Martin MAC 2000 wash Service Manual
MAC 2000 Wash
service manual
1
MAC 2000 Wash Service Manual
PROCEDURES
Head procedures
CMYC belts and flags, replace . . . . 12
CMYC module, install . . . . . . . . . . . . 5
CMYC module, remove . . . . . . . . . . . 5
CMYC module, separate . . . . . . . . . 11
CMYC motors, replace . . . . . . . . . . 13
Color wheel 1 belt, replace . . . . . . . . 6
Color wheel 1 motor, replace . . . . . . . 6
Color wheel 2 belt, replace . . . . . . . . 6
Color wheel 2 motor, replace . . . . . . . 6
Color wheel module, install . . . . . . . . 7
Color wheel module, remove . . . . . . . 5
Color wheels, adjust . . . . . . . . . . . . . 7
Dimmer blades, replace & adjust . . . 10
Dimmer motor, replace . . . . . . . . . . 11
Effect fans, replace . . . . . . . . . . . . . . 7
Head side covers, remove and install 7
Heat filter assembly, remove & install 8
Heat filter, replace . . . . . . . . . . . . . . . 9
Left lamp fan, replace . . . . . . . . . . . . 7
Reflector, replace . . . . . . . . . . . . . . . . 9
Right lamp fan, replace . . . . . . . . . . . 8
Starter, replace . . . . . . . . . . . . . . . . . 9
Zoom belt, replace . . . . . . . . . . . . . . . 4
Zoom lens assembly, replace . . . . . . 5
Zoom module, install . . . . . . . . . . . . . 3
Zoom module, remove . . . . . . . . . . . . 3
Zoom motor, replace . . . . . . . . . . . . . 4
Zoom rail, replace . . . . . . . . . . . . . . . 5
Yoke procedures
Tilt belt, left, replace . . . . . . . . . . . . .14
Tilt belt, right, replace . . . . . . . . . . . .15
Tilt motors, replace . . . . . . . . . . . . . .16
Tilt motors, synchronize . . . . . . . . . .16
Yoke covers, remove . . . . . . . . . . . .14
Base procedures
Ballast fan, replace . . . . . . . . . . . . . 19
Base fans, replace . . . . . . . . . . . . . . 19
Electronic ballast, replace . . . . . . . . 19
Left pan motor, replace . . . . . . . . . . 20
Main PCB, replace . . . . . . . . . . . . . 18
Pan belt, replace . . . . . . . . . . . . . . . 17
Pan motors, synchronize . . . . . . . . . 21
Power supply, replace . . . . . . . . . . . 18
Right pan motor, replace . . . . . . . . . 20
© 2002 Martin Professional A/S, Denmark. Updated December 23, 2002 2
INTRODUCTION
Risk of electrical shock
Removal of any cover exposes connectors
that carry lethal electric currents. While
working on a fixture under power:
• Make sure the fixture is electrically
grounded.
• Use a supply with ground-fault-interrupt protection.
• Never touch any connector that carries
voltage.
• Be careful with tools that conduct electricity.
Risk of UV radiation and
lamp explosion
Discharge lamps emit harmful ultraviolet
(UV) light that can cause eye and skin burns
through direct exposure. They also work
under high pressure that occasionally causes
them to explode. To eliminate the risk of
injury from the discharge lamp,
• Never operate the lamp with covers or
lenses removed.
• Do not look directly into the light.
Electrostatic discharge
Printed circuit boards (PCBs), individual
ICs, and Hall sensors can be damaged by
electrostatic discharge (ESD). To avoid
damaging these ESD sensitive parts:
• Ensure that you and your tools have the
same potential (ground) as the fixture
before and when handling any of the
above components.
• Store PCBs in antistatic (electrically
conducting) bags and store ICs in antistatic foam.
• Power off the fixture and allow capacitors do discharge before removing or
inserting components on the PCB.
Inductive loads
Power off the MAC 2000 Wash before
connecting or disconnecting step motors.
Failure to do so can damage the motor
drivers.
Threadlock
Threadlock is highly recommended on all
machine screws except self-tapping
(Taptite) screws to prevent loosening.
Threadlock should be reapplied if the
screws are removed.
Two types of threadlock are available from
Martin. For set screws, use Loctite 290, P/N
37020002. For all other screws, use Loctite
243, P/N 37021002. Both come in 10 ml
tubes.
Be careful to avoid getting any material on
shafts or axles. A needle and syringe makes
an idea application tool.
Long set screws: Start the screw and turn it
until it contacts the shaft. Back the screw 2
turns, apply a small drop or 2 of Loctite 290
to the threads, and then tighten the screw as
you normally would.
Short set screws: Back the set screw out of
the adaptor until 2 threads stick out of the
shaft. Apply a small drop or 2 of Loctite 290
to the threads, and then tighten the screw
within 60 minutes.
Other metric screws: Apply a drop of
Loctite 243 (blue) to 3 or 4 threads, or
spread a thin stripe with a syringe, before
starting the screw.
Self-tapping screws
The reuse of self-tapping “Taptite” screws
is not recommended as these screws are
designed to cut threads and can strip
existing threads when reinserted. Change to
metric hardware of the same size when
reinstalling parts originally held with
Taptites.
If installing a new part without threads, use
new self-tapping screws. Do not use old
taptites to cut new threads!
Lubrication
Silicone grease, P/N 37302002, “Silicon
grease, clear, 100g”, is used, for example, to
lubricate brass bushings inside of pulleys
and between moving metal plates such as
the motor bracket for color wheel 1 on the
MAC 2000 Wash.
Slides are generally lubricated with the high
viscosity silicone oil, P/N 37302005, “High
viscosity silicone oil, 200 ml, in applicator
bottle.”
Bearings are lubricated with P/N 37302004,
“Silicone oil, 200 ml, in applicator bottle”.
Comments
Your feedback is appreciated. Please send
your comments and suggestions for
improvements to:
Martin Professional
Olof Palmes Allé 18
DK 8200 Aarhus N, Denmark
Attn: Service
E-mail: service@martin.dk.
Always disconnect the fixture
from AC power before and while
servicing.
© 2002 Martin Professional A/S, Denmark. Updated December 23, 2002 3
HEAD PROCEDURES
Zoom module, remove
1 Remove the top and bottom head
covers and the front lens. Fully back out
the thumbscrew for the lens retaining
wire.
2 Unplug cables from the outside row
of the left-side zoom module junction
print. Unplug the unlabeled 2-pin connector from socket 38.
3 Unplug the wires from the outside
row of the right-side zoom module junction print. Unplug connectors 42, 23,
and the unlabeled 2-pin fan plug from
the inside row.
4 Unplug the wires from the back row
of the CMYC module junction print and
the thermo-sensor, which is in front of
the junction print.
5 Unplug connector 16 from the dimmer junction print.
6 Remove the 4 zoom module fastening screws.
7 Pull the zoom module (and attached
color wheel module) up, out of the
head.
Zoom module, install
1 Lock the head in the horizontal, top
up position.
2 Place the ends of the wire bundles
outside of the head, forward of the
yoke.
3 Lower the module into the chassis,
working it past each “sticking point” in
turn. Fasten.
4 Reconnect the wires to the left and
right junction prints.
5 Plug connector 16 into the dimmer
junction print. (Fig. 4)
6 Insert the CMYC wire bundle into
the slot in the zoom module. Connect
The color wheel module remains
attached to the zoom module in
this procedure.
Fig. 1 Unplug left junction print
Fig. 2 Unplug right junction print
Fig. 3 CMYC thermo-sensor PCB
Fig. 4 Dimmer junction PCB
Fig. 5 Zoom module screws
Fig. 6 Place wires forward of yoke
Fig. 7 “Sticking points”
Fig. 8 Right junction connections
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MAC 2000 Wash Service Manual
the wires to the junction print. Secure
the bundle under the flexible tie.
Zoom belt, replace
1 Remove the zoom module. (p. 3)
2 Remove the belt clamp screws.
3 Loosen the set screws and remove
the belt clamp from the belt.
4 Flip the module over and loosen the
zoom motor screws. Push the motor in
to loosen and remove the old belt.
5 Pull the belt tension pulley forward
and loop the new belt over it as shown
in Fig. 12.
6 Lead the belt to the motor and loop
it over the gear. Loop the other end of
the belt over the front pulley.
7 Tighten the belt by moving the zoom
motor back until the tension pulley
starts to move. Tighten the motor
screws.
8 Place the belt clamp on the belt with
the set screws inside the loop and the
small bar between the belt and the
screws. Tighten the set screws.
9 Fasten the belt clamp to the lens
car.
10 Install the zoom module. (p. 3)
Zoom motor, replace
1 Remove the zoom module. (p. 3)
2 Unplug the motor wires and remove
the motor screws. Loosen the bracket
enough to remove the motor.
3 Transfer the gear to the new motor
with 0.6 mm (0.025 in.) clearance
between the motor and the gear.
Tighten the set screw.
4 Position the motor in the bracket
with the socket facing out. Tighten the
bracket screws. Start the motor screws
but do not tighten.
5 Place the belt over the gear. Push
the motor out to tighten the belt until the
tension pulley just begins to move.
Tighten the motor screws.
6 Plug in the motor wires.
7 Install the zoom module. (p. 3)
Fig. 9 CMYC wire bundle path
Fig. 10 Belt clamp screws
Fig. 11 Loosen the belt
Fig. 12 Loop belt over tensioner
Fig. 13 Zoom belt
Fig. 14 Belt clamp
Fig. 15 Loosen bracket to remove motor
Fig. 16 0.6 mm (0.025 in.)
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MAC 2000 Wash Service Manual
Zoom lens assembly, replace
1 Remove the zoom module. (p. 3)
2 Remove the belt clamp screws.
(Fig. 10)
3 Remove the 4 screws that fasten
the zoom car to the zoom slide. Do not
remove the slide from the rail.
4 Fasten the replacement zoom lens
assembly to the slide.
5 Fasten the belt clamp.
6 Install the zoom module. (p. 3)
Zoom rail, replace
1 Remove the zoom lens assembly.
(p. 5)
2 Separate the color wheel module
from the zoom module. (p. 5)
3 Remove the white plastic plate at
the back of the module.
4 Unscrew and remove the zoom rail.
5 Starting with the third hole from the
front, fasten the new zoom rail to the
zoom module with 5 M3x6 panhead
Torx screws, P/N 08050702.
6 Place the stand-off on the M3x12
panhead Torx screw and insert the
screw through the first hole in the rail.
Fasten with an M3 nut.
7 Install the zoom lens car stop. (Fig.
18)
8 Install the color wheel module. (p. 7)
9 Install the zoom lens assembly. (p.
5)
10 Install the zoom module. (p. 3)
CMYC module, remove
1 Remove the zoom module. (p. 3)
2 Remove the module fastening
screws: there are two on the top and
two on the bottom.
3 Slide the module forward as far as it
will go, then lift it out of the top of the
head.
CMYC module, install
1 Lock the head in the horizontal, top
up position.
2 Move the wire bundles forward and
out of the way.
3 Orient the module with the junction
print up and to the right. Lower the
module into the chassis at an angle.
Square the module with the flaps over
the chassis and slide it back as far as it
will go. Align the screw holes and fasten
at the top and bottom.
4 Install the zoom module. (p. 3)
Color wheel module, remove
1 Remove the top head shell.
2 Disconnect plugs 28/29, 9, and 10
from the inside row of the left-side zoom
module junction print. (Fig. 1)
When removing the zoom car, do
not remove the slide from the rail.
Fig. 17 Do not remove slide from rail
Fig. 18 Zoom lens car stop
Fig. 19 Zoom slide stop
Fig. 20 1 of 4 CMYC module screws
Fig. 21 Insert module at an angle
Fig. 22 Color wheels 1 & 2
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MAC 2000 Wash Service Manual
3 Remove the color module attachment screws and separate the color
wheel module from the zoom module.
Color wheel 1 belt, replace
1 Remove the top head shell.
2 Press the motor down to release
belt tension. Remove the old belt and
install a new one.
Color wheel 1 motor, replace
1 Remove the color wheel module. (p.
5)
2 Release belt tension and slip the
belt off the motor gear. (Fig. 24)
3 Remove the sensor print to access
the screw underneath. Remove the
screws that fasten the motor bracket to
the module plate.
4 Unhook the spring from the motor
bracket. (Fig. 28)
5 Transfer the gear (or install a new
one) to the shaft of the replacement
motor with 10 mm clearance between
the bottom of the gear and the face of
the motor. Tighten the set-screw. (No
further adjustment is required.)
6 Transfer the mounting bracket to the
new motor. Do not open the new motor!
7 Apply a drop or two of silicone
grease (P/N 37302002) to the motor
bracket. Attach the bracket to the plate
with metric screws and bushings.
8 Hook the tension spring onto the
motor bracket and connect the motor
wires.
9 Reinstall and connect the Hall sensor circuit board.
10 Reinstall the drive belt.
11 Install the color wheel module. (p. 7)
Color wheel 2 belt, replace
1 Remove the color wheel module. (p.
5)
2 Unscrew and remove the wheel.
3 Remove the old belt. Place the new
belt over the motor gear and the axle.
4 Reinstall the color wheel and loop
the belt onto the color wheel gear.
5 Place the open position over the
tension pulley, pull the pulley in, and
loop the belt over the pulley.
6 Install the color wheel module.
Color wheel 2 motor, replace
1 Remove the color wheel module.
2 Remove the belt from the tension
pulley and motor gear.
3 Unscrew and unplug the old motor.
4 Transfer the standoffs to the
replacement motor. Do not open the
new motor!
5 Transfer the gear (or install a new
one) to the shaft of the replacement
motor with 1.1 mm clearance between
the bottom of the gear and the face of
the motor and tighten the set-screw.
(No further adjustment is required.)
6 Place the motor on the plate with
the socket towards the other motor.
Fig. 23 Color module screws
Fig. 24 Release belt tension
Fig. 25 Motor bracket screws
Fig. 26 10 mm clearance
Fig. 27 Motor and bracket
Fig. 28 Color wheel 1 motor
Fig. 29 Color wheel 2 belt
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