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Carlisle BGK AutoCure 6000-2216 Assembly And Operating Manual

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AutoCure 6000 - 2216 Overhead Heater
Assembly and Operating Manual

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Summary of Contents for Carlisle BGK AutoCure 6000-2216

  • Page 1 AutoCure 6000 - 2216 Overhead Heater Assembly and Operating Manual...

  • Page 2: Table Of Contents

    AC6-2216 TABLE OF CONTENTS WARNINGS AND DANGER ................... 4 WARNING, CAUTION & NOTE ................5 • EQUIPMENT SAFETY GUIDELINES CAUTION ....................... 6 • Lamps, Pyrometer Positioning Beam, Environment ..........7 • OPERATING INSTRUCTIONS Temperature Controllers Single or Double Ramp Operation ........8 •...
  • Page 3 AUTOCURE MODEL NUMBERS ................. 47 AC6-2216-480-SP ....................47 • • Electrical Schematic (2 pgs) ............... 48-49 Spray/Bake ..................... 50 • Heater Heads (5 pgs) ................. 51-55 • Recommended Spare Parts ................56 • BGK-CARLISLE FLUID TECHNOLOGIES CUSTOM PRODUCTS WARRANTY ..57...

  • Page 4: Warnings And Danger

    1. Warnings and Danger 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 5: Warning, Caution & Note

    In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows: NOTE ! WARNING ! WARNING ! CAUTION in minor ! WARNING Read the following warnings before using this equipment READ THE MANUAL PINCH POINT HAZARD Moving parts can crush and cut.

  • Page 6: Equipment Safety Guidelines

    2. Equipment Safety Guidelines (Read and understand this manual before operating equipment.) CAUTION!! 1. Turn power off at source before servicing equipment or attempting any electrical or mechanical maintenance, especially lamp replacement. 2. If the control panel main power switch is ON, voltage may exist at the lamps even though the lamps are not emitting light.

  • Page 7: Lamps, Pyrometer Positioning Beam, Environment

    LAMPS All lamp end covers and grills must be installed before operating and using the repair arms to avoid electrical shock. The lamps of the repair arms have similarities to a standard incandescent light bulb. During the repair arm curing cycle, the repair arm lamps can sometimes emit bright light similar to a standard incandescent light bulb.

  • Page 8: Operating Instructions

    3. 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.

  • Page 9: Setting The Temperature Controller Parameters

    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 10: Lamp Installation And Replacement Instructions

    4. Lamp Installation a nd 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.

  • Page 11: Heater Position Instructions

    5. Heater Position Instructions Important: Precautions and Instructions General Instructions (Read All) 1. 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 12: Heat Masking

    Heat Masking 1. Any heat sensitive materials or surfaces (including plastic, rubber, trim, pin stripes, decals, light lenses, 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. 2.
  • Page 13 Positioning/Set-Up of an arm on roof posts (heavy reinforcements/multiple metal thickness) 1. Follow any of the instructions previously mentioned in the precautions and instructions section. 2. Position heaters parallel to the surface, the length of the heater along the length of the roof post.

  • Page 14: Yellow Pendent (For Overhead Arm Movement)

    Yellow Pendent (for overhead arm movement) The yellow pendant has a button labeled “Beam On” and “Start”. Toggling the “Beam on” activates the position beam and toggling the start button will initiate the heating cycle. Refer to “Setting the Temperature Controller Parameters” in the Operating Instructions for further instructions.

  • Page 15: Maintenance

    6. Maintenance The AutoCure™6000 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. Actuator 1. Periodically check clevis ends for wear, cracks or distortion. 2.

  • Page 16: Troubleshooting Guide Heater Power Problems

    7. Troubleshooting 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.

  • Page 17: Temperature Controller Problems

    Temperature Controller Problems Problem Temperature controller has no display. Possible Cause and Corrective Action Check the supply voltage (24 VAC) to the unit at terminals 11 and 12. If voltage is present, replace the controller. If voltage is not present, check source of power (fuses, transformers, wiring, etc.) Problem No output signal from temperature controller.

  • Page 18: Temperature Problems

    Temperature Problems Problem The heater reaches set-point temperature, but the paint isn't cured properly or is darkened, or the heater does not reach set-point temperature. Possible Cause and Corrective Action • Read the instructions in the manual on how to position and run the heater. •...

  • Page 19: Temperature Controller Error Codes

    8. TEMPERATURE CONTROLLER ERROR CODES Display Problem Actions Err.H Open Sensor Check sensor,wiring, and input Err.L Reversed Sensor Check Sensor polarity LPbr Correct problem and Loop Break Reset controller 0100 Checksum Error Press Any Key to 0101 RAM Error perform a soft reset 0202 Defaults Loaded and reinitialize...

  • Page 20: Pyrometer Assembly (Drawing# Ac-61231

    ,:I, REVISION HISTORY DESCRIPTION DATE APPROVED UPDATEDBOM 18943 8/16/12 ADDED NEW PYROMETER 19524 8/16/13 CHANGED 6655-01 TO AC-200077, 6655-05 20079 1/21/15 TO AC-200078 CHANGED QTY OF #18 FROM 2 TO 1 AND 20168 3/13/15 REMOVED REF QTYS ON PAGE 2 �...
  • Page 21 NOTE 15 NOTE 6&7 REFERENCE TABLE ONLY SEE FIRST PAGE FOR PART NUMBERS AND QUANTITIES REFERENCE TABLE ITEM PART NUMBER DESCRIPTION 42936 SENSOR AC-6S427 LASER AC-61229 PLATE,INTERMEDIATE AC-61228 INSULATOR,PYROMETER AC-61227 MOUNT,INSULATOR,PYROMETER AC-61232 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...

  • Page 24: Service Instructions For Pyrometer

    10. SERVICE INSTRUCTIONS FOR PYROMETER RAYTEK PYROMETER REPLACEMENT CALIBRATION VERIFICATION ON OVERHEAD OR PORTABLE REPAIR ARM USING A HAND HELD PYROMETER (Raytek MID Pyrometer with BGK Temperature Controller ONLY) Purpose: This procedure is to be completed to verify the temperature display is correct on the BGK temperature controller.

  • Page 25: Old And New Raytek Units (2

    Shown below are photos of the differences between sensors: OLD UNIT (RAYMID10LT) Sensor Connections – Brown, white, green and yellow remain the same colors between old and new units. Power Connections – Black Wire – GND next to +8-32V Red Wire – +8-32V White Wire –...
  • Page 26 The new unit is hinged as shown in Figure 1-3. Performance - the new sensor is equal, a direct replacement to the older unit. There is no change in emissivity or response time between units, they are equal. Figure 1-3 The front cover over lay is solvent resistant.

  • Page 27: Replacement Of New Pyrometer Sensor (2

    Replacement of New Pyrometer Sensor 1. Open Cover for Raytek Sensor, loosen and remove wire from terminals shown below. 2. Undo wires from two wire nuts, as shown. 3. Loosen nut on pyrometer side, and remove wires from housing. 4. Open enclosure on top of heat sink, and isolate wires for laser (black/red leads) 5.

  • Page 28: Replacement Of Pyrometer Controller (2

    9. Install new pyrometer into heat sink, making sure to adjust fit using varnish tape wrapped on the outside. 10. Install heat sink onto lower insulators 11. Install intermediate plate 12. Crimp laser leads to leads in pyrometer bundle – red to green and brown to black. 13.
  • Page 29 7. Once installed, insert leads for thermocouple into terminals indicated in Step 1. 8. Insert and tighten down to 20 Nm. 9. From AC arm, insert nut, AC-200104 Nylon washers and Grommet, similar to diagram in step 10. Insert leads into terminals indicated in step 1. Reconnect leads into wire terminals. 11.

  • Page 30: Verification / Calibration Procedure

    Verification / Calibration Procedure Position the good condition testing surface (door, fender, etc.) in front of the heater head. Adjust the heater head about 10” away from the painted test surface. (Approx. an open hand width.) 2. On the good condition, scrap painted testing surface with a pen, pencil or grease pen make a small “X”...

  • Page 31: Begin Verification / Calibration Cycle

    Begin Verification / Calibration Cycle 1. Verify that the Ramp 1 and Ramp 2 (if used) cure temperatures (ct1 and ct2) settings are at the proper temperature set points used for the area. 2. Press the “Cycle Start” button two times with in two seconds. Lamp cycle should begin with a ramp-up to the final cure ramp settings.

  • Page 32: Adjusting Raytek Calibration Procedure (3

    Adjusting Raytek Calibration Procedure 1. Verify correct settings on Raytek box – Press the page button until “BOX SETUP” is displayed. OUT2 Mode Using the arrow keys until “OUT2 Mode” is displayed. Verify the setting for mode is 0-5V. If the setting is incorrect, press the enter button and the setting should be highlighted.
  • Page 33 Temperature Unit Using the arrow keys until “Temperature Unit” is displayed. Press the enter button and the setting should be highlighted. Press the arrows keys until the correct setting is displayed, ˚F or ˚C. After settings is correct, press the enter button to save setting.

  • Page 34: Begin Calibration Cycle

    3. On the scrap painted testing surface with a pen, pencil or grease pen make a small “X” or dot where the surface is mainly flat and there are NO reinforcements or multiple thickness metals within about 12 inches of the mark. 4.

  • Page 35: Calibration Adjustment

    Calibration Adjustment 1. Depress the page button until “BOX SETUP” is displayed. Press the arrow buttons until “OUT2 high temp” is displayed. Press the enter button to allow the temperature setting to be changed. 2. If the reading on the handheld pyrometer is higher than that of the process temperature on the temperature controller, decrease the temperature number using the down button .

  • Page 36: Lock" Out The Comm Box

    “Lock” out the Comm Box 1. Press the page button until “BOX SETUP” is displayed. Key Enter Lock 2. Using the arrow keys until “Key Enter Lock” is displayed. Verify the setting “YES”. If the setting is incorrect, press the enter button and the setting should be highlighted.

  • Page 39: Junction Box

    Parts List ITEM TYPE PART NUMBER DESCRIPTION 6" CUT DIN RAIL A8066CH J-BOX,8X6X6 A8P6 INNER PANEL,8X6 AC-200058 AB IEC ONE CIRCUIT FEED THROUGHT BLOCK AC-200059 AB END ANCHOR AC-200060 AB END BARRIER ITEM 1 AC-200061 AB IEC ONE CURCUIT FEED THROUGH GND BLOCK ITEM 5 ITEM 6 ITEM 4...

  • Page 40: Mechanical Drawings/Parts List (3

    ..MODIFICATIONSANDI.FDATES OONlROLSNOWONUNfT:SEEIAM.FI..E at.oHGEDACT\JATORBRKTFORMORETRA ..., ..., REPUICED�N-;NXlEDlllHB'IACOvER Ir---� REPI.ACEACTW.TOR;RE\IMTGPARTS �- ---+ -- DETAIL D " " """" � AC,3IOS " DETAIL C " 1.USE ACI DRAWING FOR ASBY OF AC-182'8 " 0 - VIEWO<ANGE 2.APPLY THREAD LOCK BLUE 7NMl3 £...
  • Page 41 REMOVET1'11SBOLTAFTERINSTAI..I.ATION � DETAIL J SCALE0.40: 1...
  • Page 42 AVK LOCATIONS (AC6) AVK-TMLE <m 3MOREOl'ITEM21ARE LOCf,ffOONCf'P.810EOI' ITEM 101 ISPI..ACEON�INNER SIDEONTHE PANB.. WHEN INSTALLING A\IK ALI.OWINGTI-E ELECTRIOO.P#IEL TO SIT UPOFF THE SURf"ACEOF Tl£ INNER PANEL OF ITEM 47 ARM,MAIN DETAIL G SCALE 1 /2 DRAWINGNO: """" NEXTAlJB'f: PNUNO:...

  • Page 47: Autocure Model Numbers

    AUTOCURE MODEL NUMBER AC6-2216-480-SP...

  • Page 50: Spray/Bake

    **THIS DOCUMENT APPLIES IF YOUR SYSTEM IS EQUIPPED WITH A SPRAY/BAKE SWITCH Small junction box to interlock controls during spraying. Maximum Load: 40A FLA, 50A Resistive Four configurations: 240V 1ø 480V 1ø 240V 3ø 480V 3ø 2 Modes of Operation Local: There is a 2 position switch on the front of the box to switch from Spray to Bake.

  • Page 51: Heater Heads (5

    REVISION HISTORY X2 #14 PINCH POINT DESCRIPTION DATE APPROVED X2 #14 UPDATED BOM ADDED ENGINEERING 19112 1/30/13 NOTES 19887 CHANGED #28 TO AC-50686-3 7/7/14 11/12/2015 20524 ADD NOTES TO SHT 4 REF SHEET 5 OF 5 FOR ASSY DETAIL OF PWER AND GRND CONTROL DETAIL C DETAIL D CAUTION...
  • Page 52 PRESS NUT INTO PLACE W/PRESS TOOL ON WORK BENCH TYPICAL (X4) TYPICAL JOB NO REL BY ENG REL SHOP VENDER P.O. NO PROD REL TYPICAL TOLERANCES DRAWN: SCALE: THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS 2 PLACE FRACT. IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT ...
  • Page 53 TYPICAL TYPICAL TYPICAL NUMBER PART No. DESCRIPTION AC-200098-1 AVK 8/32 AC-4002 AVK 10/32 BLACK, RIVET AC-200097 AC-4012 AVK 3/8 TYPICAL TYPICAL TYPICAL TYPICAL JOB NO REL BY ENG REL SHOP VENDER P.O. NO PROD REL TOLERANCES DRAWN: SCALE: THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS 2 PLACE FRACT.
  • Page 54 PARALLEL AC-200048 13" AC-200048 13" REMOVE ALL UNUSED HARDWARE FROM CIRCUITS INSIDE CERAMIC BLOCK AC-200192 GROUND WIRE REMOVE ALL UNUSED HARDWARE FROM CIRCUITS INSIDE CERAMIC BLOCK SERIES AC-200048 25" AC-200048 13" AC-200048 13" REMOVE ALL UNUSED HARDWARE FROM CIRCUITS INSIDE CERAMIC BLOCK AC-200192 GROUNDWIRE REMOVE ALL UNUSED HARDWARE FROM CIRCUITS INSIDE CERAMIC BLOCK...
  • Page 55 (X2 ASSY) REFERENCE SHEET ONE JOB NO REL BY ENG REL SHOP VENDER P.O. NO PROD REL TOLERANCES DRAWN: SCALE: THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS 2 PLACE FRACT. IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT ...

  • Page 56: Recommended Spare Parts

    RECOMMENDED SPARE PARTS TO ORDER: CONTACT: SPARE PARTS ORDER ENTRY PHONE: 1-800-726-8097 E-MAIL: orderentry@CarlisleFT.com AC6-2216-480-SP Spares Reference Number Part Number Part Description CON110, CON11 005898 CONTACTOR, 40A, 2-POLE, 24 COIL FU105 E-178 FUSE,2A,600V,CLASS CC FU109A, FU109B AC-200046 FUSE,2A,250VAC,TIME DELAY FU109C, FU109D AC-200045 FUSE,10A,250VAC,TIME DELAY FU101A, FU101B, FU104A,...

  • Page 57: Bgk-Carlisle Fluid Technologies Custom Products Warranty

    WARRANTY POLICY This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid Technologies, will void all warranties. Failure to reasonably follow any maintenance guidance provided, may invalidate any warranty.

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