Aktilite CL16 User manual

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Page 1

SERVICE MANUAL

Aktilite

Ver 1.

CL16

Photoc

Hoffsveien 48

NO-

0377 OSLO, Norway

Phone: +47 22 06 22 10

www.photocure.com

ure ASA

Page 2

Service Manual Aktilite

SERVICE

Aktilite

Any kind of service should only be carried out by authoris

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

TABLE OF CONTENTS

Assembly of Aktilite

CL16 Lamp with Parallel Arm

MANUAL

CL16

ed personnel.

.................................................

1.1 Material/Equipment

1.2 Housing bottom module (16

1.3 Housing fansid

1.4 Light module (16

1.5 Housing top module (16

1.6 Lamp head module (16

1.7 Lamp head and parallel arm module (16

1.8 Labels placement description

Replacing the DC Power Plug

Assembly of Aktilite

3.1 Material/Equipment

3.2 Cable pack input (16

3.3 Cable pack output (16

3.4 Power supply (16

Error Codes

....................................................................................................................17

.....................................................................................................

-0-

200) assembly

e module (16

-0-

400) assembly

CL16 CON

...................................................................................................14

-0-

650) assembly

-0-

300) assembly

-0-

500) assembly

-0-

800) assembly

....................................................................................12

.......................................................................................13

DOR Power Supply

670) assembly

-0-

680) assembly

.............................................................

............................................................

..............................................................................

...................................................................

....................................................................

-0-

900) assembly

......................................................................14

....................................................................15

...........................................................................15

.......................................11

...............................................14

3 4 5 6 7 8

Version 1.1

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1.1 Material/Equipment

Assembly of Aktilite

Tools needed for the assembly of the Aktilite

Required tools

# of items 1 1 1 1 1

Description Screwdriver, Torx 10 Tool A Screwdriver, Tor Tool C: special tool for pressing the axle, arm into the heat sink Tool D: small, flat screwdriver Plug assembler tool (ELFA 80-490-58) Silicone Glue B Rubbing alcohol (fat free)

Service Manual Aktilite

CL16 Lamp with Parallel Arm

x 20 Tool B

CL16

CL16 lamp

Tool E

Version 1.1

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Service Manual Aktilite

1.2 Housing bottom module (16

Required items

Part # 16

-1-

201

-1-

202

-1-

203

-1-

206

# of items

Description Housing bottom Gasket, cable, bottom Protective window Silicone Rubbing alcohol (fat free)

-0-2

00) assembly

CL16

Assembly description

Step 1) Clean the recessed area at pro Step 2) Attach the protective window (16 Step 3) Remove the protective paper from the Gasket, cable, bottom (16

against the hou

As a spare part this comes fully assembled.

sing bottom (16

tective window (16

-1-

203) to the housing bottom (16

-1-

201).

-1-

203) using a cloth and rubbing alcohol.

-1-

201) using silicone.

-1-

202), and press it firmly

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Service Manual Aktilite

1.3 Housing fanside module (16

Required items

Part # 16

-1-

301

-1-

302

-1-

303

# of items

Description Housing, fan side Fan Papst 612 FH, with cable and connector Screws, Fan - Housing, fan side Tool A: Screwdriver, Torx 10 Glue B

-0-

300) assembly

CL16

Assembly description

Step 1) Place the fan (16 Step 2) Screw the two screws (16

together.

Step 3) Put a drop of glue in the channel where the cords go into the centre section of the fan.

-1-

302) in the housing

-1-

303) in the upper holes to keep

fan side

(16

-1-

301) with the cable oriented correctly the fan and the housing

fan side

Version 1.1

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1.4 Light module (16

Required items

Part # 16

-1-

401

-1-

402

16-1-

420

-1-

404

-1-

405

-1-

406

-1-

407

-1-

408

-1-

410

# of items

Service Manual Aktilite

-0-

400) assembly

Description Lens LED-panel Heat sink, machined with logo Heat conductive pad, LED Gasket, frame, bottom Axle, arm Washers, for screws in LED-panel Screws, LED-panel - heat sink Tool B: Screwdriver, Torx 15 T

ool C (special tool for pressing the axle, arm into the heat sink)

Glue B

CL16

Assembly description

Step 1) Press the axle, arm (16

Step 2) Turn the heat sink upside-down and place the "heat conductive pad, LED" (16

Step 3) Perform a visual inspection of the soldering joints on the Step 4) Place the LED panel (16

Step 5) Screw the screws (16

Step 6) Remove the protective paper from the self-adhesive Gasket, frame, bottom (16

Step 7) Apply a small drop of Glue B (16

Step 8) Put a light pressure onto the lens module until the glue has cured. Step 9) This module is now going to be optically tested before further assembly.

Version 1.1

-1-

406) into the hole on the heat sink (16

on the axle is facing straight downwards. Special

that its holes lines up with the holes in the heat sink.

-1-

402) on the "heat conductive pad, LED" (16

the contact on the LED panel is facing in the correct direction.

-1-

408) with washers (16

the heat sink.

place it on the heat sink, as close as possible to the LED-panel on its contact side.

lens in position, assuring that its four "towers" enters the holes.

-1-

410) in the four holes on

pressing tool or jig should be used for this.

-1-

407) through the holes on the LED-panel to

-1-

420), assuring that the tap

-1-

LED array PCBs.

the LED panel and place the

-1-

404), assuring that

-1-

404) on it so

405), and

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Page 7

1.5 Housing top modul

Required items

Part # 16

-1-

501

-1-

502

-1-

503

-1-

602

# of items

Service Manual Aktilite

e (16

-0-

500) assembly

Description User interface Housing top Screws Electronics- Housing, top System electronics Tool A: Screwdriver, Torx 10 Rubbing alcohol

CL16

Assem

Step 1) Clean the recessed area at the top of the housing top (16

Step 2) Remove the protective paper from the self-adhesive key touch panel (16

Step 3) Put the flex-tail in the connector on the system electronics (16

Step 4) Assure that the flex-tail falls smoothly into place and assemble the system electronic

Version 1.1

bly description

alcohol

the housing top (16

by pressing the black part down and in.

600) to the housing top (16

-1-

502), leading the flex-tai

-1-

502) using the 4 screws (16

-1-

502) using a cloth and rubbing

-1-

501) and glue it to

l through the corresponding hole.

-0-

600) and close the connector

-1-

503).

s (16

-0-

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Service Manual Aktilite

1.6 Lamp head module (16

Required items

Part # 16

-1-

801

-0-

200

-0-

300

-0-

400

-0-

500

-0-

700

-1-

802

-1-

809

-1-

810

-1-

811

# of items

Description Housing outlet side Housing bottom module Housing fanside m Light module Housing top module Arm & accessories module Screw, Housing, sides - heat sink Cable A from power supply to lamp head Cable B from LED-panel to electronics Cable tension release Tool A: Screwdriver, Torx Tool D: small flat screwdriver

-0-

800) assembly

odule

CL16

Assembly description

Step 1) Connect the cable B (16

to the connector on the LED-panel in the housing bottom module (16

Step 2) Connect the Earth cable between the 'M2' plated hole of the PCB and the chassis of the lamp

(cooling fin/metal body of the lamp). Refer to cable spec. from Kitron Development "LED cables CL16" Rev.A

Step 3) With the front of

500) into it from left to right

Step 4) Put the Cable A 16

connector A in the housing top module (16 connector open.

-1-

810) to the connector B in the housing top module (16

-0-

200)

the Light module (16

-1-

809 through the hole in the housing top module and put it in the

-0-

400) against you, slide the Housing top module (16

-0-

500), using a smal

l screwdriver to press the

-0-

500) and

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Service Manual Aktilite

Step 5) Seen from the terminal input side, cord marked 1 [+] goes to the right side of the terminal, and

cord marked 2 [-] goes to the left side of the terminal.

Step 6) Still with the front of the Light module (16

side to its left side, using two screws (16

Step 7) Put the Housing bottom module (16

hit by the gasket on the Housing bottom module

Step 8) Connect the cable from

in the housing top module (16 Step 9) Assemble the Housing fan side, using the two screws (16 Step 10) Press in the cable tension release (16

pliers for this.

the fan in the Housing fan side module (16

-0-

500)

-0-

-1-

-0-

200) in its place, assuring that the Cable A (16

-1-

811) where the cable enters the heat sink. Us

400) a

802)

CL16

gainst you, assemble the Housing outlet

-0-

300) to the connector C

-1-

802).

-1-810) is

e a pair of

Version 1.1

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Service Manual Aktilite

CL16

Version 1.1

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Service Manual Aktilite

1.7 Lamp head and parallel arm module (16

Required items

Part # 16

-0-

800

-1-

901

-1-

902

-1-

813

Assembly description

Step 1) Unscrew the friction unit of the Parallel arm, insert the axle arm from the Lamp head module,

and tighten until the friction is sufficient Step 2) Tread the cable from the Lamp head module (16 Step 3) Put on the strain relief. Step 4) Assemble the plug onto the cable (16

and cord marked 2 to "B" [-] in the

solder the pins

the two self-threading screws to secure the pressure pad on the strain relief, with the lowered

side facing the cab

position, there is a special tool available to remove the pins again. Step 5) Remove the protective paper from the backside of the label Power Plug. (16

attach the label to the co

# of items

Description Lamp head module Parallel arm (with friction unit towards axle arm) Plug Label Power Plug Tool E: Plug assembler

. Use one drop of Loctite and screw on the strain relief to

le. NOTE:

rd, next to the

On cable fro

If you by accident put the pin in the

m lamp head to PS

-1-

902), attaching cord marked 1 to "D" [+] in the plug

bayonet

CL16

tool (ELFA 80-490-58)

-0-

ug. Use the crimping tool for the crimp pins

plug, as shown in the picture below.

-0-

900) assembly

800) through the Parallel arm (16

bayonet

plug. Use

plug in the wrong

-1-

813) and

-1-

901).

NB! Use new stronger plug Souriau UTS 6JC104P

for repaired lamp

Version 1.1

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Service Manual Aktilite

1.8 Labels placement description

Required items

Part # 16

-0-

900

-1-

904

-1-

903

# of items

Description Lamp including paralle Label Serial Number Label Warning and Special Waste

CL16

l arm

Assembly description

Place the labels according to the pictures above. Note that the two labels should be placed on opposite sides of the lamp arm:

Label Serial no. on the right side, near the bottom end of the arm Label Warning and Special Waste

on the left side, near the lamp head

Version 1.1

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Service Manual Aktilite

Replacing the DC Power Plug

Assembly description

Step 1)

Put the stain relief onto the DC power cable. Put on the male crimp pins using the specially made crimping tool. Put the cord numbered 1 into "D" [+] in the bayonet p with cord marked 2 in "B" [ specially made extractor tool to release the pins from the bayonet plug again.

Step 2)

Put a drop of Loctite on the threads at the strain relief threads and the bayonet plug.

Step 3)

Double check:

] in the bayonet plug. If you make a mistake, you can use the

Cord marked 1 into "D" [+ or red] Cord marked 2 into "B" [

CL16

or black

lug, and the pin

screw the strain relief to

]

New plug

To use the extractor tool, press the tool f 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.

Part number for (

RM16M23K Part number for the wall mounted connector is 128 pins 128

-1-

)

345

(RC16M23K)

the plug is: 128

-1-

261 Souriau UTS 6JC104P with pins (extra) 128

Extractor tool

irmly into the connector by holding the

-1-

323 261 Souriau UTO 0104SH

-1-

263

with mating

Version 1.1

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3.1 Material/Equipment

Assembly of Aktilite

Note: This is only used for the Nordic Markets. The other markets uses a Mascot

power supply.

Aktilite CL16 is delivered with two different power supplies, depending on the market: CONDOR power supply and MASCOT power supply. The CONDOR power supply is only de

NOTE: This assembly procedure is only valid for CONDOR power supply. The MASCOT power supply is not to be opened and must be replaced if not working.

Tools needed for the assembly of the Aktilit

livered on the Scandinavian markets.

Service Manual Aktilite

CL16 CONDOR Power Supply

e CL16 CONDOR Power Supply

CL16

Required tools

# of items 1 1 1 1 1 1 1

3.2 Cable pack input (16

Required items

Part # 16 16 16 16 16

-1-

671

-1-

672

-1-

673

-1-

674

-1-

675

Description Screwdriver, Pozidrive 2 Screwdriver, Torx 10 Tool B Screwdriver, Torx 20 Tool C Cable shoe mounting tong AMP-Connector mounting tong Crimp Voltage adjusting jig Lacquer (for sealing pot meter)

socket mounting tong

# of items

Tool A

Tool E

Tool G

-0-

670) assembly

Description Cable A, blue neutral AC conductor Cable B, brown l Cable C, green/yellow ground cable Cable shoes, flat type Connector AMP Tool E: Cable shoe mounting tong Tool F: AMP-Connector mounting tong

Tool F

ive AC conductor

Assembly description

Step 1) Assemble one cable shoe (16 Step 2) Assemble the three cables to the connector using tool F. Assure that they are placed like this:

Version 1.1

-1-6

74) to each of the three cables, using tool E.

pin 1 = Cable A (AC neutral), pin 2 = Cable C (NO Pin), Pin 3= Cable B (AC Live)

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Service Manual Aktilite

3.3 Cable pack output (16

Required items

Part # 16

-1-

681

-1-

682

-1-

683

-1-

684

Assembly description

Step 1) Assemble one crimp socket (16 Step 2) Assemble the two cables to the connector using tool F. Assure that they are placed like this:

in 5= Cable E (

in 2= Cable D (+) Red

# of items

-) Black

CL16

-0-6

80) assembly

Description Cable D, red load cable Cable E, black load cable Crimp socket Connector AMP Tool F: AMP-Connector mounting tong Tool G: Crimp socket mountin

-1-

683) to each of the two cables, using tool G.

g tong

n 1 is marked on the Printed Circuit Board

3.4 Power supply (16

Required items

Part # 16

-1-

651

-1-

652

-1-

653

-1-

654

1 W

-1-

655

-1-

656

-1-

657

-1-

658

-1-

659

-1-

660

-1-

661

-1-

662

-1-

664

-0-

670

-0-

680

# of items

-0-

650) assembly

Description Casing, machined Power - Condor GLM65 Washer

all mounted connector Souriau UTO 0104SH Screws PS-casing In plug (IEC 320) Screws In-plug Dist washer Ferrite (Load side) Ferrite (Mains side) Feet pads (self adhesive) Screws Out-plug Label with Approvals Cable pack input Cable pack output Tool A: Screwdriver, Pozidrive 2 Tool B: Screwdriver Torx 10 Tool C: Screwdriver Torx 20 Voltage adjusting jig Laquer (for sealing pot meter)

-48

Version 1.1

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Service Manual Aktilite

Assembly

Step 1) Connect the

Step 2) Assemble the

Step 3) Thread both cables in the Cable pack input (16

Step 4) Thread all three cables in the

Step 5) Assemble the

Step 6) Assemble the

Step 7) Connect the crimp sockets of the

Step 8) Assemble the

Step 9) Connect the three cables in the

Step 10) Fix the ferrites to the casing with a strip, silicon or other means. Step 11) Step 12) Connect the 5 cables to the

Step 13) Apply Step 14) Remove the protective paper and assemble the four self-adhesive

Step 15) Note the serial number on the underside of the box. Take out the QA documen

Step 16) The unit is now ready for further testing.

description

connector.

(16

-1-

cable) (16

658)

that the red and black load cables are on the same side as the power outlet plug. Use the Tool C.

Screws Out plug (16

3 locking pins facing upwards. Use Tool B.

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

(16

-1-

upwards. Use Tool B.

Cable A (blue) is connected to pin m marked L, and Cable C (green/yellow) is connected to pin marked with the ground symbol.

Close the

Volt by adjusting the blue pot meter near the DC power output terminals. Secure the pot meter by a drop of lacquer. (ref. TCU-002

underside of the casing, one in each corner.

follows the "Traveller" for the DHR.

660)

4 times.

-1-

between. Use the 4

657)

. Make sure it is fastened in the correct position, with the central pin facing

casing (16

Label Nemko

Cable pack input (16

Cable pack output (16

659)

3 times.

Power (16

DC power outlet plug (16

AC in plug (16

-1Screws PS-Casing (16

-1-

662)

-1-

651)

(16

-1-

-0-

Cable pack output (16

652)

into the

. Make sure it is fastened in the correct position, with one of the

Cable pack output (16

-1-

656)

Cable pack input (16

and screw it tog

voltage adjusting jig

663)

to the underside of the casing.

670)

-0-

680) the

casing (16

-1-

onto the

arked N, Cable B (brown) is connected to the tongue

CL16

to the

power (16

-0-

-1-

654)

onto the

casing (16

ether.

terminals, and set the output voltage to 50.4

-16C)

670)

through the

-0-

680)

-1-

651)

655)

with

-0-

670)

-1-

652)

in its responding AMP

-1-

652) in its responding AMP

ferrite (mains cables)

through the other

with the

casing (16

680)

-1-

651)

to the

distance

washers (16

to the DC out plug. Pl

with the 2 Screws in plug

-1-

653)

-1-

651)

, with the four

AC in plug (16

feet pads (16

ferrite (load

washers (16

. Make sure

ug the

-1-

656)

-1-

661)

to the

tation that

-1-

Version 1.1

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Page 17

Service Manual Aktilite

The Aktilite CL16 has in-built monitoring features. If an error should occur, the display will show the following message and

If an error code is displayed, or if any other unexpected c following steps should be taken:

1. Disconnect the mains cable for at least 20 seconds

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 e

Error Codes

five rapid beeps will be heard:

rror persists, refer to the table below

CL16

ondition occurs (e.g. lamp does not operate), the

Error

Code

1101 1102 1103 1104

1105 1107 1109 1110 1112 1117

1206

1208

1211

2105 2107 2109 2110 2112

NOTE: Refer to the instructions above before using the table

Device internal error Device internal e Device internal error Key was pressed during switch-on self-test or Device internal error Device internal error Device internal error Device internal error Device internal error Device intern The lamp has reached the maximum allowed number of illumination hours.

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 Device internal error Device internal error Device internal error Device internal error

Possible Causes

rror

al error

Aktilite CL16

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

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

POST too high enclosure temperature error.

POST too high LED driver temperature error.

POST to high LED array t

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

Error Codes

Description

rature error.

emperature error.

Version 1.1

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Error

Code

2206

2208

2211

2213 2214 2215 221

Service Manual Aktilite

NOTE: Refer to the instructions above before using the table

Possible Causes

CL16

Aktilite CL16

Self-test too high en

Self-test too high LED driver temperature error.

Self-test too high LED array temperat

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

Error Codes

Description

closure temperature error.

ure error.

Version 1.1

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