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ergoline PL191 Series Service Instructions Manual
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ergoline PL191 Series Service Instructions Manual

ergoline PL191 Series Service Instructions Manual

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Service Instructions
Model-No.: PL191/..
1032876-00 en 10
/
/
.2024

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Summary of Contents for ergoline PL191 Series

  • Page 1 Service Instructions Model-No.: PL191/.. 1032876-00 en 10 .2024...
  • Page 2 General Legal notice Manufacturer: JK-Products GmbH Rottbitzer Straße 69 53604 Bad Honnef (Rottbitze) GERMANY Tel: +49 (0) 22 24 / 818-0 Fax: +49 (0) 22 24 / 818-166 Customer Service / JK-International GmbH, Technical Service JK-Global Service Division (Spare Parts Ordering Köhlershohner Straße for Components): 53578 Windhagen, Germany...
  • Page 3 Table of contents Table of contents General ................6 Symbol explanation ..............6 Safety information for assembly and disassembly ....8 Safety information for avoiding damage to the unit ....9 Information for service technicians ......... 10 Electrical connection .............. 10 Disconnecting the unit from the power supply and secure it against re-connection ........
  • Page 4 Table of contents Acrylic..................33 3.6.1 5.1 Acrylic bed panel .............. 33 3.6.2 5.2 Acrylic canopy panel ............34 3.6.3 5.3 Acrylic side panel ............. 36 3.6.4 5.4 Acrylic bed: Intermediate panel ........36 3.6.5 5.5 Acrylic bed: Shoulder tanning unit........36 3.6.6 5.6 Headrest pad ..............
  • Page 5 Table of contents 3.14 Mechanical components ............66 3.14.1 12.1 Seats ................66 3.14.2 Plastic panels ................66 3.14.3 12.3 Contact guard ..............66 3.14.4 12.4 Nozzle carriage ............... 66 3.14.5 12.5 Warning stickers ............. 67 Acceptance test ............... 72 Storing the device ..............
  • Page 6 General General Symbol explanation The following types of safety notices are employed in these operating instructions: DANGER! Type and source of hazard This safety notice indicates the existence of a direct danger to body and life. DANGER! Type and source of hazard This safety notice warns of dangers to body and life which are caused by electricity.
  • Page 7 General Glossary Symbol Notes/Screw type Torx screw: loosen Torx screw: tighten Allen screw: loosen Allen screw: tighten Phillips screw: loosen Phillips screw: tighten 10/2024 1032876-00 Service Instructions – 7/76...
  • Page 8 General Safety information for assembly and disassembly DANGER! Electricity is present throughout the entire unit! Assembly and connection to the mains electrical supply must comply with the national regulations (VDE in Germany). The on-site electrical installation must be fitted with an easily accessible all-pole isolating device (master switch), that complies with overvoltage category III.
  • Page 9 General Safety information for avoiding damage to the unit CAUTION! The unit can be damaged or destroyed! – Always perform assembly work in the order speci- fied in the assembly instructions # 1031975-... 10/2024 1032876-00 Service Instructions – 9/76...
  • Page 10 Information for service technicians Information for service technicians Electrical connection Only permit a licensed electrical engineering company to make  the electrical connection on the building side (mains socket)! Observe the national regulations in the country where the unit is operated.
  • Page 11 Information for service technicians Disconnecting the unit from the power supply and secure it against re-connection DANGER! Electricity is present throughout the entire unit! Ensure that the units are de-energized before starting work on them. Make sure that all live cables are switched off.
  • Page 12 Information for service technicians Maintenance DANGER Risk of electric shock, which may lead to death or se- vere injury! Disconnect the unit from the power supply when per- forming maintenance work that requires the unit to be opened. See page 11. Once the maintenance work is complete, return all safety equipment (e.g.
  • Page 13 Information for service technicians The unit is equipped with earth bonding points (EBP) allowing an earth connection of the wrist strap. The EBPs are located in several places in the unit. Technical data 2.5.1 Power, connection rating and noise level Information on the technical data and dimensions can be found in the operating instructions for the respective unit.
  • Page 14 Checking and replacing components Checking and replacing components WARNING! Risk of hand injuries! – Wear safety gloves during maintenance work. Preparation 1. Acrylic panels (canopy, bed panel, intermediate panel) 2. Lamp covers 3. Canopy hood 4. Front panel 5. Parts carrier 6.
  • Page 15 Checking and replacing components Electrical connection The electrical connections are located throughout the unit: in the can- opy, at the head and feet end, in the parts carrier and in the front panel. 3.2.1 Plug connector 3.2.2 Connector (CEE connection terminal) 3.2.3 Connection terminals 3.2.4...
  • Page 16 Checking and replacing components 3.2.1 1.1 Plug connectors – Refer to the circuit diagram in the 'Electrical wires/cables' section on page Fehler! Textmarke nicht definiert. for the position of the plug connectors. – Check or replace the components in accordance with the check- list # 1019858-...
  • Page 17 Checking and replacing components Electrical ballast connector. Connector for the lighting control circuit board. All-purpose 3-pin, 6-pin and 9-pin connectors 10/2024 1032876-00 Service Instructions – 17/76...
  • Page 18 Checking and replacing components 3.2.2 1.2 Connectors DANGER! Switch off the unit before conducting any assem- bly/disassembly work. – Switching off the unit alone is insufficient, as cer- tain points may remain energized. Therefore, switch off fuses before performing any work and –...
  • Page 19 Checking and replacing components 3.2.3 1.3 Connection terminals – Check or replace the components in accordance with the check- list # 1019858-… – Check the connection terminals for damage and discolouration. 10/2024 1032876-00 Service Instructions – 19/76...
  • Page 20 Checking and replacing components 3.2.4 1.4 Internal terminals (spring-loaded) – Check or replace the components in accordance with the check- list # 1019858-… Overview of connection terminals The terminals are located at the coin connection and on the audio board. 3.2.5 1.5 Internal terminals (screw terminals)
  • Page 21 Checking and replacing components 3.2.6 1.6 Cable bushings – Check or replace the components in accordance with the check- list # 1019858-… – Check all visible cable bushings and edge protection for damage and correct fit. 10/2024 1032876-00 Service Instructions – 21/76...
  • Page 22 Checking and replacing components 3.2.7 1.7 Electrical wires/cables – Check or replace the components in accordance with the check- list # 1019858-… NOTE! Refer to the 'Annual inspection' document 1018811- .. 22/76...
  • Page 23 Checking and replacing components Electrical components – Check or replace the components in accordance with the check- list # 1019858-… 3.3.1 Electrolytic capacitors Does not apply to this unit. 3.3.2 Interference suppressor filter 3.3.3 PCBs 3.3.4 Relays/contactors 3.3.5 Skin sensor Does not apply to this unit.
  • Page 24 Checking and replacing components 3.3.2 2.2 Interference suppressor filter If installed, check for wear and damage. Replacement: – Disconnect the connector – Undo the M8 nuts – Replace the interference suppressor filter 3.3.3 2.3 Power connection boards NOTE! The number of power connection boards depends on the unit's functions.
  • Page 25 Checking and replacing components Control box Lighting controller circuit board Audio circuit board Power control 10/2024 1032876-00 Service Instructions – 25/76...
  • Page 26 Checking and replacing components Replacing EASY CONTROL NOTE! The service kit (cushion) is not included with every unit. Place a scratch guard, e.g. foam or cardboard, between the canopy and base to avoid damage to the unit. – Undo 3 screws. –...
  • Page 27 Checking and replacing components – Replace the EASY CONTROL. The new EASY CONTROL is installed in reverse order. 3.3.4 2.4 Relays/contactors Replacement Relays and contactors are located in the base of the unit. – If installed, check for wear and damage. Replacement: –...
  • Page 28 Checking and replacing components 3.3.6 2.6 Power supply units and switching power supplies Power supply units and contactors are located in the unit’s canopy and base. – Loosen the cable from the connection terminal. – Undo the screws. – Replace the power supply unit. 3.3.7 2.7 Audio Replacing the audio system circuit board...
  • Page 29 Checking and replacing components – Slide the audio system to the left and remove it. – Carefully pull the cables with the connectors through the open- ings. – Loosen the connector. – Undo the nuts – Remove the audio circuit board. The new circuit board is installed in reverse order.
  • Page 30 Checking and replacing components Replacing the audio cards in the audio system – Undo the screws and remove the panel. – Replace the audio cards. Assembly is carried out in reverse order. 30/76...
  • Page 31 Checking and replacing components Aqua Fresh 3.4.1 AF compressor Does not apply to this unit. 3.4.2 AF valves / Aroma Does not apply to this unit. 3.4.3 AF pumps Does not apply to this unit. 3.4.4 AF aroma hoses Does not apply to this unit. 3.4.5 Aqua Fresh liquid Does not apply to this unit.
  • Page 32 Checking and replacing components Air conditioning 3.5.1 Condensate pump Does not apply to this unit. 3.5.2 Float switch Does not apply to this unit. 3.5.3 Air conditioning system Does not apply to this unit. 3.5.4 Heating Does not apply to this unit. 3.5.1 4.1.
  • Page 33 Checking and replacing components Acrylic 3.6.1 Acrylic bed panel 3.6.2 Acrylic panel canopy 3.6.3 Acrylic panel side panel Does not apply to this unit. 3.6.4 Acrylic panel intermediate panel 3.6.5 Acrylic panel shoulder tanner panel Does not apply to this unit. 3.6.6 Headrest Does not apply to this unit.
  • Page 34 Checking and replacing components – Lift up the partition with the suction cup. – Remove the partition. The assembly is the same process in reverse order. When assembling please note: – Clean the partition. – To protect against fingerprints, hold the partition with a cloth.
  • Page 35 Checking and replacing components To replace the low-pressure lamps, the canopy panel must be completely removed from the device. – Pull out the plug. – Have another person help you to remove the canopy panel. When assembling please note: – Carefully insert the canopy panel into the guide.
  • Page 36 Checking and replacing components – Support the canopy panel with one hand so that it doesn’t fall down. – Tighten the screws: the middle ones first, then the outer ones. – Carefully remove fingerprints and other soiling. 3.6.3 5.3 Acrylic side panel Not applicable for this device.
  • Page 37 Checking and replacing components Electronic ballasts, ignition units 3.7.1 Conventional ballast Does not apply to this unit. 3.7.2 Electrical ballast 3.7.3 Ignition unit Does not apply to this unit. 3.7.1 6.1 Conventional ballast Does not apply to this unit. 3.7.2 6.2 EVG CAUTION! ESD-sensitive parts!
  • Page 38 Checking and replacing components Replacing the electronic ballast in the base: The front panel has to be dismantled to replace the electronic bal- last. See assembly instructions # 1031975-.., Chapter 5.1 Remov- ing the front panel. During dismantling, consult the circuit diagram to determine how many lamps are operated by an electronic ballast.
  • Page 39 Checking and replacing components Replacing the electronic ballast in the canopy: During dismantling, consult the circuit diagram to determine how many lamps are operated by an electronic ballast. – Mount transport protection devices to fix the canopy in place. – Undo the 2 screws to open the hood.
  • Page 40 Checking and replacing components – Pull out the plug. – Undo 3 screws. – Remove the electronic ballast The new electronic ballast is installed in reverse order. Replacing the electronic ballast for the low-pressure lamps in the facial tanner: The electronic ballast for the low-pressure lamps is located behind the central LED board in the canopy.
  • Page 41 Checking and replacing components – Remove the cover and disconnect the connector. – Undo the screws on the LED board. – Remove the LED board. – Disconnect the wires on the electronic ballast. – Undo 2 screws. – Remove the electronic ballast. The new electronic ballast is installed in reverse order.
  • Page 42 Checking and replacing components Exhaust air/ventilation 3.8.1 Exhaust air flap spring Does not apply to this unit. 3.8.2 Exhaust air hose Does not apply to this unit. 3.8.3 Internal air hoses Does not apply to this unit. 3.8.4 Bellows 3.8.5 EPP air ducts Does not apply to this unit.
  • Page 43 Checking and replacing components – Undo the 3 screws on each of the bellows. – Detach the catches from the recesses on each of the bellows. Now remove the bed panel; see the assembly instructions # 1031975-.., Chapter 'Removing the acrylic bed panel' –...
  • Page 44 Checking and replacing components 3.8.6 7.6 EPP control boxes – If installed, check for wear and damage. 3.8.7 7.7 Fan – Check or replace components in accordance with the checklist # 1018814-... Further information is available in the assembly instructions # 1031975-..
  • Page 45 Checking and replacing components The main fan and partition fan are installed in the base of the unit. One fan is installed in each LED module in the canopy. The face/body fan is installed in the canopy. – Check all the fans for damage and correct fit. –...
  • Page 46 Checking and replacing components – Loosen the connector. – Remove the canopy panel from the unit. – Remove the low-pressure lamps – Remove the filter mat. – Undo the screws. 46/76...
  • Page 47 Checking and replacing components – Undo the screws. – Loosen the connector. – Remove the fan. Replacing the partition fan Before the partition fan can be replaced, the bed panel and lamp covers have to be dismantled, see assembly instructions # 1031975-...
  • Page 48 Checking and replacing components – Pull the partition fan forwards and replace it. 3.8.8 7.8 Servo motors Does not apply to this unit. 3.8.9 7.9 Air filters – Check or replace components in accordance with the checklist # 1018814-... Further information is available in the operating instructions # 103267-..
  • Page 49 Checking and replacing components Replacing the air filter Filter in the canopy – Cover the canopy if necessary to prevent the paintwork from be- ing scratched. – Remove the filter mat on the back of the canopy. – Clean the filter dry or wet. Replace the filter if necessary. IMPORTANT NOTE FOR WET CLEANING! Fully dry the filter before re-inserting the filter into the unit.
  • Page 50 Checking and replacing components – Clean the filter dry or wet. Dry cleaning: Vacuum cleaner (depending on the degree of soiling) Moist cleaning: water and detergent, also a dishwasher. – Refit the cleaned and dried filters. The two outer filter mats audibly engage.
  • Page 51 Checking and replacing components Bearings, springs, shock absorbers 3.9.1 Springs 3.9.2 Bearings/slide bearings 3.9.3 Rubber-metal buffer (lifting mechanism and fan) 3.9.4 Cables and guide rollers Does not apply to this unit. 3.9.5 Fall protection Does not apply to this unit. 3.9.6 Lifting mechanism 3.9.7...
  • Page 52 Checking and replacing components 3.9.3 8.3 Rubber-metal buffer (lifting mechanism) – If present, check for wear and damage. Two rubber buffers are installed. – Check rubber buffers for damage and wear. – Check the rubber buffers for their cushioning effect; replace if punctured! Replacing the rubber buffer –...
  • Page 53 Checking and replacing components 3.9.6 8.6 Lifting mechanism – Check the lifting mechanism for damage and correct fit. 3.9.7 8.7 Gas pressure absorbers/ oil dampers Replacing the gas pressure absorber There is one safety splint located on the top of each gas pressure absorber.
  • Page 54 Checking and replacing components 3.10 UV components 3.10.1 Lamps / LP / HP 3.10.2 Filter panels Does not apply to this unit. 3.10.3 Reflectors Does not apply to this unit. 3.10.4 Starter Does not apply to this unit. 3.10.5 Chip cards (NFC card) Does not apply to this unit.
  • Page 55 Checking and replacing components 3.10.1 9.1 Lamps / LP / HP The long (UV) low-pressure lamps are installed in the canopy and base. The type and number of lamps vary depending on the type of unit. The operating instructions in the 'Lamp set' section provide more detailed information on the lamps.
  • Page 56 Checking and replacing components – Undo the screws on the LED board. – Remove the LED board. The new LED board is installed in reverse order. Replacing the Beauty Light LED in the canopy – Undo 3 screws. – Fold down the acrylic panel. –...
  • Page 57 Checking and replacing components – Unscrew and remove the plates. – Undo the screws. – Loosen the connector. – Remove the LED. The new LED is installed in reverse order. Replacing the decorative lighting – Open the hood – Loosen the connector for the LED strip in the head and foot area.
  • Page 58 Checking and replacing components Replacing the effect lighting on the decorative plate – Open the hood – Loosen the connector. – Undo the screws. The new LED panel is installed in reverse order. 3.10.2 9.2 Filter panels Does not apply to this unit. 3.10.3 Reflectors Does not apply to this unit.
  • Page 59 Checking and replacing components 3.10.6 9.6 Lamp sockets – Check lamp sockets for damage and discolouration. – Check the connections of the sockets for discolouration, dam- age and correct fit. – Use a service PC for a test run when fitted Replacing lamp sockets, shown on the canopy Note: Only replace the lamp sockets for each lamp in pairs.
  • Page 60 Checking and replacing components 3.11 Safety switch/locks 3.11.1 Sensors (temperature, pressure, UV, etc.) 10.1 Does not apply to this unit. 3.11.2 Temperature limiter 10.2 3.11.3 Switches/panel switches/safety switches 10.3 3.11.4 Opening/closing mechanism 10.4 Does not apply to this unit. 3.11.1 10.1.
  • Page 61 Checking and replacing components The thermal cut-offs are located in the canopy. – Remove the lamps. – Undo the screws and pull the thermal cut-off down and out. – Remove the cable lugs. – Attach the new thermal cut-off to the two cable lugs. The new thermal fuse is installed in reverse order.
  • Page 62 Checking and replacing components 3.11.3 10.3 Switches/sliding switches/ safety switches – Check the safety switches for damage and correct fit. – Check the switch flag/sickle for deformation and correct fit. – Check the electrical connections for damage. Replacing the panel switch, shown on the canopy –...
  • Page 63 Checking and replacing components – Close the canopy. – Undo the 2 screws to open the hood. – Open the hood and support it with props. – Undo the 2 screws on the panel switch. – Loosen the cable – Remove the safety switch (emergency off switch) downwards and out.
  • Page 64 Checking and replacing components 3.11.4 10.4 Opening/closing mechanism Does not apply to this unit. 3.12 Option: Vibra Shape Does not apply to this unit. 64/76...
  • Page 65 Checking and replacing components 3.13 Control 3.13.1 Handles/retaining cables 11.1 Does not apply to this unit. 3.13.2 Control films/switching mat 11.2 Does not apply to this unit. 3.13.1 11.1 Handles/retaining cables Does not apply to this unit. 3.13.2 11.2 Control films/switching mats Does not apply to this unit.
  • Page 66 Checking and replacing components 3.14 Mechanical components 3.14.1 Seats 12.1 Does not apply to this unit. 3.14.2 Plastic panels 12.2 Does not apply to this unit. 3.14.3 Contact guard 12.3 3.14.4 Nozzle trolley 12.4 Does not apply to this unit. 3.14.5 Warning sticker 12.5...
  • Page 67 – Damaged or missing warning or instruction signs must be re- placed! Example based on Ergoline Spirit Pure Light: 1: Type plate The name plate is attached to the interior side of the canopy. It con- tains important information for identifying the device (e. g. the serial number = Serial-No.).
  • Page 68 Checking and replacing components 2: Maintenance instruction sticker (800701-..) The sticker is mounted at the foot end on the inside of the canopy. 3: Lamp set sticker The precise details of the required lamps are available in the separate appendix. 68/76...
  • Page 69 Checking and replacing components 4: EU warning sticker (1012638-..) This sticker also includes the language form (see accessories Tech- nical Documentation). 5: Emergency off sticker (1512131-..) The sticker is mounted at the head end on the inside of the canopy. This sticker also includes the language form 1018688-..
  • Page 70 Checking and replacing components 7: 'No export USA/Canada' sticker (84829-..) The sticker is mounted on the controller support. 8: 'Not disconnected from power supply' warning sticker (800698-..) 9: 'Lock control box' sticker 1032324-.. 1: Note! Only genuine parts (800702-..)! The sticker is mounted on the controller support. 70/76...
  • Page 71 Checking and replacing components 10: 'Remove lattice' sticker (842971-..) The sticker is mounted at the top of the rear panel. 10/2024 1032876-00 Service Instructions – 71/76...
  • Page 72 Acceptance test Acceptance test After installation and before handover and commissioning, the unit must be checked in accordance with VDE 0701-0702. The results of the individual checks must be recorded in the handover report. The signed handover report must be sent to Technical Service: JK-International GmbH, Division JK-Global Service Köhlershohner Straße...
  • Page 73 Acceptance test 4.1.3 Disposal Environmental regulations – disposal of lamps and batteries Lamps contain fluorescent materials and other waste containing mer- cury. Batteries contain heavy metal compounds. Within the European Union the national implementation of the Waste Framework Directive 2018/851/EG applies. According to the national waste disposal laws and in accordance with the municipal waste regu- lations, proof must be provided of the proper disposal of lamps and batteries.
  • Page 74 Index Index Acrylic bed panel ..................33 Acrylic canopy panel ................34 Acrylic glass panel, permitted load ............13 Air filter ....................48 Audio ....................... 28 Bearings/slide bearings ................. 51 Bellows ....................42 Bonding Points ..............12, 13, 24, 37 Cable bushings ..................
  • Page 75 Index Interference suppressor filter ............... 24 Intermediate panel ................. 36 Internal terminals (screw terminals) ............ 20 Internal terminals (spring-loaded) ............20 Lamp sockets..................59 Lamps ..................... 55 Lifting mechanism ................. 53 Maintenance ..................12 Noise level ....................13 Overview of connection terminals ............20 Packaging ....................
  • Page 76 Index UV components ..................54 Warning stickers ..................67 76/76...