Page 1 AP30 - 5000 AP30 - 8000 High Resolution Printer Service Manual 94MS36 Rev. F2 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. 94MS36 Rev. F2 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 Optional reflectors ............... 1-2 Intensity ..................1-2 Cooling ..................1-2 Exhaust ..................1-2 Room Air Supply ................. 1-2 Water Drain ................. 1-2 Electrical specifications and connections ........
Page 4 Selecting a Memory Location............ 3-10 Quick Keypad ................3-10 Entering an Exposure Time ............3-10 Setting the Light Intensity ............3-11 Making an exposure..............3-11 Blank frame cycle ..............3-11 Error Handling System .............. 3-12 Diagnostics Output Diagnostics ..............4-1 Output Functions Check ..............
Page 5 Exposure Trays Mylar® Replacement ..............9-1 If Mylar® Pulls Out of the Frame ..........9-1 Outer Frame Replacement ............9-1 Tray Assembly Drawing .............. 9-3 Mylar Frame Assembly ............... 9-5 Gas Strut Removal ............... 9-7 Replacing the linear bearings ............9-7 Frame Glass Replacement ............
Page 6 Shutter Motor ................13-17 Installing the Motor ..............13-17 Shutter Removal ..............13-18 LT1 Shutter Assembly Drawing ..........13-19 LT8 Shutter Assembly Drawing ..........13-21 Idle Setting................13-22 Lamp Head Blowers ..............13-23 Blown Fuse on PC Board ............13-23 Lamp Head Signals ..............
Page 7: Specifications
Specifications 72" 81" 38" 35" 45" 45.5" 48.5" 89" with A/C Crated dimensions Length Width Height 95" 60" 80" 241 cm 152 cm 203 cm Shipping weight Crated 1600 lbs. 727 kg. Uncrated 1375 lbs. 625 kg. Actual dimensions Cabinet welded heavy gauge steel construction with access doors on both sides.
Page 8: Optional Reflectors
Optional reflectors Width 24" 61 cm Depth: 18" 46 cm Intensity Medium High AP 30-5000 2.5kW AP 30-8000 Cooling A self-contained air conditioning system is integrated into the rear of the AP 30-5000 / AP 30-8000. Exhaust Two exhaust ducts, diameter 8 in.(203 mm) To minimize the impact on the working environment, the exhaust must be vented to the outside, a heat exchanger or up through a dropped ceiling.
Page 9: Electrical Specifications And Connections
Electrical specifications and connections 380 / 415V~ 50Hz Connection 380 / 415V~ Wye: 3 Wires + Neutral + Ground OLITE Terminal Block Power Supply L1 L2 L3 Blowers Vacuum Pumps Figure A Electronics Drives Etc. Earth Ground 208/240V~ 50Hz Connection 208V~ DELTA: 3 Wires + Ground OLITE...
Page 10: Connecting Power
AP 30 - 5000 printer input 3 phase (Delta) See Figure C 3 wires + ground 480V~ 60 Hz, 18 amp. 3 phase (Delta) See Figure B 3 wires + ground 208/240V~ 60 Hz, 44 amp. 3 phase (Wye) See Figure A 3 wires + neutral + ground 380/415V~ 50 Hz, 24 amp.
Page 11: 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 12 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 13: 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 14: 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 15 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 16: 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 17: 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 18: 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 19: 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 20: 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 21: 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 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 28: 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 29: 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 30: 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 31: 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.
Page 32: Functions Table
Functions Table Function Value [ 0 001] A/C Compressor On/Off [ 0 002] A/C Blower On/Off [ 0 004] Upper Vacuum Pump On/Off [ 0 008] Lower Vacuum Pump On/Off [ 0 016] Work Light and Nose Section Fans On/Off [ 0 032] Motor Direction Control [ 0 064]...
Page 33: 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 34: Typical Values That You Will See When A Fault Occurs
• 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 35: Lamp Changing Instructions
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 36 They carry the OLEC Warranty of Satisfaction. Substitutes and copies of lamps are not approved by OLEC, nor do they carry our Warranty. Use approved OLEC replacement parts ONLY! 94MS36 Rev. F2 S/W Ver 2.06...
Page 37: 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 38 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 39: 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 GO 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 40: 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 41: 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 42: 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 43 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 44: 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 45: 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 46: 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 47: 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 48: 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 49 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 94MS36 Rev.
Page 50 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 51: Exposure Trays
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 52 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 53: 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 54 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 55: 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 56 12D2476A00 KEP NUT, #10-32 41B12NKP FRAME, MYLAR, OUTER-FRONT 12D2380B76 SCREW, SHLDR ø.187 X 1.25 41-0BSBL1.25 FRAME, MYLAR, OUTER-REAR 12D2380A76 ITEM NO. DESCRIPTION OLEC P/N QTY. P A R T S L I S T 94MS36 Rev. F2 S/W Ver 2.06...
Page 57: 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 58: 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 59: 10. Center/Drive Assembly
10. 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 60 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 61: 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 62: 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 63: 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 64: 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 65: 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 66 • 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 67: 11. Air Conditioning System
11. Air Conditioning System Compressor The air conditioning compressor requires no routine maintenance. It is hermetically sealed, properly lubricated at the factory, and should provide years of satisfactory operating service. Should the refrigerant charge be lost, recharging ports (access fittings) on the suction and discharge sides of the compressor are provided for recharging and/or checking suction and discharge pressures.
Page 68 Intake Filter Removal And Installation Note: Orient the filter according to AIR FLOW arrow on filter frame. • The filter is located on the back of the exposure unit. Lift the filter high enough for the bottom to clear the lower filter retainer. •...
Page 69 • After flushing, allow filter to drain. Placing it with a corner down will assure complete drainage. • Amounts of airborne dust and dirt particles are different in every location. When a fine layer of dust or lint is visible on the surface of the filter, remove and clean the filter.
Page 70 11-4 94MS36 Rev. F2 S/W Ver 2.06...
Page 71: 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 72 12-2 94MS36 Rev. F2 S/W Ver 2.06...
Page 73: Control Box Wiring Diagram (Standard With 5Kw)
Control Box Wiring Diagram (Standard with 5kW) 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...
Page 74: Control Box Wiring Diagram (Standard With 8Kw)
Control Box Wiring Diagram (Standard with 8kW) WHITE BLUE BROWN BLACK GTOOL POWER BLACK DISTRIBUTION (240V) BLOCKS VIOLET BLUE (RED, 16GA) BLACK BLACK (240V) YELLOW BROWN 64CT464V00 WHITE YELLOW BLUE BLUE (240V) 12VDC VACUUM PUMPS RELAY COOLING FAN (240V) (240V) YELLOW EVAPORATOR VIOLET...
Page 75: Control Box Wiring Diagram (480V All)
Control Box Wiring Diagram (480V all) POWER DISTRIBUTION BLOCKS WHITE BLUE BROWN GTOOL BLACK VIOLET BLUE (RED, 16GA) YELLOW BLACK BLACK 5ASB (240V) YELLOW 64CT464V00 WHITE BLUE (120V) YELLOW BLUE 12VDC VACUUM PUMPS (120V) 5ASB RELAY VIOLET COOLING FAN (240V) (240V) EVAPORATOR YELLOW...
Page 76: Control Box Wiring Diagram (Ce All)
Control Box Wiring Diagram (CE all) 62D4049A00 or 62D4049B00 (RED, 8GA) (BROWN) (18GA) (BROWN, 8GA) FILTER POWER 29PLF02 SUPPLY (BLUE or BLACK, 8GA) RELAY (12VDC) (RF1, RF2) (R1, R2) (BLUE, 8GA) FILTER (BLACK, 16GA) 29PLF02 (RED, 16GA) (RF3, RF4) (BROWN, 18 GA) RESET (BLUE, 18GA) FIGURE "A"...
Page 77: Unit Cabling Diagram (Old Nose)
Unit Cabling Diagram (old nose) 16D1003A11 16D1003A09 62D2369A00 UPPER 16D1827A00 MAG. TRAY SW 16D1003A06 COMPRESSOR LOWER 16D1003A10 SENSORS BOARD EVAPORATOR 16D1003A08 62D2369A00 UPPER TRAY GAGE AIR CONDITIONER 16D1825A00 DISPLAY 16D1695B13 BOARD EMER. SW TRANSFLOW BLOWER LOWER TRAY GAGE 16D2412A00 UPPER MAIN REMOTE ACCESSORIES...
Page 78: Unit Cabling Diagram (New Nose)
Unit Cabling Diagram (new nose) BLOWER (120V) 16D2651A00 BLOWER (RED, 22 GA) (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 79: Unit Wiring And Tubing Diagram
Unit Wiring and Tubing Diagram UPPER VACUUM TUBING RIGHT & LEFT DOOR SWITCH WIRES/ PHOTOCELL CONNECTOR CABLE TO LEFT DOOR SWITCH 3 PL TO RIGHT DOOR SWITCH 2 PL TRAY ASSY. HARNESS AND TUBING (UPR) ACCESSORY 3 PL (CLSD LOOP ONLY) USED W/CLSD LOOP ONLY CONTROL/OUTPUT/INPUT/MOTOR...
Page 80: Base Assembly Diagram
Base Assembly Diagram 4 PL 2 PL 4 PL NSI 8-32 X 3/8 PHIL PAN MS BLK 41B08PPS.37 NSI #6 FLAT WASHER SAE 41-06WFR 2 PL EXT. REFL., SIDE(G) 11D2362B00 AP30 EXT. REFL., FRONT(G) 11D2361B00 NSI 6-32 X 5/16 PPMS ZINC 41-06PPS.31 HF1 BLOWER, ASSEMBLY SEE B.O.M.
Page 81: 13. Light Source
13. Light Source Component Layout Lamphead for AL 54 and AL 64 50/60Hz 64TR408 62SA 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 31MOT06 39BLO03 Safety Interlock Switch Knob...
Page 82 Power Supply for AL 54-480 60Hz Power Supply for AL 64 50Hz 13-2 94MS36 Rev. F2 S/W Ver 2.06...
Page 83 Lamphead for AL 84 and AL 94 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 39BLO14 55SW03 45KOB05 PA91 Shutter Motor...
Page 84 Power Supply for AL 84-480 60Hz Power Supply for AL 94 50Hz 13-4 94MS36 Rev. F2 S/W Ver 2.06...
Page 85: Ballast/Tap Switch Wiring
Ballast/Tap Switch Wiring AL 54 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 54-480 Ballast Wiring TERMINAL STRIP 18 17 15 14...
Page 86 AL 64 Ballast Wiring TERMINAL STRIP 12 11 10 9 NO. 29 (VIOLET). CONTACTOR ORANGE TO CAP. PACK. 50 Hz BALLAST 50 Hz BALLAST BALLAST BALLAST 50 Hz BALLAST 50 Hz BALLAST BALLAST BALLAST AL 94 Ballast Wiring TERMINAL STRIP NO.
Page 87 AL 84 Ballast / Tap Switch Wiring 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 84-480 Ballast Wiring TERMINAL STRIP NO.
Page 88: Interlock System
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. • On 240V equipment, the power cord enters the rear of the unit.
Page 89: 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 traditional needle movement meters in our factory, due to the trigger pulses on the lamp before striking.
Page 90: 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 91: 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 AL 54, AL 54-480, AL 64, AL 84, AL 84-480, AL 94, are divided into three sections. All units have one or two idle capacitors, they are connected with a yellow wire.
Page 92 AL 54-480 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 4) BLUE WITH WHITE STRIPE...
Page 93 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 10µƒ 16µƒ AL 84-480 Capacitor Assembly CAPACITOR ASSEMBLY PART # 62D3533A00 12µƒ 12µƒ WIRE COLORS 1) YELLOW 2) BROWN 3) BLUE...
Page 94 AL 94 Capacitor Assembly WIRES FROM HARNESS CAPACITOR ASSEMBLY PART # 62D2723A00 1 2 3 FRONT VIEW OF 12µƒ 16µƒ PC BOARD WIRES TO CAPACITOR SWITCH ON CAPACITOR MOUNTING BRACKET 4µƒ 12µƒ 16µƒ 4 3 2 1 WIRE COLORS 1) YELLOW REAR VIEW OF 2) BROWN PC BOARD...
Page 95: 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 96: 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 97: 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 98: 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 99: 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 100 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 101: 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 102: 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 103: 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 104: 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 105: Light Function States
increases to regulate the lamp. At idle, this voltage is typically 45 - 90V~ 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 106 Idle - Between exposures, the lamp is held in idle. During this period, the lamp fans vary in speed to maintain the proper lamp temperature. This allows the unit to consume less power on idle, and provides a wider range of exposure capabilities, since this same low power level is available for exposures.
Page 107: 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 64MV407V24 Control Board layout. Used on all 8kW light sources Note: Graphic of the new style p.c.board is shown.
Page 108: 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 109 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 110: Circuit Diagram (64Mv407 60Hz)
Circuit Diagram (64MV407 60Hz) *No Switches on Models AL55, 65, 75, 95, 96 13-30 94MS36 Rev. F2 S/W Ver 2.06...
Page 111: Lamphead For All Lights
Lamphead for all Lights Thermostat Thermostat Shutter Position Switch Safety Glass Switch Shutter Motor Blowers Lamp Trigger Board 94MS36 Rev. F2 S/W Ver 2.06 13-31...
Page 112: Al 54 Power Supply 60Hz
AL 54 Power Supply 60Hz 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 12µƒ 12µƒ 16µƒ Fuse Position 2 Position 1 10 blu Medium High Relay Relay...
Page 113: Al 54-480 Power Supply 60Hz
AL 54-480 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 114: Al 64 Power Supply 50Hz
AL 64 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 12µƒ 8µƒ 16µƒ 12µƒ 16µƒ Fuse Position 2 Position 1 10 blu Medium High Relay Relay...
Page 115: Al 84 Power Supply 60Hz
AL 84 Power Supply 60Hz 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...
Page 116: Al 84-480 Power Supply 60Hz
AL 84-480 Power Supply 60Hz 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 117: Al 94 Power Supply 50Hz
AL 94 Power Supply 50Hz 220 VAC 50HZ INPUT Toward front of unit Safety Interlock Power Relay Ballast Ballast 3 Amp Slow Blow Socket 16µƒ 12µƒ 4µƒ 16µƒ 12µƒ Fuse Position 2 Position 1 10 blu Medium High Relay Relay Power Supply Blower...
Page 118: Interconnect Cable
Interconnect Cable WHITE GREEN YELLOW VIOLET BLUE BROWN ORANGE HEAT SHRINK BLACK WHITE GREEN YELLOW VIOLET BLUE BROWN ORANGE HEAT SHRINK BLACK 13-38 94MS36 Rev. F2 S/W Ver 2.06...
Page 119: 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 120 • 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 121 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 122 5kW with L1250 LAMP ORANGE YELLOW BROWN BLUE #1 BLUE #2 IDLE/LOW 500+ 500+ 500+ 500+ MEDIUM 500+ 500+ 500+ HIGH 500+ 5kW with L1252 or L1261 LAMP ORANGE YELLOW BROWN BLUE #1 BLUE #2 IDLE/LOW 500+ 500+ 500+ 500+ MEDIUM 500+ 500+...
Page 123 ‡ 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 124 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 125: 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 126: 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 127: 16. Parts List
16. Parts List Part Number Description Qty. per unit 62AP30C Assy Kit Base Expo AP30 1 EA 11D1648A02 Flangeplate, HF1 2 EA 11D3994A07 External Reflector, AP30 4 EA 15D3830A00 Overlay, control panel 1 EA 32TRC05 Transformer (480V~ units only) 1 EA 39ACD02 Air Conditioner 8K BTU 1 EA...
Page 128 Part Number Description Qty. per unit 44ORNG02 "O" Ring 11/16x9/16x1/16" 4 EA 49DCT24 Tubing, 5/16 1.D.x1/2 O.D 2 FT 81TAP12 Tape, Teflon Sealant 1/2" 1 RL 81TAP17 Transfer Tape,3/4 X 18 1 RL 82ADH11 Adhesive, rubber gasket 1 EA 62D2429A00 Assy, AP 30 Nose - Integ 1 EA 11D1791A02...
Page 129 Part Number Description Qty. per unit 64MI441E-4236 Inegrator pcb master 1 EA 64MI441E-4239 Inegrator pcb remote 1 EA 64PCB-DIS01 Assy, PCB, System, Disply 1 EA 16D2656A00 Cable, 15P, Dip to DB 15 1 EA 64MI477V00 Quick Mem Key Bd AP30 1 EA 64MI478V00 Assembly, Key Bd AP30...
Page 130 Part Number Description Qty. per unit 32TRC01 Autoformer 208-240V~ 1 EA 33RLY20 Relay, 12VDC, Chassis 1 EA 44CPG08 Plug,plastic,black 1.5" 3 EA 44RUB03 Grommet,Continuous .06 52FUH04 Fuse Holder, 3AG/3AB 4 EA 52FUH08 Fuseholder, 3AG, .25 Tab 2 EA 52RCP21 Receptacle, 250V/15A 2 EA 52RCP24 Receptacle, 250V/50A...
Page 131 Part Number Description Qty. per unit 56FUS20 Fuse, 20A 250V, Slow Blow 3 2 EA 56FUS38 Fuse, 30A 500V SlowBlow 4 EA 62D2483A00 Blower, 50 Hz 220V~ 1 EA 62D331A Voltage Selector Assembly 1 EA 55SW26 Switch, 3PDT, 250V, 10A 1 EA 64VS409 Assembled Voltage Sel...
Page 132 Part Number Description Qty. per unit 12D4474A76 Frame mylar outer rear 1 EA 12D4475A76 Frame mylar outer side 2 EA 81TAP25 Tape blue.015"x.50"x10'Rl 10.5 FT 62PUM01 Assy, Pump, 220V 60Hz 2 EA 11D1633A02 Plate Pump 1 EA 13D2170 Rubber Washer 4 EA 16D2741A00 Cable, Vac Pump...
Page 133 Part Number Description Qty. per unit 54PWR01 Power Cable for AL53 1 EA 54PWR05 Pwr Crd 18/3 SJT 12' 1 EA 62D3654A00 Assy, Capacitor AL54-480 1 EA 64MV407V03 Assy UV Lt Ctrl 5K 60Hz 1 EA 62CL64 5kW 220V~ 50Hz Power Supply 1 EA 16D0277A00 Harness, 5K Power Supply...
Page 134 Part Number Description Qty. per unit 11D3605A62|0 Bracket Idler-Shutter Ay 1 EA 12D700 Sprocket 10 Tooth .250 1 EA 41-06NHX NSI 6-32 Hex Nut Zinc 1 EA 41-06SBL.62 NSI 6-32x5/8 Shoulder Bolt 1 EA 41B10WFR NSI #10 Flat Washer Black 1 EA 43BLB15 Bearing, Flanged .187 I.D...
Page 135 Part Number Description Qty. per unit 56FUS15 Fuse, 3A 250V 3AG Slow Blow 1 EA 62D3533A00 Assy, Capacitor 60H,480V 1 EA 64MV407V24 Prnt Light Ctrl PCB w/Min 1 EA 62CL94 8kW 50Hz 220V~ Power Supply 2 EA 16D1045A00 Harness, Beau Plug OEM 1 EA 16D1585 Interlock Harness...
Page 136 16-10 94MS36 Rev. F2 S/W Ver 2.06...
Page 137: 17. 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 138 Corporation 17112 Armstrong Avenue, Irvine Ca U.S.A. 92614 U.S.A. (949) 399-6500 Fax (949) 399-6501...

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