Aktilite CL128 User manual

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Page 1

SERVICE MANUAL

Aktilite

Ver 1.

CL128

Photoc

Hoffsveien 48

NO-

0377 OSLO, Norway

Phone: +47 22 06 22 10

www.photocure.com

ure ASA

Page 2

Service Manual Aktilite

SERVICE

MANUAL

Aktilite

Any kind of service should only be carried out by authorised personnel.

Refer

to the User Manual for further information regarding safety and precautions.

TABLE OF CONTENTS

ASSEMBLY OF AKTILITE

1.1 M

1.1.1 Tools needed for the assembly of lamp with fixed lamp head................................3

1.1.2

1.2 R

1.3 HO

1.4 L

1.5 G

1.6 P

1.6.1

1.6.2

1.7 H

1.8 H

1.9 L

1.9.1

1.9.2

1.9.3

1.10 S

1.11 L

1.11.1

1.11.2

1.12 P

1.12.1

1.12.2

1.13 L

ATERIAL/EQUIPMENT..................................................................................................

Tools need

EADY TESTED SYSTEM ELECTRONICS MODULE

USING TOP MODULE

IGHT MODULE

LUE LENSES .................................................................................................................

OSITIONING ARM MODUL

Fixed lamp head .....................................................................................................

Detachable lamp head............................................................................................

OUSING BOTTOM MODULE OUSING BACK MODULE

AMP HEAD MODULE

Fixed lamp head ...................................................................................................10

Detachable lamp head..........................................................................................11

Disassemly and Assembly of the lamp

TOP BLOCK MODULE (TS1 AMP INCLUDING PARALL

Fixed lamp head (128 Detachable lamp head (128

ARALLEL ARM WITH LAM

Fixed lamp head (128 Detachable lamp head (128

ABELS PLACEMENT DESC

CL128 LAMP WITH PAR

ed for the assembly of lamp with detachable lamp head ......................

(128

-0-

610)

ASSEMBLY .............................................................

(128

-0-

750) ..........................................................................................

(128

-0-

400)

ASSEMBLY ......................................................

(128

-0-

820) .......................................................................

(128

-0-

810)

ASSEMBLY ..........................................................

(128

-0-

200)

ASSEMBLY..............................................................10

-0-

250)

ASSEMBLY ............................................................27

EL ARM ASSEMBLY...............................................................28

-0-

250)...............................................................................28

-0-

252)......................................................................29

P HEAD HOLDER UNIT A

-0-

210)...............................................................................31

-0-

212)......................................................................32

RIPTION ...............................................................................33

CL128

slide series............................................12

ALLEL ARM.....................

(128

-0-

439)

ASSEMBLY.....................

SSEMBLY ........................................31

3 3

3 4 5 6 6 7

7 8

9 9

2 REPLACING THE DC POW 3

ASSEMBLY OF AKTILITE

3.1 M

3.2

3.3

3.4

3.5 P

ERROR CO

Version 1.

ATERIAL/EQUIPMENT................................................................................................35

ELECTRONICS MODULE

HOUSING MODULE

OWER SUPPLY

DES ..............................................................................................................40

(128

-0-

A B

300)

(128 (128

ER PLUG.......................................................................34

CL128 POWER SUPPLY.............................................35

(128

-0-

330)

ASSEMBLY......................................................36

-0-

310)

ASSEMBLY..........................................................37

-0-

320)

ASSEMBLY..........................................................38

ASSEMBLY.......................................................................39

Page 2 of 41

Page 3

This service manual is primarily meant for mechanical repairs with fixed and deta

The electronic control board in the lamp head has to be programmed with the parameters calibrated light module. If the electronic control board is faulty then the complete board is changed and programmed with the original p Device History Record for the lamp kept at the factory mode can only be done by trained service personnel. The and lenses.

If a power supply Photocure. However, this has to be tested for leakage current, test by qualified personnel.

1.1 Material/Equipment

Assembly of Aktilite CL128 Lamp with Parallel Arm

If a led diode is faulty then the complete

chable lamp head.

electronics board

Service Manual Aktilite

arameters for the light module. These

is faulty, a new tested power supply can be obtained from

CL128

and entering the device factory programming

light module consist of led arra

light module

and covers both Aktilite

can

only

be retrieved from the

is changed.

eart

h continuity and withstanding voltage

CL128 lamps

to match

ys, heat sink

the

1.1.1 Tools needed for the assembly of lamp with fixed lamp head

Required tools

# of items

1 1 1 1 1

1.1.2 Tools needed for the assembly of lamp with detachable lamp head

Required tools

# of items

1 1 1 1 1 1 1 1 1 1 1

Description

Screwdriver, Screwdriver, Pozidrive 2 Screwdriver, Torx Screwdriver, Torx Screwdriver, Torx T 20

Description

Screwdriver, Pozidrive 1 Screwdriver, Pozidrive 2 Screwdriver, Torx T 10 Screwdriver, Torx T 15 Screwdriver, Torx T 20 Allen key, 5mm Press nut tool Crimping tool LEMO DPC.91-701V Locator male DCE.91.135.BVC Locator female DCE.91.130.BVM Ex

traction tool LEMO DCF.91.133.5LT

Pozidrive 1

T 7 T 10

Umbraco

Version 1.

Page 3 of 41

Page 4

Service Manual Aktilite

1.2 Ready Tested System

Electronics

Module

CL128

(128

-0-

439

) assembly

Version 1.

Page 4 of 41

Page 5

Service Manual Aktilite

1.3 Housing top module (128

Required items

Part # 128

-0-

978

128

-1-

637

128

-1-

932

128

-1-

626

128

-1-

628

128

-1-

931

128

-1-

636

# of items

CL128

-0-

610) assembly

Description Housing top (mould Housing top slide bearing Screw Housing right (moulded plastic) Housing left (moulded plastic) Screw User interface (foil keyboard w/ta Rubbing alcohol (fat free)

PT4x16 countersunk

PT4x25

ed plastic)

il)

Version 1.

Assembly description

Step 1)

Assemble the housing top slide bearing (128 the five countersunk PT4x16 screws (128

Step 2)

Assemble the housing left (128 (128

-0-

978) using the four PT4x25 screws (128

Step 3)

Clean the recessed area at the top of the housing top (128 alcohol

Step 4)

Glue the Key Touch panel (128

-1-

637) to the housing top (128

-1-

932).

-1-

628) and housing right (128

-1-

931).

-1-

636) to the housing top (128

-1-

626) to the housing top

-0-

978) using a cloth and rubbing

-0-

978).

-0-

978) using

Page 5 of 41

Page 6

1.4 Ligh

t module (128

Service Manual Aktilite

-0-

750)

CL128

This light module comes as a ready control electronics the documentation f comprehensive tests has to be done with spectrometer and radiometer so this can only be done at the factory. The dose factor is a factor that is a combination of wavelength and irradiance and will vary slightly from light modu

1.5 Glue lenses

If one of the lenses is loose they can be glued on to the substrate using glue

and currents

ollowing

the specific light module. To determine the dose factor,

tested and

(set in factoring mode) has to be adjusted according to

calibrated part. The dose factor in the

le to light module.

Loctite 435

Version 1.

Page 6 of 41

Page 7

Service Manual Aktilite

1.6 Positioning arm module (128

1.6.1

ixed lamp head

Required items

Part # 128

-0-437 1 T-piece (Moulded plastic)

128

-1-

910

128

-0-

428

128

-1-

914

128

-1-

912

128

-1-

916

128

-1-

424

1 T-

128

-1-

926

# of items

Description

Plastic bearing Main arm (Moulded plastic) Aluminium washer Conical spring Circlip

Screws PT3x25

CL128

-0-

400) assembly

piece cover (Moulded plastic)

Version 1.

Assem

Step 1)

Step 2)

Step 3)

Step 4)

Step 5)

Step 6)

bly description

Press the two plastic bearings (128 tool is necessary for this or a jig made by Kitron.) Slide conical spring (128 end of the Assemble one aluminium washer (128 already assembled plastic bearings (128 Compress the conical spring (128 the main arm (128 Assemble another aluminium washer (128 the Circlip is well located in the g Assemble T-piece cover (128

conic spring (128

-1-

910) into the T-piece (128

-1-

912) onto aft tube of the main arm (128

-1-

912) goes towards the plastic of the main arm (128

-1-

914) and the T-piece (128

-1-

912) by

-1-

428). (This compression and holding can be done with one hand.)

roove.

-1-

424) using the two PT3x25 screws (128

910)). holding the T-piece (128

-1-

914) and circlip (128

-0-437

). (Specially made

-0-

428), The pointed

-0-437

) (Including the

-1-437) tightly against

-1-

916). Make sure that

-1-

926).

-0-

428).

Page 7 of 41

Page 8

1.6.2

Deta

chable lamp head

Required Items

Part # 128

-0-

437

1 T-

128

-1-

910

128

-0-

428

128

-1-

914

128

-1-

912

128

-1-

916

128

-0-

988

128

-1-

926

Service Manual Aktilite

# of items

Description

piece (Moulded plastic) Plastic bearing Main arm (Moulded plastic) Aluminium washer Conical spring Circlip Cable from system electronics to lamp head connector Screw

PT3x25

CL128

Version 1.

Assembly description

Step 1) Press the two plastic bearing

is necessary for this or a jig made by Kitron.) Step 2) Broach the plastic bearings to Ø16,2mm after insertion in T-piece Step 3) Slide conical spring (128

the conic spring (128 Step 4) Assemble one aluminium washer (128

already assembled plastic bearings (128 Step 5) Compress the conical

the main arm (128 Step 6) Assemble another aluminium washer (128

Circlip is Step 7) Assemble power cable assembly (128

module (128 Step 8) Put in the cord and fasten the T-piece cover (128

988) using the two PT3x25

well located in the groove.

-0-

s (128

-1-

910) into the T-piece (128

-1-

912) onto aft tube of the main arm (128

-1-

912) goes towards the plastic of the main arm (128

-1-

914) and the T-piece (128

-1-

910)).

spring (128

-1-

428). (This compression and holding can be done with one hand.)

400).

-1-

912) by holding the T-piece (128

-0-

screws (128

-1-

914) and circlip (128

988) by inserting the cable thru the positioning arm

-1-

424) in the power cable assembly (128

-1-

926).

-0-

437). (Specially made tool

-0-

428), T

he pointed end of

-0-

428).

-0-

437) (Including the

-0-

437) tightly against

-1-

916). Make sure that the

Page 8 of 41

-0-

Page 9

Service Manual Aktilite

1.7 Housing bottom module (128

-0-

820)

CL128

The housing bottom c

Clean the glass if necessary before final assembly.

1.8 Housing back module (128

Required items

Part # 128

-1-

812

128

-1-

905

128

-1-

814

128

-1-

815

Assembly description

Step 1)

Place the fan (128 using the four M4x10 screws (128 must face upwards relative to the housing back (128 the top than at the bottom)

# of items

-1-

905) in the recess of the back housing (128

omes fully assembled as a s

-0-

810) assembly

Description Housing back (Moulded plastic) Fan Screws M4x10 (DIN 7985) Washer

-1-

814) and the four washers (128

-1-

pare part.

-1-

812) and mount the fan

812). (The housing back is wider at

-1-

815). The fan cable

Version 1.

Page 9 of 41

Page 10

Service Manual Aktilite

1.9 Lamp head module (128

1.9.1

see slide series

ixed lamp head

Required items

Part # 128

-0-

610

128

-0-

400

128

-1-

914

128

-1-

912

128

-1-

916

128

-1-

202

128

-0-

810

128

-1-

928

128

-0-

439

128

-1-

921

128

-0-

750

128

-0-

820

128

-1-

929

128

-1-

890

128

-1-

923

128

-1-

945

inm Chapter 1.9.3

# of items 1 1 2 1 1 1 1 4 1 6 1 1 4 1 2 1

CL128

-0-

200) assembly

Description Housing top module Positioning arm module Aluminium washer Conic spring Circlip Power cable Housing back module Screws PT 4x30 System electronics module Screws PT 2,5x8 Light module Housing bottom module Screws PT 4x10 Main arm mini cover (moulded plastic) Screws PT 3x10 Ca

ble tension release

From PS to lamp head (fixed lamp head only)

(fixed lamp head only)

Assembly description

Step 1)

Assemble position arm module (128 the short axle of the main arm (128

Step 2)

Slide an alumi aluminium washer (128 inside of the housing.

Step 3)

Compress the conical spring (128 easiest

done with a special made tool (see pictures)

securely in the groove.

Step 4)

Assemble power cable (128 (128

-0-

400). Leave exc

Step 5)

Position housing back module (128 0-

610). Do not assemble with screws yet.

Step 6)

Insert power cable (128 cable marked 2 is minus [-]), fan cable plug from housing back module (128 from the user interface of the housing top module 128 the system electronics module (128

06.03.2002: "LED cables CL128, Rev. A".

Step 7)

Fasten the system electronics module (128 using the six PT 2,5x8 screws (128

302) from the lamp head.

Step 8)

Plug the six cables from the system electronics module (128 connectors on the LED-panels (128

Step 9)

Tidy the cables from the system electronics modul

four miniature cable holders (128 Step 10) Seat the light module (128 Step 11) Remove the protective foil from the protective window

module (128 Step 12) Assemble the housing bottom module (128

using the four PT 4x10 screws (128 Step 13) Fasten the housing back module (128

4x30 screws (128 Step 14) Assemble the main arm mini cover (128

using the two PT 3x10 screws (128 Step 15) Assemble the cable tension release (128

inserting it into the T-piece cover (128

nium washer (128

-1-

914) onto the short axle of the main arm (128

This is very important.

ess cable inside the lamp head to simplify assembly in a later step.

-1-

302) ends into appropriate rece

-0-

820).

-1-

928).

-0-

400) to housing top module (128

-0-

428) thru the housing top slide bearing (128

-1-

914), a conical spring (128

-1-

912) and assemble the circlip (128 . Make sure that the circlip is located

-1-

302) by inserting the cable thru the positioning arm module

-0-

810) at the back end of the housing top module (128

-0-

439

). Refer to cable spec from Kitron Development

-0-

439

) to the housing top module (128

-1-

921). And pull out the excess powe

-1-

762) of the light module (128 e (128

-1-

944) on the light module (128

750) properly in the housing top module (128

-0-

820) to the housing top module (128

-1-

929).

-0-

820) to the rest of the lamp head us

-1-

890) to the positioning arm module (128

-1-

923).

-1-

945) around the power cable (128

-1-

424) of the positioning arm module (128

-0-

610) by sliding

-1-

632).

-1-

912) and another

-0-

428) from the

-1-

916). This is

ptors (cable marked 1 is plus [+],

-0-

810) and tail

610 into appropriate connectors on

-0-

610)

r cable (128

-0-

439

) into the appropriate

-0-

750).

-0-

439) by inserting them thru the

-0-

750).

-0-

(128

-1-

826) of the housing bottom

ing the four PT

-1-

610).

-0-

302) and

-0-

-1-

610)

400)

400).

Version 1.

Page 10

of 41

Page 11

Service Manual Aktilite

1.9.2 Detachable lamp head Required items

Part # 128

-0-

610

128

-0-

400

128

-1-

914

128

-1-

912

128

-1-

916

128

-0-

810

128

-1-

928

128

-0-

439

128

-1-

921

128

-0-

750

128

-0-

820

128

-1-

929

128

-1-

890

128

-1-

923

# of items

CL128

Description Housing top module Positioning arm module Aluminium washer Conic spring Circlip Housing back module Screw System electronics module Screw Light module Housing bottom module Screw Main arm mini cover (moulded plastic) Screw

PT-K 40x30 WN 1452

PT 2,5x8

PT 4x10

PT 3x10

Assembly description

Step 1)

Assemble position arm module (128 the short axle of the main arm (128

Step 2)

Slide an aluminium washer (128 aluminium washer (128 inside of the housing.

Step 3)

Compress the be done with a special made tool. Similar to a large pair of channel locks, but with custom heads. Make sure that the circlip is located securely in the groove.

Step 4)

Position housing bac 0-

610). Do not assemble with screws yet.

Step 5)

Insert power cable (128 cable marked 2 is minus [-])

Step 6)

Fan cable plug from housin the housing top module 128 system electronics module (128

Step 7)

Refer to PCU-010-128 for the connection of the cables going fro board to the LED arrays..

Step 8)

Fasten the system electronics module (128 using the six PT 2,5x8 screws (128

302) from the lamp head.

Step 9)

ug the six cables from the system electronics module (128

connectors on the LED-panels (128

Step 10) Tidy the cables from the system electronics module (128

four miniature cable holders (128 Step 11) Seat the light module (128 Step 12) Remove the protective foil from the protective window (128

module ( Step 13) Assemble the housing bottom module (128

using the four PT 4x10 screws (128 Step 14) Fasten the housing back module (128

K 40x30 screws (128 Step 15) Assemble the main arm mini cover (128

using the two PT 3x10 screws (128

128

-1-

914) onto the short axle of the main arm (128

conical spring (128

k module (128

-0-

988) ends into appropriate receptors (cable marked 1 is plus [+],

g back module (128

-0-

820).

-1-

928)

-0-

400) to housing top module (128

-0-

428) thru the housing top slide bearing (128

-1-

914), a conical spring (128

-1-

912) and assemble the circlip (128

-0-

810) at the back end of the housing top module (128

-0-

810) and tail from the user interface of

610 shall be inserted into appropriate connectors on the

-0-

439

-0-

439

) to the housing top module (128

-1-

921). And pull out the excess power cable (128

-1-

762) of the light module (128

-0-

-1-

944) on the light module (128

750) properly in the housing top module (128

-0-

820) to the housing top module (128

-1-

929).

-0-

810) to the rest of the lamp head using the four PT

-1-

890) to the positioning arm module (128

-1-

923).

-0-

610) by sliding

-1-

912) and another

-0-

428), from the

-1-

916). This must

m the electronic control

-0-

439

) into the appropriate

-0-

750).

439

) by inserting them thru

-0-

750).

-0-

610).

-1-

826) of the housing bottom

-0-

632).

610)

-1-

610)

-0-

the

400)

Version 1.

Page 11

of 41

Page 12

Service Manual Aktilite

1.9.3 Disassemly and Assembly of

The lamp head module assembly slide series in this chapter is based on head. However, there are only minor differences between lamp head module assembly for fixed and detachable lamp head

Warning: The gas springs inside the arm is very powerful

. The below slide series is therefore common for both lamp head variations.

the lamp

therefore secure the arm with a strap

CL128

slide series

Required Tools

Nylon Strap length minimum 45 cm Pair of telephone pliers Circlip pliers for 16 mm circlip Torx T7 screwdriver Torx T10 screwdriver Torx T20 screwdriver Philips PH Tool to compress the spring mechanism Allen key (5mm)

the Aktilite

2 screwdriver

CL128 with fixed lamp

Step 1

Put on a strap or similar to secure the parallel arm.

Step 2

Step 2-5 is only necessary if you need to take off the main arm, the housing or replace the cable.

Remove the main arm using a pair of pliers

or lamps with deta

Disconnect the plug and lamp head holder locking screw using the Allen key

strain relief (black) on the end of the

chable lamp head:

cable

plug

from the T-piece cover

detach

the lamp head by

removing

the

provided

Version 1.

Page 12

of 41

Page 13

Service Manual Aktilite

Step 3

Step 2-5 is only necessary if you need to take off the main arm, the housing or replace the cable.

Remove the strain relief.

Not applicable for lamps with detachable lamp head

Step 4

Step 2-5 is only necessary if you need main arm, the housing or replace the cable.

Remove the small cover on the main arm T10 screwdriver

CL128

to take off the

using the

Step 5

Step 2-5 is only necessary if you need to take off the main arm, the housing or replace the cable.

Feed a few cm loop as shown.

of cord through the arm to make a

Version 1.

Page 13

of 41

Page 14

Service Manual Aktilite

Step 6

Unscrew the fan housing screwdriver.

CL128

(4 Screws)

using the T20

Step

Unscrew the screwdriver. (

Step 8

The last screw sits by the fan.

housing bottom using the T20

4 screws)

Version 1.

Page 14

of 41

Page 15

Service Manual Aktilite

Step 9

Carefully lift up the light module.

Do not lift by the lenses, but lift the heat sink.

Step 10

Gently remove the light module.

CL128

Step 11

Place the light module on the side of the housing. Be careful with the leads.

Version 1.

Page 15

of 41

Page 16

Service Manual Aktilite

Step12

ut somethin

support it.

Step 13

Step 13 the main arm or the housing

CL128

g underneath

is only necessary if you need to change

the light module to

Use the circlip pliers to release the circlip.

Step 14

Step 13 t

Circlip tool

is only necessary if you need to change

he main arm or the housing

Version 1.

Page 16

of 41

Page 17

Service Manual Aktilite

Step 15

Step 13 the main arm or the housing

Take off the washers and spring.

Step 16

Step 13 the main arm or the

Bring out

CL128

is only necessary if you need to change

housing

the main arm

Step 17

The control electronics is fastened with 6 Torx 0,7 screws

Step 18

The picture shows the electronics control board and its connections. Wiring can be found in chapter 1.2

assembly

shown by the arrows.

Read

y tetst system electronics module (128

and on the next page.

-0-

439

)

Version 1.

Page 17

of 41

Page 18

PWR

FAN

NTC s

KEYPAD

Service Manual Aktilite

CL128

Version 1.

LED

LED2 LED

Page 18

of 41

Page 19

Service Manual Aktilite

CL128

Version 1.

Page 19

of 41

Page 20

Service Manual Aktilite

CL128

Version 1.

Page 20

of 41

Page 21

Service Manual Aktilite

Step 19

If you change the electronics, the DC input cable and

Step 20

CL128

flat

DC cable (+) is at the right most position The cable is marked with a (1) sign The fan connector can be seen to the left most position

keypad cable has to be

disconnected.

Version 1.

Step 21

It is easier to engage the flat cable to the connector receptacle by having a

Step 22

You can use a very small flat pair of pliers to engage the cable.

0.5 mm spacer underneath.

Page 21

of 41

Page 22

Service Manual Aktilite

Step 23

Step 23 the housing or main arm.

Put back on the washers and spring.

Step 24

Step 23 the housing or main arm.

The last washer must be properly seated into the hole.

CL128

is only relevant if you have changed

Step 25

Step 23 the housing or main arm.

You have to get the washer well inside the hole else it will not fit on to the axle.

is only relevant if you have changed

Version 1.

Page 22

of 41

Page 23

Service Manual Aktilite

Step 26

Step 23 the housing or main arm.

Test that the washer fits on to the axle.

Step 27

Step 23 the housing or main arm.

Use a tool to compress the spring mechanism. tool may look different to the one on the picture) A

modified

CL128

is only relevant if you have changed

clamp can also be used.

(The

Step 28

Step 23 the housing or main arm.

Compressing the spring by turning the rotary wheel on the tool clock-wise.

Step 29

Step 23 the housing or main arm.

The circlip can now be engaged on the main arm axle.

is only relevant if you have changed

Version 1.

Page 23

of 41

Page 24

Service Manual Aktilite

Step 30

Step 23 the housing or main arm.

Make sure that the circlip is properly engaged in the groove.

This is very important.

The main arm my fall of and heart the patient if this is not done properly.

Step 31

Place the light module back on the housing. You

CL128

can see the positioning marks on the housing.

is only relevant if you have chang

Step 32

Position the housing bottom

Step 33

Mount back the 4 Torx

20 screws.

Version 1.

Page 24

of 41

Page 25

Service Manual Aktilite

Step 34

Put

Make sure that the fan wires are not hitting the fan blade.

CL128

back

the fan

and

cover.

Step 35

Step 36

Tighten up the cord and put on the side cover using the T10 screwdriver.

asten the fan with the 4 Torx 20 screws.

Version 1.

Page 25

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Page 26

Service Manual Aktilite

Step 37

Put on the strain relief

or lamps with deta

Place the lamp head in the lamp head holder on t parallel arm and secure the connection with the locking screw using the provided Allen key. Connect the cable plug in the T-piece cover plug

Step 38

Position the strain relief into the hole in the cap.

CL128

chable lamp head:

Not applicable for lamps with detachable head

Step 39

Use a pair of of the strain relief.

Not applicable for lamps with detachable lamp head

telephone

pliers for the final assembly

lamp

Step 40

After final assembly, test that the lamp is functioning OK and that nothing is obstructing the fan.

This is done by:

If the repairs are done to the light module or electronics the lamp has to be fully tested according to test specifications.

Version 1.

Attaching power to the lamp and pressing the start button on the display panel. After self test is over, press start again to start the lamp. Do not stair into the light. Press stop after a few seconds of operation to stop the

Ref. Instructions in PCU-009-128.

lamp.

Page 26

of 41

Page 27

Service Manual Aktilite

1.10 Stop block module (TS1 Required items

Part # 128

-1-

223

TS1

-1-

250

# of items

-0-

250) assembly

Description Parallel arm Stop block module

CL128

Version 1.

Assembly description

Step 1)

Fit the stop block module onto the shaft of the parallel arm.

stop plate points upwards and engages with the slot on the parallel arm.

ham

mer and a purpose-made cylinder over the shaft to knock the stop block module into place. The gap between the arm and the stop block module should be as little as possible and no more than 1 mm.

Step 2)

Secure the stop plate by tightening the S3 driver.

Assure that the tap on the

Use a

Allen

screw to a t

orque of 3.0 Nm using a torque

Page 27

of 41

Page 28

Service Manual Aktilite

1.11 Lamp including parallel arm assembly

1.11.1 Fixed lamp head (128 Required items

Part # 128

-0-

200

128

-0-

210

128

-1-

216

128

-0-

213

128

-1-

937

128

-1-

942

128

-1-

916

128

-1-

211

128

-1-

936

128

-1-261 1

128

-1-

136

128

-1-

956

# of items

-0-

250)

Description Lamp head module Parallel arm with lamp head holder unit Fricti Spring unit Screw Aluminium washer Circlip Cover Screws M4x10 countersunk Re

ceptacle Body (Bayonet plug) Label Power Plug Loctite 243 glue

on pad

Set screw M8x12

Lamp head holder unit

CL128

Assembly description

Step 1)

Insert the friction pad (128

210).

Step 2)

Slide the vertical axle of the lamp head modul of the parallel arm (128

Step 3)

Slide the aluminium washer (128

Step 4)

Assemble the circlip (128 sure that the circlip is fully engaged in the groove

Step 5)

Insert the spring unit (128 unit of the parallel arm (128

Step 6)

Assemble the M6x12 set screw (128 holder unit of the parallel arm (128 friction in the vert

Step 7)

Assemble the cover (128

210) using the two countersunk M4x10 screws (128

Step 8)

Pull the power cable (128 arm (128 (128 extreme positions of the lamp head.)

Step 9)

Put the stain relief onto the DC power made crimping tool. Put the cord numbered 1 into "D" [+] in the with cord marked 2 in "B" [-] in the specially made extract

Step 10) Put a drop of Loctite 243 on the threads at the strain relieve threads and screw the strain

relief to the

Step 11) Remove the pr

attach the label to the cord, next to the

-0-

200) and the parallel arm (128

-1-

216) in the lamp head holder unit of the parallel arm (128

e (128

-0-

200) into the lamp head holder unit

-0-

210).

-1-

942) onto the vertical axle.

-1-

916) onto the vertical axle. Make on the axle.

-0-

213) into the lamp head holder

-0-

210).

-1-

937) into the lamp head

-0-

210). Tighten until the

ical axle is appropriate.

-1-

211) onto the lamp head holder unit of the parallel arm (128

-1-

302) from the lamp head module (128

210). Leave about 10 cm of slack on the cable between the lamp head module

or tool to release the pins from the

bayonet

plug. Secure the lead with the cross bar and two self threading screws.

otective paper from the backside of the Label Power Plug (128

-1-

936).

-0-210). (So the cable doesn t get stretched at the

cable. Put on the male crimp pins using the specially

bayonet

NB! Use new stronger plug

plug. If you make a mistake, you can use the

bayonet

plug (see picture below).

for repair

ed lamps, ref Chapter

bayonet

-0-

200) thru the para

bayonet

plug again.

Souriau UTS 6JC104P

plug, and the pin

-1-

136) and

-0-

llel

Version 1.

Page 28

of 41

Page 29

1.11.2

Service Manual Aktilite

etachable lamp head (128

Required items

Part # 128

-0-

200

128

-0-

212

128

-1-

959

128

-1-

960

128

-1-

963

128

-1-

964

128

-1-

974

128

-1-

973

128

-1-

975

128

-1-

972

128

-1-

976

128

-1-

977

128

-1-

980

128

-1-

916

128

-1-

263

128

-1-

956

128

-1-

991

128

-1-

136

# of items

CL128

-0-

252)

Description Lamp head module Parallel arm with lamp head holder unit Lamp head holder inner right Lamp head holder Lamp head holder top cover Break shoe Break pad spring Umbraco screw DIN912 M5×25 Hexagonal nut DIN934 M5 Spring lock washer DIN127A M5 Teflon-bronze wash Security pin DIN1481 Ø4×20 Umbraco screw DIN912 M5×45 Circlip Crimp pin Loctite 243 glue Plug UTS6JC104P Label Power Plug

inner left

er (Frimet)

Version 1.

Page 29

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Page 30

Service Manual Aktilite

Assembly description

Step 1) Ass

Step 2) Insert break shoe (128

Step 3) Assemble the inner lamp head holders (128

NOTE: The parallel arm shall be secured with

Step 4) Assemble the lamp head module (128

Step 5) Assemble the top cover (128

Step 6) Put the stain

Step 7) Put a dr

Step 8) Remove the protective paper from the backside of the Label Power Plug (128

emble chronologically the security pin (128

(128

-1-

916) onto the T-piece

engaged in the groove on the axle.

959 and 128 lamp head holder for the

437) corresponding nuts (128

open uncontrolled. There are very strong springs inside the parallel arm that can cause serious damage when the lamp head is not installed.

outer lamp head holder on the parallel arm (128 spring lock washer (128 and outer lamp head holders.

Note that the cover shall be installed with the knobs located on the inside of the cover at the lamp head side, i.e. away from the parallel arm.

made crimpi cord marked 2 in "B" [-] in the bajonet plug. If you make a mistake, you can use the specially made extractor tool to release the pins from the bajonet plug again.

relief

attach the label to the cord, next to the bajonet plug

-1-

vertical axle and secure them using the two M5×25 umbraco screws (128

relief

ng tool. Put the cord numbered 1 into "D" [+] in the bajonet plug, and the pin with

op of Locktite 243 (128

to the bajonet plug.

(128

-0-

437)

vertical axle. Make sure that the circlip is fully

-1-

964)

and

sprin

g (128

960). The orientation of the break shoe is given by a small recess spring to rest again

-1-

975)

the

-0-

200) by position the inner lamp head holder to the

-1-

972) and the M5×45 umbraco screw (128

-1-

963) onto the lamp head holder by pressing it down in pos

onto the DC power cable. Put on the male crimp pins using the specially

-1-

956) on the threads at the strain

CL128

-1-

977), teflon washer (128

-1-

974) in

-1-

959 and 128

attached strap to avoid the

-0-

212

both

inner lamp head

-1-

960

) onto the T-piece (128

). Secure the position by installing the

relief

(see picture below).

-1-

parallel arm to

-1-

980) through both inner

and screw the strain

976) and circlip

holders (128

in the inner

-1-

973) and

-1-

136) and

-1-

-0-

ition.

Version 1.

Page 30

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Page 31

Service Manual Aktilite

1.12 Parallel arm with lamp head holder unit

1.12.1 Fixed lamp head Required items

Part # 128

-1-

223

128

-1-

220

128

-1-

221

128

-1-

222

128

-1-

943

128

-1-

939

128

-1-

940

Assembly description

Step 1)

Screw one side plate R (128 that the bracket has the right orientati

Step 2)

Put the bushings (128

Step 3)

Assemble the bracket with the side plate to the parallel parallel arm enters the bushings.

Step 4)

Assemble the side plate L (128 the parallel arm. Screw it to the bracket using 4

Step 5)

Secure the two 52 x 6 mm Caps on both sides. Use a plastic hammer to prevent the C

(128

# of items

-0-210)

Description Parallel arm Bracket Side plate R Side pl Bushing Screws PT-5 x 12 mm Starlocks Caps BV 6666-03C

ate L

-1-

221) to the bracket (128 on, refer to drawing.

-1-

943) in the holes in both side plates.

-1-

222) to t

pin bolts

going through the

CL128

assembly

he bracket, so that the bushing enters the axle on

-1-

220) using 4

arm;

assuring that the axles from the

screws.

side plates

aps to be damaged.

screws . Assure

R and L with Starlock

Version 1.

Page 31

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Page 32

Service Manual Aktilite

1.12.2 Detachable lamp head (128 Required Items

Part # 128

-1-

223

128

-1-

961

128

-1-962 1

128

-1-

968

128

-1-

969

128

-1-

965

128

-1-

966

128

-1-

967

128

-1-

940

128

-0-

989

# of items

Description Parallel arm Lamp head holder outer right Lamp head holder outer left Pinbolt upper Pinb Screw cap for top screw Screw cap for bottom screw Screw Starlock Caps BV 6666-03C Cable from PS unit to lamp head connector

-0-

212)

olt lower

PT-K 40x35

CL128

Step 1) Position the pow

Step 2) Install the upper (128

Step 3) Assemble the right (128

Step 4) Screw the two PT-K 40x35 (128

Step 5) Assemble the upper (128

Version 1.

Assembly description

er cable (128 connector at the lamp head side. The power cable shall be positioned with sufficient slack (approx. 15cm) on the lamp head side to avoid the cable to get stretched at the extreme positions of the lamp head.

parallel

arm

secure the position with the four

(128

-1-

961)

-0-

989) in the parallel arm (128

-1-

968) and lower (128

-1-

961) and left ( starlock

-1-

967) through the holes in the outer right lamp head holder

-1-

965) and lower (128

-1-

223) with the installed male

-1-

969) pinbolt in the respective holes in the

128

-1-

962

) lamp head holders in the pinbolts and

cap

s (128

-1-

940)

. Avoid damage to the starlocks.

-1-

966) screw cap

Page 32

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Page 33

Service Manual Aktilite

1.13 Labels placement description Required items

Part # 128

-0-

250

128

-1-

138

128

-1-

142

128

-1-

146

# of items

Description Lamp including parallel arm Label Serial Number Label Warning and Special Waste Label Detachable Lamp Head Warning

Only applicable for lamps with detachabl

CL128

e lamp head

Assembly description

Step 1)

Place the labels

Product label with S arm (ref. position A) Label Warning and Special Waste on the left side head

(ref. position C)

Label Detachable Lamp Head Warning

Only applic

according to the pictures above

erial no.

able for lamps with detachable lamp head

and manufacturing date on

on the left lamp head holder

of the parallel arm

the inside of the positioning

, near the lamp

(ref. position

Version 1.

Page 33

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Page 34

Service Manual Aktilite

Replacing the DC Power Plug

Assembly description

Step 1)

Dismantle the existing plug

Step 2)

Step 3)

Step 4)

Step 5)

cross bar. to release the pins from the bajonet plug Put the stain relief crimp pins using the specially made crimping tool. Put the cord numbered 1 into "D" [+] in the make a mistake, you can use the specially made extractor tool to release the pins from the bayonet Put a drop of Loc the Double check:

If you have a CL16 power supply available when you perform the plug replacement on the CL128, you can use this to t the lamp with full light, but you can start the lamp and see that the menu switches on when you push the start button. The CL16 supply is not powerful enough to harm the lamp in any way, but wrong polarity is used. If the test is OK, switch over to the CL128 power supply.

Unscrew the

bay

onet

plug again.

bayonet

the CL128 power supply will damage the protection circuit of the lamp if the

(128

-1-

strain relieve

for the new plug

plug, and the pin with cord marked 2 in "B" [

tite on the threads at the strain relief thread

plug.

Cord marked Cord marked

est that you have the right polarity. You will not be able to run

CL128

261)

by removing the two self threading screws for the

from

the plug. Use the specia

(128

-1-

991)

onto the DC power cable. Put on the male

1 into "D" [+ 2 into "B" [

] in the

or red

or black

lly made extractor tool

bayonet

s and screw the strain relief to

] ]

plug. If you

Version 1.

New plug

The plug may look s instead of

To use the extractor tool, press the tool firmly into the connector by holding the centrepiece of the tool, and continue to press onto the top piece.

If wires have to be reconnected to the pins, it is recommended to solder them on, as otherwise this requires special crimping tools.

black

Part

number for the

(

RM16M23K

rt number for the wall mounted

128

-1-

345 (RC16M23K)

lightly different from the

Souriau UTS 6JC104P plug is

)

connector

above picture. It also comes with a

128

-1-

323 Souriau UTO 0104SH with mating pins

Extractor tool

-1-991 with pins (extra) 128

silver

ring in the front

-1-

263

Page 34

of 41

Page 35

3.1 Material/Equipment

Assembly of Aktilite CL128 Power Supply

Tools needed for the assembly of the Aktilite CL128 Power Supply

Required to

# of items 1 1 1 1

ols

Description Screwdriver, Pozidrive 2 Screwdriver, Torx 10 Tool B Screwdriver, Torx 20 Tool C Paint removing tool (drill or grinder)

Service Manual Aktilite

Tool A

CL128

Tool D

Version 1.

Page 35

of 41

Page 36

Service Manual Aktilite

3.2 PS electronics module (128 Required items

Part #

128

-1-

331

128

-0-

332

128

-0-

333

128

-0-

334

128

-0-

335

128

-0-

336

128

-1-

337

Assembly description

Step 1)

Assemble the cables A (128 electronics (128 marked N, Cable B (brown) is connected to the terminal marked L, and Cable C (green/yellow) is connected to the terminal marked with the ground symbol. Bend the three cable shoes to a 45 deg

Step 2)

Assemble the cables D (128 using Tool A. Cable D is connected to terminal 1, and cable E is connected to terminal 4.

Step 3)

Thread both loa

Step 4)

Make sure that the 7 cable terminal screws are securely tightened.

Step 5)

Remove the two printed forms that are tucked between some components on the power supply electronics. Save them for markin Record.

of items

-1-3

31), by using Tool A. Cable A (blue) is connected to the terminal

ree angle upwards when the electronics lies flat on the table.

d cables (Cables D and E) through the ferrite (128

CL128

-0-

330) assembly

Description PS electronics Cable A Cable B Cable C Cable D Cable E Ferrite (for the load cables) Tool A - Screwdriver, pozidrive 2

-0-

332), B (128

-0-

335) and E (128

Blue AC conductor Brown AC conductor Green/yellow

Red D Black DC cable

g of the complete unit and the Device History

Tested to medical std. and adjusted by Kitron

ground

C cable

-0-

333) and C (128

-0-

336) to the power supply electronics, by

cable

-0-

334) to the power supply

-1-

337) 5 times.

Version 1.

Page 36

of 41

Page 37

Service Manual Aktilite

3.3 PS housing module A (128 Required items

Part # 128

-1-

311

128

-1-

312

128

-1-

313

# of items

CL128

-0-

310) assembly

Description PS housing profile, type A AC power inlet plug Screws PT3x10 wn1553K30x10 Tool B, screwdriver Torx 10

Assembly description

Step 1)

Assemble the AC power inlet plug (128

311), with the 2 screws (128 the central pin facing upwards. Use Tool B.

-1-

312) onto the PS housing profile, type B (128

-1-

313). Make sure it is fastened in the correct position, with

-1-

Version 1.

Page 37

of 41

Page 38

Service Manual Aktilite

3.4 PS housing module B (128 Required items

Part # 128

-1-

321

128

-1-

323

128

-1-

324

128

-0-

330

128

-1-

322

# of items

CL128

-0-

320) assembly

Description Power supply housing profile, type B DC power outlet plug Screws PT 3x8 Power supply electronics module Screws M4x10 countersunk Tool B, screwdriver Torx 10 Tool C, screwdriver Torx 20

pan head

Assembly description

Step 1)

Assemble the DC power outlet plug (128

321), with the 4 button head PT-DG screws (128 correct position, with one of the 3 locking pins facing upwards. Use Tool B.

Step 2)

Remove the paint from two of the 4 holes in the PS h PS electronics module, to ensure electric contact between the M4 screw and the PS housing profile B. Use Tool D.

Step 3)

Assemble the PS electronics module (128 1-

321), with the 4

the same side of the profile as the power outlet plug. Use the Use Tool C.

Step 4)

Plug the red and black load cables into the correct holes in the power outlet plug. The red load cable (+) goes into the slot marked D, and the black load cable (-) goes into the slot marked B.

screws (128

-1-323) onto the PS housing profile B (128

-1-

324). Make sure it is fastened in the

ousing profile B, for assembling the

-0-

330) onto the PS housing profile, type B (128

-1-

322). Make sure that the red and black load cables are on

-1-

Version 1.

Page 38

of 41

Page 39

3.5 Power supply (128 Required items

Part # 128

-0-

320

128

-0-

310

128

-1-

301

128

-1-

302

128

-1-

306

128

-1-

307

128

-1-

309

Service Manual Aktilite

-0-

300) assembly

# of items

Description PS housing module B PS housing module A PS housing PS housing bottom cover Countersunk s Rubber pads (self adhesive) Label on Strip, glue or other suitable means of fixing the ferrite to the PS

electro

nics metal casing. Tool C screwdriver Torx T20 Tool D, paint removing tool (drill or grinder)

CL128

top cover

crews 4.2x19

side wall of power supply

Assembly description

Step 1)

Put the PS housing module B (128

Step 2)

Step 3)

Step 4)

Step 5)

Step 6)

Step 7)

module A (128 sure that the three power inlet cables are reachable. Connect the three AC power inlet cables to the AC power inlet plug. Make sure that the cables are correctly connected, blue cable to the tongue marked N, brown tongue marked L, and the green/yellow cable to the metal tongue marked with the ground symbol. See that the voltage can be adjusted to more than 51.2 Volts and then adjust the voltage down again to 50.4 Volts by means of a thin screwdriv power supply cannot be adjusted to 51.2 V or more, the power supply should be rejected. Fix the ferrite to the PS electronics' metal casing with a strip, silicone or other means. There are two holes in the PS electronics Remove the paint from two of the 8 holes in each of the PS housing end covers, to ensure electric contact between the PT-DG screw and the PS housing profiles. Use Tool D Assemble one PS housing top cover (128 Make sure that the two housing modules are aligned before inserting the two screws that engage with both modules. These two screws may be left until the other 6 screws are tightened. Ensure electric contact between the end cov Assemble the other power supply end cover (128

-0-

320) upside down on the table. Slide the PS housing

310) gently into module B.

' metal casing, suitable for this.

-1-

Make sure that all 4 grooves engage. Make

cable to the metal

er according to TCU-002-128. If the

301) with

the PT-DG screws (128

ers and one of the housing modules.

-1-

301).

-1-

306).

Version 1.

Page 39

of 41

Page 40

Step 8)

Step 9)

Service Manual Aktilite

Place the four rubber pads (128 picture above. Apply label (128

-1-

307) on the lower PS housing end cover, as shown on the

309) to the Power Supply

CL128

side wall.

The Aktilite CL128 has in-built monitoring features. If an error should occur, the display will show the following message and five rapid beeps will be heard:

If an error code is displayed, or if any other unexpected condition occurs (e.g. lamp does not operate), the following steps should be taken:

Version 1.

Error Codes

Page 40

of 41

Page 41

Service Manual Aktilite

1. Disconnect the mains ca

2. Reconnect the mains cable

3. Check all cables and connections

4. Switch on and check if the lamp can be used as normal

5. If the error persists, refer to the table below

Error

Code

1101 1102 1103 1

104

1105 1107 1109 1110 1112 1117

1206

1208

1211

2105 2107 2109 2110 2112 2206

2208

2211

2213 2214 2215 2216

Device internal error Device internal error Device internal error Key was pressed during switch-on self-test or Device internal error Device internal error Device internal error Device internal Device internal error Device internal error The lamp has reached the maximum allow Obstruction of cooling air inlet/outlet or Device internal error Obstruction of cooling air inlet/outlet or Device inte Obstruction of cooling air inlet/outlet or Device internal error Device internal error Device Device internal error Device internal error Device internal error Obstruction of cooling air inlet/outlet or Device internal error Obstruction of cooling air inlet/outlet or Device internal error Obstruction of cooling air inlet/outlet or Device internal error Device internal error De Device internal error Device internal error

ed number of illumination hours.

internal error

vice internal error

ble for at least 20 seconds

Aktilite CL128 Error Codes

NOTE: Refer to the instructions above

Possible Causes

error

rnal error

POST FLASH (Program memory) error. POST EEPROM (System parameters) error. POST RAM (Static memory) error. POST key stuck error.

POST too low enclosure temperature error. POST too low LED driver temperature error. POST too big variation LED driver temperatures error. POST too POST too big variation LED Need to recalibrate or replace the light source.

POST too high

POST too

POST to high LED array temperature error.

Self-test too low enclosure temperature error. Self-test too Self-test too big variation LED driver temperatures error. Self-test too Self-test too big variation LED driver temperatures error. Self-test too high enclosure temperature error.

Self-te

Self-test too

Self-test watchdog error. The software has been restarted. Self-test too high LED current for Self-test too high LED current for GUIDE LIGHT mode. Self-test too high or too low LED current for FULL LIGHT mode.

st too high LED

CL128

low

LED

enclosure

high

LED

low LED driver

low

LED

high

before using the table

Description

array

temperature error.

array

temperature error.

driver

temperature error.

array

temperature error.

driver

temperature error.

LED array temperature error.

temperatures error.

OFF

mode.

Version 1.

Page 41

of 41