC-200091-2 SCREW,TRUSS HD,#8-32X3/4",SST AC-60834 PLATE MOUNT, CONTROLLER AC-48904 GAS SPRING AC-200122 BGK FINISHING SYSTEMS LABEL (ARM) AC-3741 SCREW, TRUSS HEAD,#10-32 X .500 SST AC-59981 KIT, ACTUATOR RELEASE AC-3903-2 NUT,HEX,FLG,SERRATED, #10-32 AC-200099-1 SCREW FLAT HEAD 8-32 X 3/8 AC-47643 BUSHING, HEYCO 1”...
Page 32 CAUTION CAUTION 59 25 SECTION H-H SECTION N-N SO CORD & CONTROL CABLE MUST BE TO THE SCALE 1 / 8 OUTSIDE OF THE SO CORD SPACER - NOT BETWEEN THEM. DETAIL P SCALE 1 / 4 DETAIL E...
Page 33 AC5 Parts List Item No. Qty. Part No. Description AC-2455 SCREW, TRUSS HD,#10-32 X 3/4 AC-3481 SCREW, HEX HD,1/4-20 X 2-1/4" AC-3672 1/2 X 4.25 SHOULDER SCREW TABLE-B COLUMN-BC AC-4033 STUD,BALL TABLE-B COLUMN-B1 TABLE-B COLUMN-B1 SPRING AC-5780 BUSHING,HEYCO,7/8" AC-10142 8-32 SST TRUSS HEAD AC-12695 1/4 X 5/8 FLAT HEAD AC-39917...
Page 34 SEE DETAIL "F" XXX VOLTS AC5000 AUX. HEATER OFF ON US PATENT NO. IMPORTANT READ AND UNDERSTAND OPERATORS MANUAL BEFORE INSTALLING OR OPERATING THIS EQUIPMENT...
Page 35 AC5 Parts list Item No. Qty. Part Number Description AC-3502 SCREW, HEX CAP,3/8-16 X 5.000 AC-200118-2 BOLT, SHOULDER,5/16 X .625 AC-3772 1/4 FLAT WASHER TABLE-B COLUMN-BC AC-4033 STUD,BALL AC-200090-4/AC-47643 BUSHING,HEYCO,1" AC-3775 WASHER FLAT 1/2" ID SST AC-59981 KIT ACTUATOR/RELEASE F711-022 CALIBRATION LABEL AC-52841 SPACER,ARM TUBE...
Page 36 CAUTION POSITION LEVER REF. ABOVE ITEM CENTERED (AC-59981) DETAIL F...
Page 37 Item Number Qty. Part Number Description TABLE-B COLUMN-BC AC-4033 STUD,BALL AC-52841 SPACER,ARM TUBE AC-61219 BAFFLE,ELECTRICAL CORD AC-61221-1 BRACKET,GAS SPRING TABLE-C, COLUMN-CD BRACKET,POST TABLE-AAA, COLUMN-AA POST MOUNT, CONTROLS TABLE-C, COLUMN-CA ARM,UPPER,EXTENDED AC-48081 WASHER, FLAT ½ SST AC-200185-2 LABEL AC5000 UNIT...
Page 38 CAUTION CAUTION DANGER CAUTION DETAIL M SCALE 1 / 4 DANGER LETHAL SHOCK SECTION L-L SCALE 1 / 8...
Page 39 Item Part Number Description TABLE-B COLUMN-BC AC-4033 STUD,BALL AC-12695 1/4 X 5/8 FLAT HEAD AC-3775 WASHER FLAT 1/2" ID SST AC-49155 NUT METRIC GAS SHOCK AC-59981 KIT ACTUATOR/RELEASE AC-59981 KIT ACTUATOR/RELEASE AC-4090 WASHER,FLAT,#10,SST 7734-07 5/16 REG L/W ZINC AC-61243 ELECTRICAL SUB-PANEL AC-200038 INSULATOR...
Page 40 DETAIL K SCALE 1 / 4 SECTION J-J SCALE 1 / 8...
Page 41 Item Qty Part Number Description AC-4025 NUT,HEX,NYLON LOCK,1/4-20 AC-3905 NUT FLANGE 3/8-16 00412 AVK 3/8-16 AC-4033 STUD BALL AC-52823 STUD,FEMAIL THREAD,5/16-18 X 1.000 DEEP AC-63224 INSULATOR, ELECTRICAL SCR AC-200212-2 CAUTION LABEL W/O ARROW AC-200038 INSULATOR AC-200097 BLACK ALUMINUM RIVETS Parts List ITEM PART NUMBER DESCRIPTION...
Page 42 COUNTER WEIGHT BOLT 67 1 SET AC-200112 LABEL SET AC5 UNIT COMPLETE 1 AC-200185-2 LABEL AC5000 UNIT 2 AC-200122 BGK FINISHING SYSTEMS LABEL (ARM) 2 AC-3741 SCREW, TRUSS HEAD,#10-32 X .500 SST 2 AC-3903-2 NUT,HEX,FLG,SERRATED, #10-32 1 AC-200119 5/16 HEX NUT...
Page 43 1 7969-16 LOCTITE 4 20827-00 PANDUIT TYWRAP MOUNT 4 27141-044 TYWRAP SECTION A-A BLACK ATTACH #8 RING TERMINAL TO GROUND WIRE AND USE THIS SCREW TO MOUNT TO LAMP SUPPORT DETAIL B WHITE SO CORD TERMINATION DETAIL TYP (3) HEATER HEADS...
Page 44 OPTICAL PYROMETER AND SIGHTING DEVICE Parts List ITEM PART NUMBER DESCRIPTION 101861 ASSY,AC5,CRS,CRL,CTE,STE 103622 ASSY,HEATER,2306...
Page 45: Ach5-2116 Lamp Wiring Schematic
ACH5-2116 Lamp Wiring Schematic...
Page 46: Spare Parts Recommendations
This warranty shall not apply to any equipment manufactured by BGK Finishing Systems which shall have been repaired or altered outside its factory in any way so as to affect its use and operation, as determined by BGK Finishing Systems nor shall it apply to any such equipment which has been subject to misuse, negligence or accident, or has been operated contrary to printed instructions.