CL128
SERVICE MANUAL
Aktilite
CL128
Ver 1.
3
Photoc
ure ASA
Hoffsveien 48
NO-
0377 OSLO, Norway
Phone: +47 22 06 22 10
www.photocure.com
Service Manual Aktilite
CL128
Version 1.
3
Page
2
of
41
SERVICE
MANUAL
Aktilite
CL128
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
1
ASSEMBLY OF AKTILITE
CL128 LAMP WITH PAR
ALLEL ARM.....................
3
1.1 M
ATERIAL
/E
QUIPMENT..................................................................................................
3
1.1.1 Tools needed for the assembly of lamp with fixed lamp head................................3
1.1.2
Tools need
ed for the assembly of lamp with detachable lamp head ......................
3
1.2 R
EADY
T
ESTED
S
YSTEM
E
LECTRONICS
M
ODULE
(128
-0-
439)
ASSEMBLY.....................
4
1.3 HO
USING TOP MODULE
(128
-0-
610)
ASSEMBLY .............................................................
5
1.4 L
IGHT MODULE
(128
-0-
750) ..........................................................................................
6
1.5 G
LUE LENSES .................................................................................................................
6
1.6 P
OSITIONING ARM MODUL
E
(128
-0-
400)
ASSEMBLY ......................................................
7
1.6.1
Fixed lamp head .....................................................................................................
7
1.6.2
Detachable lamp head............................................................................................
8
1.7 H
OUSING BOTTOM MODULE
(128
-0-
820) .......................................................................
9
1.8 H
OUSING BACK MODULE
(128
-0-
810)
ASSEMBLY ..........................................................
9
1.9 L
AMP HEAD MODULE
(128
-0-
200)
ASSEMBLY..............................................................10
1.9.1
Fixed lamp head ...................................................................................................10
1.9.2
Detachable lamp head..........................................................................................11
1.9.3
Disassemly and Assembly of the lamp
slide series............................................12
1.10 S
TOP BLOCK MODULE (TS1
-0-
250)
ASSEMBLY ............................................................27
1.11 L
AMP INCLUDING PARALL
EL ARM ASSEMBLY...............................................................28
1.11.1
Fixed lamp head (128
-0-
250)...............................................................................28
1.11.2
Detachable lamp head (128
-0-
252)......................................................................29
1.12 P
ARALLEL ARM WITH LAM
P HEAD HOLDER UNIT A
SSEMBLY ........................................31
1.12.1
Fixed lamp head (128
-0-
210)...............................................................................31
1.12.2
Detachable lamp head (128
-0-
212)......................................................................32
1.13 L
ABELS PLACEMENT DESC
RIPTION ...............................................................................33
2 REPLACING THE DC POW
ER PLUG.......................................................................34
3
ASSEMBLY OF AKTILITE
CL128 POWER SUPPLY.............................................35
3.1 M
ATERIAL
/E
QUIPMENT................................................................................................35
3.2
PS
ELECTRONICS MODULE
(128
-0-
330)
ASSEMBLY......................................................36
3.3
PS
HOUSING MODULE
A
(128
-0-
310)
ASSEMBLY..........................................................37
3.4
PS
HOUSING MODULE
B
(128
-0-
320)
ASSEMBLY..........................................................38
3.5 P
OWER SUPPLY
(128
-0-
300)
ASSEMBLY.......................................................................39
4
ERROR CO
DES ..............................................................................................................40
Service Manual Aktilite
CL128
Version 1.
3
Page
3
of
41
This service manual is primarily meant for mechanical repairs
and covers both Aktilite
CL128 lamps
with fixed and deta
chable lamp head
.
The electronic control board in the lamp head has to be programmed with the parameters
to match
the
calibrated light module. If the electronic control board is faulty then the complete board is changed and
programmed with the original p
arameters for the light module
.
These
can
only
be
r
etrieved from the
Device History Record for the lamp kept at the factory
and entering the device factory programming
mode can only be done by trained service personnel. The
light module consist of led arra
ys, heat sink
and lenses.
If a led diode is faulty then the complete
light module
is changed.
If a power supply
electronics board
is faulty, a new tested power supply can be obtained from
Photocure.
However, this has to be tested for leakage current,
eart
h continuity and withstanding voltage
test by qualified personnel.
1
Assembly of Aktilite CL128 Lamp with Parallel Arm
1.1
Material/Equipment
1.1.1
Tools needed for the assembly of lamp
with fixed lamp head
Required tools
# of
items
Description
1
Screwdriver,
Pozidrive 1
1
Screwdriver, Pozidrive 2
1
Screwdriver, Torx
T 7
1
Screwdriver, Torx
T 10
1
Screwdriver, Torx T 20
1.1.2
Tools needed for the assembly of lamp with detachable lamp head
Required tools
# of
items
Description
1
Screwdriver, Pozidrive 1
1
Screwdriver, Pozidrive 2
1
Screwdriver, Torx T 10
1
Screwdriver, Torx T 15
1
Screwdriver, Torx T 20
1
Allen key, 5mm
Umbraco
1
Press nut tool
1
Crimping tool LEMO DPC.91
-
701V
1
Locator male DCE.91.135.BVC
1
Locator female DCE.91.130.BVM
1
Ex
traction tool LEMO DCF.91.133.5LT
Service Manual Aktilite
CL128
Version 1.
3
Page
4
of
41
1.2
Ready Tested System
Electronics
Module
(128
-0-
439
) assembly
Service Manual Aktilite
CL128
Version 1.
3
Page
5
of
41
1.3
Housing top module (128
-0-
610) assembly
Required items
Part #
# of items
Description
128
-0-
978
1
Housing top (mould
ed plastic)
128
-1-
637
1
Housing top slide bearing
128
-1-
932
5
Screw
PT4x16 countersunk
128
-1-
626
1
Housing right (moulded plastic)
128
-1-
628
1
Housing left (moulded plastic)
128
-1-
931
4
Screw
PT4x25
128
-1-
636
1
User interface (foil keyboard w/ta
il)
Rubbing alcohol (fat free)
Assembly description
Step 1)
Assemble the housing top slide bearing (128
-1-
637) to the housing top (128
-0-
978) using
the five countersunk PT4x16 screws (128
-1-
932).
Step 2)
Assemble the housing left (128
-1-
628) and housing right (128
-1-
626) to the housing top
(128
-0-
978) using the four PT4x25 screws (128
-1-
931).
Step 3)
Clean the recessed area at the top of the housing top (128
-0-
978) using a cloth and rubbing
alcohol
Step 4)
Glue the Key Touch panel (128
-1-
636) to the housing top (128
-0-
978).
Service Manual Aktilite
CL128
Version 1.
3
Page
6
of
41
1.4
Ligh
t module (128
-0-
750)
This light module comes as a ready
tested and
calibrated part. The dose factor in the
control electronics
and currents
(set in factoring mode) has to be adjusted according to
the documentation f
ollowing
the specific light module.
To determine the dose factor,
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
le to light module.
1.5
Glue lenses
If one of the lenses is loose they can be glued on to the substrate using
Loctite 435
glue
.
Service Manual Aktilite
CL128
Version 1.
3
Page
7
of
41
1.6
Positioning arm module (128
-0-
400) assembly
1.6.1
F
ixed lamp head
Required items
Part #
# of items
Description
128
-0-437 1 T-
pi
ece (Moulded plastic)
128
-1-
910
2
Plastic bearing
s
128
-0-
428
1
Main arm (Moulded plastic)
128
-1-
914
2
Aluminium washer
s
128
-1-
912
1
Conical spring
128
-1-
916
1
Circlip
128
-1-
424
1 T-
piece cover (Moulded plastic)
128
-1-
926
2
Screw
s
PT3x25
Assem
bly description
Step 1)
Press the two plastic bearings (128
-1-
910) into the T
-
piece (128
-0-437
). (Specially made
tool is necessary for this or a jig made by Kitron.)
Step 2)
Slide conical spring (128
-1-
912) onto aft tube of the main arm (128
-0-
428), The pointed
end of the
conic spring (128
-1-
912) goes towards the plastic of the main arm (128
-0-
428).
Step 3)
Assemble one aluminium washer (128
-1-
914) and the T
-
piece (128
-0-437
) (Including the
already assembled plastic bearings (128
-1-
910)).
Step 4)
Compress the conical spring (128
-1-
912) by
holding the T
-
piece (128
-1-4
37
) tightly against
the main arm (128
-1-
428). (This compression and holding can be done with one hand.)
Step 5)
Assemble another aluminium washer (128
-1-
914) and circlip (128
-1-
916). Make sure that
the Circlip is well located in the g
roove.
Step 6)
Assemble T
-
piece cover (128
-1-
424) using the two PT3x25 screws (128
-1-
926).
Service Manual Aktilite
CL128
Version 1.
3
Page
8
of
41
1.6.2
D
et
a
chable lamp head
Required Items
Part #
# of items
Description
128
-0-
437
1 T-
piece (Moulded plastic)
128
-1-
910
2
Plastic bearing
128
-0-
428
1
Main arm (Moulded plasti
c)
128
-1-
914
2
Aluminium washer
128
-1-
912
1
Conical spring
128
-1-
916
1
Circlip
128
-0-
988
1
Cable from system electronics to lamp head connector
128
-1-
926
2
Screw
PT3x25
Assembly description
Step 1)
Press the two plastic bearing
s (128
-1-
910) into the T
-
piece (128
-0-
437). (Specially made tool
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
-1-
912) onto aft tube of the main arm (128
-0-
428), T
he pointed end of
the conic spring (128
-1-
912) goes towards the plastic of the main arm (128
-0-
428).
Step 4)
Assemble one aluminium washer (128
-1-
914) and the T
-
piece (128
-0-
437) (Including the
already assembled plastic bearings (128
-1-
910)).
Step 5)
Compress the conical
spring (128
-1-
912) by holding the T
-
piece (128
-0-
437) tightly against
the main arm (128
-1-
428). (This compression and holding can be done with one hand.)
Step 6)
Assemble another aluminium washer (128
-1-
914) and circlip (128
-1-
916). Make sure that the
Circlip is
well located in the groove.
Step 7)
Assemble power cable assembly (128
-0-
988) by inserting the cable thru the positioning arm
module (128
-0-
400).
Step 8)
Put in the cord and fasten the T
-
piece cover (128
-1-
424) in the power cable assembly (128
-0-
988) using the two PT3x25
screws (128
-1-
926).
Service Manual Aktilite
CL128
Version 1.
3
Page
9
of
41
1.7
Housing bottom module (128
-0-
820)
The housing bottom c
omes fully assembled as a s
pare part.
Clean the glass if necessary before final assembly.
1.8
Housing back module (128
-0-
810) assembly
Required items
Part #
# of items
Description
128
-1-
812
1
Housing back (Moulded plastic)
128
-1-
905
1
Fan
128
-1-
814
4
Screw
s
M4x10 (DIN 7985)
128
-1-
815
4
Washer
s
Assembly description
Step 1)
Place the fan (128
-1-
905) in the recess of the back housing (128
-1-
812) and mount the fan
using the four M4x10 screws (128
-1-
814) and the four washers (128
-1-
815). The fan cable
must face upwards relative to the housing back (128
-1-
812). (The housing back is wider at
the top th
a
n at the bottom)
Service Manual Aktilite
CL128
Version 1.
3
Page 10
of 41
1.9
Lamp head module (128
-0-
200) assembly
-
see slide series
inm Chapter 1.9.3
.
1.9.1
F
ixed lamp head
Required items
Part #
# of items
Description
128
-0-
610
1
Housing top module
128
-0-
400
1
Positioning arm module
128
-1-
914
2
Aluminium washer
s
128
-1-
912
1
Conic spring
128
-1-
916
1
Circlip
128
-1-
202
1
Power cable
From PS to lamp head
(fixed lamp head only)
128
-0-
810
1
Housing back module
128
-1-
928
4
Screw
s
PT 4x30
128
-0-
439
1
System electronics module
128
-1-
921
6
Screw
s
PT 2,5x8
128
-0-
750
1
Light module
128
-0-
820
1
Housing bottom module
128
-1-
929
4
Screw
s
PT 4x10
128
-1-
890
1
Main arm mini cover (moulded plastic)
128
-1-
923
2
Screw
s
PT 3x10
128
-1-
945
1
Ca
ble tension release
(fixed lamp head only)
Assembly description
Step 1)
Assemble position arm module (128
-0-
400) to housing top module (128
-0-
610) by sliding
the short axle of the main arm (128
-0-
428) thru the housing top slide bearing (128
-1-
632).
Step 2)
Slide an alumi
nium washer (128
-1-
914), a conical spring (128
-1-
912) and another
aluminium washer (128
-1-
914) onto the short axle of the main arm (128
-0-
428) from the
inside of the housing.
Step 3)
Compress the conical spring (128
-1-
912) and assemble the circlip (128
-1-
916). Thi
s
is
easiest
done with a special made tool
(s
ee pictures)
. Make sure that the circlip is located
securely in the groove.
This is very important.
Step 4)
Assemble power cable (128
-1-
302) by inserting the cable thru the positioning arm module
(128
-0-
400). Leave exc
ess cable inside the lamp head to simplify assembly in a later step.
Step 5)
Position housing back module (128
-0-
810) at the back end of the housing top module (128
-
0-
610). Do not assemble with screws yet.
Step 6)
Insert power cable (128
-1-
302) ends into appropriate rece
ptors (cable marked 1 is plus [+],
cable marked 2 is minus [
-
]), fan cable plug from housing back module (128
-0-
810) and tail
from the user interface of the housing top module 128
-0-
610 into appropriate connectors on
the system electronics module (128
-0-
439
). Refer to cable spec from Kitron Development
06.03.2002: "LED cables CL128, Rev. A".
Step 7)
Fasten the system electronics module (128
-0-
439
) to the housing top module (128
-0-
610)
using the six PT 2,5x8 screws (128
-1-
921). And pull out the excess powe
r cable (128
-1-
302) from the lamp head.
Step 8)
Plug the six cables from the system electronics module (128
-0-
439
) into the appropriate
connectors on the LED
-
panels (128
-1-
762) of the light module (128
-0-
750).
Step 9)
Tidy the cables from the system electronics modul
e (128
-0-
439) by inserting them thru the
four miniature cable holders (128
-1-
944) on the light module (128
-0-
750).
Step 10)
Seat the light module (128
-0-
750) properly in the housing top module (128
-0-
610).
Step 11)
Remove the protective foil from the protective window
(128
-1-
826) of the housing bottom
module (128
-0-
820).
Step 12)
Assemble the housing bottom module (128
-0-
820) to the housing top module (128
-0-
610)
using the four PT 4x10 screws (128
-1-
929).
Step 13)
Fasten the housing back module (128
-0-
820) to the rest of the lamp head us
ing the four PT
4x30 screws (128
-1-
928).
Step 14)
Assemble the main arm mini cover (128
-1-
890) to the positioning arm module (128
-0-
400)
using the two PT 3x10 screws (128
-1-
923).
Step 15)
Assemble the cable tension release (128
-1-
945) around the power cable (128
-1-
302) and
inserting it into the T
-
piece cover (128
-1-
424) of the positioning arm module (128
-0-
400).
Service Manual Aktilite
CL128
Version 1.
3
Page 11
of 41
1.9.2
Detachable lamp head
Required items
Part #
# of items
Description
128
-0-
610
1
Housing top module
128
-0-
400
1
Positioning arm module
128
-1-
914
2
Aluminium washer
128
-1-
912
1
Conic spring
128
-1-
916
1
Circlip
128
-0-
810
1
Housing back module
128
-1-
928
4
Screw
PT
-
K 40x30 WN 1452
128
-0-
439
1
System electronics module
128
-1-
921
6
Screw
PT 2,5x8
128
-0-
750
1
Light module
128
-0-
820
1
Housing bottom module
128
-1-
929
4
Screw
PT 4x10
128
-1-
890
1
Main arm mini cover (moulded plastic)
128
-1-
923
2
Screw
PT 3x10
Assembly description
Step 1)
Assemble position arm module (128
-0-
400) to housing top module (128
-0-
610) by sliding
the short axle of the main arm (128
-0-
428) thru the housing top slide bearing (128
-1-
632).
Step 2)
Slide an aluminium washer (128
-1-
914), a conical spring (128
-1-
912) and another
aluminium washer (128
-1-
914) onto the short axle of the main arm (128
-0-
428), from the
inside of the housing.
Step 3)
Compress the
conical spring (128
-1-
912) and assemble the circlip (128
-1-
916). This must
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
k module (128
-0-
810) at the back end of the housing top module (128
-
0-
610). Do not assemble with screws yet.
Step 5)
Insert power cable (128
-0-
988) ends into appropriate receptors (cable marked 1 is plus [+],
cable marked 2 is minus [
-
])
Step 6)
Fan cable plug from housin
g back module (128
-0-
810) and tail from the user interface of
the housing top module 128
-0-
610 shall be inserted into appropriate connectors on the
system electronics module (128
-0-
439
).
Step 7)
Refer to PCU
-
010
-
128 for the connection of the cables going fro
m the electronic control
board to the LED arrays..
Step 8)
Fasten the system electronics module (128
-0-
439
) to the housing top module (128
-0-
610)
using the six PT 2,5x8 screws (128
-1-
921). And pull out the excess power cable (128
-1-
302) from the lamp head.
Step 9)
Pl
ug the six cables from the system electronics module (128
-0-
439
) into the appropriate
connectors on the LED
-
panels (128
-1-
762) of the light module (128
-0-
750).
Step 10)
Tidy the cables from the system electronics module (128
-0-
439
) by inserting them thru
the
four miniature cable holders (128
-1-
944) on the light module (128
-0-
750).
Step 11)
Seat the light module (128
-0-
750) properly in the housing top module (128
-0-
610).
Step 12)
Remove the protective foil from the protective window (128
-1-
826) of the housing bottom
module (
128
-0-
820).
Step 13)
Assemble the housing bottom module (128
-0-
820) to the housing top module (128
-0-
610)
using the four PT 4x10 screws (128
-1-
929).
Step 14)
Fasten the housing back module (128
-0-
810) to the rest of the lamp head using the four PT
-
K 40x30 screws (128
-1-
928)
.
Step 15)
Assemble the main arm mini cover (128
-1-
890) to the positioning arm module (128
-0-
400)
using the two PT 3x10 screws (128
-1-
923).
Service Manual Aktilite
CL128
Version 1.
3
Page 12
of 41
1.9.3
Dis
a
ssemly and Assembly of
the lamp
slide serie
s
The lamp head module assembly slide series in this chapter is based on
the Aktilite
CL128 with fixed lamp
head. However, there are only minor differences between lamp head module assembly for fixed and detachable
lamp head
. The below slide series is therefore common for both lamp head variations.
Warning: The gas springs
i
nside the arm is very powerful
therefore secure the arm with a strap
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
2 screwdriver
Tool to compress the spring mechanism
Allen key (5mm)
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
strain relief (black) on the end of the
main arm using a pair of pliers
.
F
or lamps with deta
chable lamp head:
Disconnect the
cable
plug
from the
T-
piece cover
plug and
detach
the lamp head by
removing
the
lamp head holder locking screw using the
provided
Allen key
.
Service Manual Aktilite
CL128
Version 1.
3
Page 13
of 41
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
to take off the
main arm, the housing or replace the cable.
Remove the small cover on the main arm
using the
T10 screwdriver
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
of cord through the arm to make a
loop as shown.
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