Olec OLITE Service Manual

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OLITEOLITE 60Hz

Printing Light Service Manual

94MS20 Rev. B4

This manual is designed for technical personnel

and should only be used by authorized dealer

service personnel.

This manual is written to provide an understand-

ing of the equipment, as well as a plan for

troubleshooting.

94MS20 Rev. B4

0. Contents

1 Introduction

Introduction .................................................................................1-1

2 Safety

The Nature of UV ........................................................................ 2-1

UV, Source of Health ..................................................................2-1

Bad UV ........................................................................................ 2-1

UV in Nature ...............................................................................2-1

Ozone, UV“B” and UV“C” ......................................................... 2-2

Safety Glass ................................................................................. 2-2

Light Leaks .................................................................................. 2-2

Overexposure to UV....................................................................2-2

3 Component Layout

Lamphead for AL 83, 84, 84-480, 85, 56, 56-480......................3-1

Power Supply for AL 83..............................................................3-1

Power Supply for AL 84..............................................................3-2

Power Supply for AL 84-480 ......................................................3-2

Power Supply for AL 85..............................................................3-3

Power Supply for AL 56..............................................................3-3

Power Supply for AL 56-480 ......................................................3-4

Lamphead for AL 53, 54, 54-480, 55, 55-480, 35, 25, 25-2, 23 .3-4

Power Supply for AL 53, AL 50 .................................................3-5

Power Supply for AL 54, 55........................................................3-5

Power Supply for AL 54-480, 55-480 ......................................... 3-6

Power Supply for AL 35..............................................................3-6

Power Supply for AL 25-2, AL 25 .............................................. 3-7

Power Supply for AL 23..............................................................3-7

Lamphead for AL 15, 19, 20 .......................................................3-8

Power Supply for AL 19, 20........................................................3-8

Power Supply for AL 15..............................................................3-9

Lamphead for AL 100 .................................................................3-9

4 Ballast / Tap Switch Wiring

94MS20 Rev. B4 0-1

AL 83 Ballast / Tap Switch Wiring ............................................. 4-1

AL 84, 85 Ballast / Tap Switch Wiring ....................................... 4-1

AL84-480 Ballast Wiring ............................................................ 4-2

AL 56 Ballast / Tap Switch Wiring ............................................. 4-2

AL56-480 Ballast Wiring ............................................................ 4-3

AL54 / AL55 Ballast / Tap Switch Wiring..................................4-3

AL54-480 / AL55-480 Ballast Wiring ........................................4-4

AL53/50 Ballast / Tap Switch Wiring.........................................4-4

AL 35 Ballast / Tap Switch Wiring ............................................. 4-5

AL23 and AL20 Ballast Wiring ..................................................4-5

AL 19 and AL15 Ballast Wiring .................................................4-6

5 General

Path of Power to the PC Board....................................................5-1

Interlock System .......................................................................... 5-1

Lamp Voltage ..............................................................................5-2

Lamp Power Path.........................................................................5-2

Trigger Board ..............................................................................5-3

Capacitors and Level Switching .................................................. 5-4

AL 83 Capacitor Assembly .........................................................5-4

AL 84 Capacitor Assembly .........................................................5-5

AL 84-480 Capacitor Assembly..................................................5-5

AL 85 Capacitor Assembly .........................................................5-6

AL 56 Capacitor Assembly .........................................................5-6

AL 56-480 Capacitor Assembly..................................................5-7

AL 54, AL 55 Capacitor Assembly.............................................5-7

AL 54-480, AL 55-480 Capacitor Assembly .............................. 5-8

AL 53, AL 50 Capacitor Assembly.............................................5-8

Old Style AL 53, AL 50 Capacitor Assembly............................. 5-9

AL 35 Capacitor Assembly .........................................................5-9

AL 25, AL 25-2 Capacitor Assembly........................................5-10

AL 23 Capacitor Assembly .......................................................5-10

AL 20, AL 19 Capacitor Assembly...........................................5-11

AL 15 Capacitor Assembly .......................................................5-11

Opening the Lamp Head............................................................5-12

Shutter........................................................................................ 5-12

Shutter Switch ........................................................................... 5-13

Shutter Brake .............................................................................5-13

Shutter Motor............................................................................. 5-14

Installing the Motor ...................................................................5-14

Shutter Removal ........................................................................5-14

LT1 Shutter Assembly Drawing................................................5-16

LT8 Shutter Assembly Drawing................................................5-18

Idle Setting................................................................................. 5-19

Lamp Head Blowers ..................................................................5-20

Blown Fuse on PC Board .......................................................... 5-20

Lamp Head Signals.................................................................... 5-21

Light Function States................................................................. 5-23

Printed Circuit Board Layout ....................................................5-24

Signal Description ..................................................................... 5-25

Circuit Diagram (64MV407 60Hz) .......................................... 5-27

Old Style (64MV210A) Control Board Layout......................... 5-28

Signal Description (64MV210A) .............................................. 5-29

6 Check List for Troubleshooting and Service

0-2 94MS20 Rev. B4

Check List for Printing Light Troubleshooting and Service ....... 6-1

7 Wiring Diagrams

Lamphead for AL 83, 84, 84-480, 85, 56, 56-480, 53, 54, 54-480,

55, 55-480, 50, 35, 25, 25-2, 23...................................................7-1

Lamphead for AL 100 ................................................................ 7-2

AL 83 Power Supply ..................................................................7-3

AL 84,85 Power Supply .............................................................7-4

AL 84-480 Power Supply...........................................................7-5

AL 56 Power Supply ..................................................................7-6

AL 56-480 Power Supply...........................................................7-7

AL 54,55 Power Supply .............................................................7-8

AL 54-480,55-480 Power Supply...............................................7-9

AL 53 Power Supply .................................................................7-10

AL 50 Power Supply ................................................................7-11

AL 35 Power Supply 60Hz...................................................... 7-12

AL 25-2 Power Supply.............................................................7-13

AL 25 Power Supply ................................................................7-14

AL 23 Power Supply ................................................................7-15

AL 20 Power Supply ................................................................7-16

AL 19 Power Supply ................................................................7-17

ALI 15 Power Supply...............................................................7-18

AL 15 Power Supply ................................................................7-19

Interconnect Cable for AL23, AL25, AL25-2, AL35, AL50, AL53,

AL83..........................................................................................7-20

Interconnect Cable for AL85, AL84, AL84-480, AL56, AL56-480,

AL55, AL55-480, AL54, AL54-480 ......................................... 7-21

8 Fault Trees

No Strike Fault Tree ....................................................................8-1

Shutter Rotation Fault Tree ......................................................... 8-2

9 AL 13 / AL 9

AL 13 Component Layout...........................................................9-1

AL 13 Control Board (64MV427C2) ..........................................9-2

AL 13 (120V~) Wiring Diagram ................................................. 9-3

AL 13 (220V~) Wiring Diagram ................................................. 9-4

AL 9, AL 9-PLUS Component Layout .......................................9-5

64MV427-Plus Board Layout for AL 9-Plus ..............................9-6

AL 9-Plus Wiring Diagram ......................................................... 9-7

64MV247 Board Layout for AL 9............................................... 9-8

AL 9 Wiring Diagram.................................................................. 9-9

AL 9, AL 13 Cover Removal .................................................... 9-10

Path of Power to the P.C.Board.................................................9-10

Interlock Systems ......................................................................9-10

Lamp Voltage ............................................................................ 9-11

Path Of Power To The Lamp..................................................... 9-11

Capacitors and Level Switching ................................................ 9-11

94MS20 Rev. B4 0-3

AL 9, AL 9 Plus Capacitor Wiring............................................9-12

AL 13 Capacitor Wiring ............................................................ 9-12

Shutter........................................................................................ 9-13

Shutter Switch ........................................................................... 9-13

Shutter Motor............................................................................. 9-13

Changing Shutter Motor Brushes ..............................................9-13

Steps to change shutter motor brushes. .....................................9-14

Idle Setting................................................................................. 9-17

Blower .......................................................................................9-18

Blown Fuse................................................................................9-18

Photocell .................................................................................... 9-18

Photocell Rod Removal (AL9 Only) .........................................9-19

Shrouding The Lamp ................................................................. 9-19

10 Parts Lists

Parts Lists .................................................................................. 10-1

11 Warranty

Limited Warranty ...................................................................... 11-1

Lamp Warranty.......................................................................... 11-1

0-4 94MS20 Rev. B4

1. Introduction

This manual is designed for technical personnel and is written to provide an understanding of the equipment, as well as a plan for troubleshooting.

All OLEC lights respond to existing conditions. There are no fixed cycles or timers. This allows the unit to respond correctly to conditions that are not normal to operation, such as power failure or surges. Learning what conditions cause the various responses will guide you to the solutions.

This manual was written in several sections, each to provide information in a different manner or specialized locations. Here is a quick guide to the sections.

Features: A comparison between our lights and conventional light sources, with an explanation of each feature, is provided to demonstrate why we chose to design a light source so different from other sources.

Component Layout: Where to look for components referred to in the manual.

Note: The AL9 and AL13 units are very similar. The AL15, ALI15,

AL19, AL20, AL23 (power supply only for the AL23) units are very similar but some have fewer parts. The AL23 (lamphead only for the AL23) AL25, AL25-2, AL35, AL50, AL53, AL54, AL54-480, AL55, AL55-480, AL56, AL56-480, AL83, AL84, AL84-480, AL85 and AL100 (power supply only for the AL100) units are very similar but some have fewer parts. The AL100 lamphead shares some of the same internal components with the other lampheads but the arrangement is quite different.

Troubleshooting: An outline of where to look for various symptoms. This guide refers to the more detailed information in the general information section that follows.

General: Contains specific information about the components in the light and the path of the signals and power. It can be used for information, or used with the troubleshooting guide.

Lamp Head Signals: Provides information about all the conductors to the lamp head, their functions, and the voltages present.

Light Function States: A chart of the different functions the board directs and the conditions that cause these functions. There is also a description of the states.

Printed Circuit Board Pins: Provides the pin-outs from the printed circuit board and an explanation of each.

Schematics: Full-unit schematics are provided. They are for the AL 9, AL 13, AL 15, ALI 15, AL19, AL20, AL23, AL35, AL50, AL53, AL54, AL54-480, AL55, AL55-480, AL56, AL56-480, AL83, AL84, AL84480, AL85, AL100.

94MS20 Rev. B4 1-1

1-2 94MS20 Rev. B4

2. Safety

Questions have been raised regarding the possible danger of exposure to UV for equipment operators using high power lights. We address this issue in terms of overall safety of such lights. OLEC lights are UL approved and meet the strictest US electrical and safety standards, including all OSHA requirements. Users and dealers should insist on U.S. safety approval. It is required by law.

The Nature of UV

UV rays have been divided into three categories: UV“A” from 400315nm, UV“B” from 315-280nm, UV“C” for the shorter waves. UV extends to about 10nm but air will filter out most rays shorter than 200 nm. To put this into perspective, the “near UV” or UV“A” is immediately adjoining the visible spectrum extending from the color violet. Violet extends to about 380 nm; red is at the opposite end of the visible spectrum at 700 nm (see Illustration: Electromagnetic Spectrum). Most light sources, including light bulbs, emit a certain amount of UV.

UV, Source of Health

Before one becomes unduly concerned with the harm UV can cause, it is important to understand the many beneficial effects connected with working outside and in bright areas with a certain amount of the “right” UV. The germicidal effect, for instance, can rid the air of bacteria and is used for that purpose extensively in hospitals. Exposure of the skin to UV produces Vitamin D, necessary for the formation of bones and teeth. Exposure to UV“A” is essential to life itself. Most life, human, animal and plant, depends on it for growth and health.

Bad UV

One must avoid UV“B” and UV“C” even in small doses. UV“A” is harmful only through overexposure. Never confuse the effects of UV with the great harm that can be caused by microwave and X-ray radiation, much of such damage being irreversible.

UV in Nature

Sunlight contains an abundance of UV, UV“A”, “B” and “C”, and the negative effects of overexposure to sunshine have become well known. These are primarily sunburn, sore eyes, headaches. Cataracts and skin cancer are caused by prolonged exposure. Very damaging is the erythematic energy, UV“B”, that penetrates the natural filter of ozone in the upper layers of the atmosphere.

94MS20 Rev. B4 2-1

Ozone, UV“B” and UV“C”

No UV“C” is generated by OLEC lamps. OLEC lights and lamps use “Ozone Free Quartz” for safety reasons to filter out most of the potentially harmful rays in the UV“B” region. Some manufacturers do not use “ozone free quartz.” Such lamps require greatly enhanced protection through safety glass, curtains, light tight housings, and special exhaust systems to rid the air of ozone. If you smell ozone in your workplace, speak to your supervisor or employer. DO NOT work under those conditions!

Safety Glass

Carefully selected safety glass is used on all OLITE UV lights under the reflector. It filters out nearly all the remaining UV“B” so effectively that any transmission is almost impossible to measure. This safety glass is equipped with an important electrical interlock to prevent use of the light if the glass is missing or installed improperly. Never use a light that does not have a protective safety glass.

Light Leaks

Light heads that leak light around the safety glass during idling periods should be avoided. Light above the safety glass always contains a certain amount of UV“B”, particularly when NON-ozone free lamps” are used. Poorly constructed light housings, with even small parts of the lighted area of the lamp or the reflector visible during standby, can be dangerous. Such lights are best used within an enclosure that is shut completely at all times, especially during extended idling time. According to NIOSH, UV“B” is quite different in its effect from UV“A.” It is cumulative and between 600 to 1000 times as destructive.

Being exposed to constant UV leakage during idling time can quickly exceed the daily maximum safe limit and eventually cause serious personal damage. Never use or have anyone else use a light with leaks past the safety glass (where you can see lamp or reflector from any direction)!

Overexposure to UV

What constitutes overexposure to UV“A” should be considered in terms of safe limits and the trade-off between documented health-promoting effects of UV and danger of overexposure. For the UV“A” region, the UV effecting exposure on film and plates, it is recommended that the total radiant incidence on unprotected skin and eyes should not exceed

1.0 mW per cm2 for periods longer than 1000 seconds (16 minutes). This is the Standard, documented and recommended by the National Institute for Occupational Safety and Health, NIOSH, a basis for OSHA.

For UV intensity under 1.0 mW per cm2 there is no time limit. With higher intensity the time should be reduced so that the total dose does not exceed 1000 mW-sec/cm2 (1 mW/sec = 1 mJoule).

2-2 94MS20 Rev. B4

3. Component Layout

39BLO14

64MV414

55SW02

L1280, L1281 or L1282

63D0142B03

62SA83-B

Lamphead for AL 83, 84, 84-480, 85, 56, 56-480

Shutter Position Switch

39BLO14

PA91

Photocell

Trigger Board

55SW03

Safety Interlock SwitchBlower

Power Output

Power

Input

120 VAC

Coil Voltage

Shutter Assembly

45KOB05

Knob

Replacement Lamp

Lamp Support Assembly

90RF83-C Reflector

Power Supply for AL 83

CL 83

18 1

Terminal Strip

Interconnect Cable

To Lamphead

31MOT06

Shutter Motor

Blower

Interconnect Cable To

Power Supply

62D331 Voltage

Selection

Switch

64MV422-83

Resistor

Board

53JKP01

Saftey

Interlock

Jack

55SW01

Rocker

Switches

64MV407V04

Control Board

94MS20 Rev. B4 3-1

62D127-83 Capacitors

33RLY04

Mercury Relay

39BLO03

Blower

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

32TRC03

Autoformer

52FUH04

Fuse Holder

33RLY18

Power Relay

32BAL01

Ballast

16D0334A18

Interconnect Cable

Power Supply for AL 84

Power Output

Power Input

120 VAC Coil Voltage

56FUS15 3Amp 250V 3AG Slow Blow Fuse

32TRC08 Autoformer

62D2652A00 Capacitor Assembly

53JKP01 Safety Interlock

33RLY04 Sealed Relays

64MV407-83 Control Board

Terminal Strip

33RLY02 Power Relay

39BLO03 Blower

52FUH04 Fuse Holder

CL 84

32BAL01 Ballast

Power Supply for AL 84-480

Power Output

Power Input

120 VAC Coil Voltage

56FUS15 3Amp 250V 3AG Slow Blow Fuse

62D3533A00

Capacitor

Assembly

53JKP01 Safety Interlock

33RLY04 Sealed Relays

Terminal Strip

T1 T2

33RLY02 Power Relay

CL 84-480

3-2 94MS20 Rev. B4

64MV407-83 Control Board

39BLO03 Blower

52FUH04 Fuse Holder

32BAL01 Ballast

Power Supply for AL 85

Power Output

Power Input

120 VAC Coil Voltage

56FUS15 3Amp 250V 3AG Slow Blow Fuse

32TRC08 Autoformer

62D1046-85 Capacitor Assembly

53JKP01 Safety Interlock

33RLY04 Sealed Relays

64MV407V04 Control Board

Terminal Strip

33RLY18 Power Relay

39BLO03 Blower

52FUH04 Fuse Holder

62D1047 Voltage Selection Switch

CL 85

32BAL01 Ballast

Power Supply for AL 56

Power Output

Power Input

120 VAC Coil Voltage

56FUS15 3Amp 250V 3AG Slow Blow Fuse

32TRC08 Autoformer

62D2726A00 Capacitor Assembly

53JKP01 Safety Interlock

33RLY04 Sealed Relays

Terminal Strip

33RLY02 Power Relay

CL 56

94MS20 Rev. B4 3-3

64MV407V04 Control Board

39BLO03

Blower

52FUH04 Fuse Holder

62D1047 Voltage Selection Switch

32BAL01 Ballast

Power Supply for AL 56-480

Power Output

Power Input

120 VAC Coil Voltage

56FUS23 3Amp 250V 3AG Slow Blow Fuse

32TRC08 Autoformer

62D2723B00 Capacitor Assembly

53JKP01 Safety Interlock Jack

33RLY04 Sealed Relays

64MV407V02 Control Board

Terminal Strip

33RLY02 Power Relay

39BLO03 Blower

52FUH04 Fuse Holder

CL 56-480

32BAL01 Ballast

55SW02 Shutter Position Switch

PA91 Photocell

Lamphead for AL 53, 54, 54-480, 55, 55-480, 35, 25, 25-2, 23

64TR408 Trigger Board

39BLO03 Blower

62SASE-SW Shutter Assembly

55SW03 Safety Interlock Switch

L1250, L1252, L1261 Replacement Lamp

45KOB05 Knob

62D142 Lamp Support Assembly

90RF53-SW Reflector

31MOT06 Shutter Motor

39BLO03 Blower

3-4 94MS20 Rev. B4

Power Supply for AL 53, AL 50

Power Output

Power Input 120 VAC Coil Voltage

62D331

Voltage

Selection

Switch

64MV422V00

Resistor

Board

53JKP01

Saftey

Interlock

Jack

55SW01

Rocker

Switches

64MV407V03

Control Board

18 1

Terminal Strip

33RLY04*

Sealed Relay

* Older AL50 units used just one of these relays

62D127

Capacitors

T1 T2

33RLY18

Power Relay

39BLO03

Blower

32TRC01

Autoformer

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

52FUH04

Fuse Holder

CL 53 CL 50

Interconnect Cable

To Lamphead

32BAL01

Ballast

16D0334A18

Interconnect Cable

62D331

Voltage

Selection

Switch

on older

units

Power Supply for AL 54, 55

Power Output

Power Input

120 VAC

Coil Voltage

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

32TRC01

Autoformer

62D104 Capacitor Assembly

53JKP01 Safety Interlock

33RLY04 Sealed Relays

Terminal Strip

33RLY02 Power Relay

94MS20 Rev. B4 3-5

64MV407 Control Board

39BLO03 Blower

52FUH04 Fuse Holder

62D1047 Voltage Selection Switch

32BAL01 Ballast

Power Supply for AL 54-480, 55-480

Power Output

Power Input

120 VAC

Coil Voltage

56FUS15 3Amp 250V 3AG Slow Blow Fuse

62D3654A00 Capacitor Assembly

53JKP01 Safety Interlock

33RLY04 Sealed Relays

64MV407 Control Board

Terminal Strip

33RLY02 Power Relay

39BLO03 Blower

52FUH04 Fuse Holder

32BAL01 Ballast

Power Output

Power Input 120 VAC Coil Voltage

62D331

Voltage

Selection

Switch

64MV422V00

Resistor

Board

53JKP01

Saftey

Interlock

Jack

55SW01

Rocker

Switches

Power Supply for AL 35

18 1

33RLY04

Sealed Relay

Terminal Strip

L1 T1 T2

33RLY18

Power Relay

32TRC01

Autoformer

CL 35

Interconnect Cable

To Lamphead

16D0334A18

Interconnect Cable

64MV407V03

Control Board

62D127-35 Capacitors

3-6 94MS20 Rev. B4

39BLO03

Blower

56FUS15

3Amp 250V 3AG

Slow Blow Fuse

52FUH04

Fuse Holder

32BAL01

Ballast

Power Supply for AL 25-2, AL 25

62BLO15

Power Output

Power Input 120 VAC Coil Voltage

64MV422-25

Resistor

Board

53JKP01

Saftey

Interlock

Jack

55SW01

Rocker

Switches

64MV407V03

Control Board

18 1

33RLY04

Sealed Relay

62D126

Capacitors

Terminal Strip

L1 T1 T2

33RLY18

Power Relay

39BLO03

Blower

32TRC01

Autoformer on AL 25-2 units ONLY

CL 25-2 CL 25

Interconnect Cable

To Lamphead

32BAL01

Ballast

16D0334A18

Interconnect Cable

62D331

Voltage

Selection

Switch

on AL 25-2

units ONLY

53JKP01-1

Safety

Interlock Jack

55SW01

Rocker

Switches

CL 23

32TRC01

Autoformer

Power Supply for AL 23

64MV407V03

Control

Board

62D2753A00

Capacitor Assembly

33RLY08

Power Relay

Medium Relay

High Relay

Power Supply Fan

32BAL01

Ballast

54PWR04

Power Cord

16D0334A18

Interconnect

Cable

94MS20 Rev. B4 3-7

Lamphead for AL 15, 19, 20

63D0142B00

45KOB05

39BLO03-15

L1150A or L1250E Lamp for AL15 ONLY

62BLO15

L1250E Lamp for AL19 /AL 20 ONLY

62RA Reflector Assembly

For AL15 ONLY

62RA-1 Reflector Assembly

For AL19 / AL 20 ONLY

Power Supply for AL 19, 20

Knob

55SW04

Safety

Interlock Switch

Lamp Support Assembly

55SW02

Shutter

Position

Switch

31MOT06

Shutter

Motor

Blower

16D271

Interconnect Cable

PA85 PA91

Photocell

64TR408-T

Trigger

Board

53JKP01-1

Safety

Interlock Jack

55SW01

Rocker

Switches

CL 19 / 20

32TRC01 Autoformer AL 20 units

ONLY

64MV407V03

Control

Board

62D139-3A

Capacitor Assembly

33RLY08

Power Relay

Medium Relay

High Relay

32BAL01

Ballast

Power Supply Fan

16D0334A18

Interconnect

Cable

3-8 94MS20 Rev. B4

Power Supply for AL 15

62BLO15

64MV414

16D334

55SW04

L1250, L1252 or L1261

39BLO03

63D1437

53JKP01-1

Safety

Interlock Jack

55SW01

Rocker

Switches

CL 15

64MV407V03

Control

Board

Capacitor Assembly

Lamphead for AL 100

62D139

33RLY08

Power Relay

Medium Relay

High Relay

Power Supply Fan

32BAL01

Ballast

16D0334A18

Interconnect

Cable

Blower

Shutter Assembly

Note: AL100 uses two AL53 power supplies

Replacement Lamps

Safety Interlock

Switches (Qty. 2)

Trigger Board

Interconnect

Cables

64TR468

Safety Interlock

Interconnect

Board

39BLO03

Blower

31MOT06

Shutter

Motor

39BLO03

Blower

PA89

Photocell

11D1442

End Reflector

11D599

Rear Reflector

94MS20 Rev. B4 3-9

45KOB05

Knob

62D142

Lamp Support Assembly

55SW02

Shutter Position Switch

64MV414

Trigger Board

3-10 94MS20 Rev. B4

4. Ballast / Tap Switch Wiring

D3328A

TERMINAL STRIP

AL 83 Ballast / Tap Switch Wiring

TERMINAL STRIP

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AC IN

RED

6 GA.

BLK

CONTACTOR

BALLAST #1

CAP 240 208 COM

BALLAST #3

CAP 240 208 COM

VOLTAGE SELECTOR SWITCH

AL 84, 85 Ballast / Tap Switch Wiring

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AC IN 6 GA.

BLK

CONTACTOR

ORANGE TO CAP. PACK

BALLAST #2

COM

208

240 CAP

BALLAST #4

COM 208 240 CAP

YELLOW TO

RED

T2T1

AUTOFORMER

RED TO FUSE

AUTOFORMER

240 VOLT

ORANGE TO CAP. PACK

94MS20 Rev. B4 4-1

BALLAST #1

BALLAST #3

CAP 240 208 COM

VOLTAGE SELECTOR SWITCH

COM

BALLAST

208

240 CAP

COM

BALLAST #4

208 240 CAP

YELLOW TO

AUTOFORMER

RED TO FUSE

AUTOFORMER

240 VOLT

AL84-480 Ballast Wiring

TERMINAL STRIP

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CAP

BALLAST #1

277 COM

BLK

CONTACTOR

AC IN 6 GA.

T1 T2

L1 L2

(BLK)

RED

(RED)

NO. 29 (VIOLET).

NO. 20 (ORANGE TO CAP. PACK).

COM

BALLAST

#2 277 CAP

CAP

BALLAST #3

277 COM

AL 56 Ballast / Tap Switch Wiring

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

BLK

CAP

BALLAST

240

208 COM

CAP 240

BALLAST #3

208 COM

AC IN 10 GA

T1 T2

CONTACTOR

RED

COM 208 240

CAP

COM 208 240 CAP

COM

BALLAST #4

277 CAP

ORANGE TO CAP. PACK

BALLAST #2

BALLAST #4

4-2 94MS20 Rev. B4

VOLTAGE SELECTOR SWITCH

YELLOW TO

AUTOFORMER

RED TO FUSE

AUTOFORMER

240 VOLT

AL56-480 Ballast Wiring

TERMINAL STRIP

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

BALLAST #1

CAP

277 COM

BLK

CONTACTOR

AC IN 6 GA.

T1 T2

L1 L2

(BLK)

RED

(RED)

29 (VIOLET).

COM

277 CAP

NO. 20 (ORANGE TO CAP. PACK).

BALLAST #2

CAP

BALLAST #3

277 COM

AL54 / AL55 Ballast / Tap Switch Wiring

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AC IN

RED

10 GA.

BLK

T1 T2

CONTACTOR

CAP 240

BALLAST

208

COM

CAP 240

BALLAST #3

208 COM

COM

208

240

CAP

COM

208

240

CAP

COM

277 CAP

BALLAST #4

ORANGE TO CAP. PACK

BALLAST #2

BALLAST #4

94MS20 Rev. B4 4-3

VOLTAGE SELECTOR SWITCH

YELLOW TO

AUTOFORMER

RED TO FUSE

AUTOFORMER

240 VOLT

AL54-480 / AL55-480 Ballast Wiring

TERMINAL STRIP

D3328A

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

BLK

CONTACTOR

(BLK)

BALLAST #1

BALLAST #3

CAP

120 COM

CAP

120 COM

AL53/50 Ballast / Tap Switch Wiring

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

TERMINAL STRIP

BLK

AC IN 6 GA.

T1 T2

L1 L2

(BLK)

RED

(RED)

RED

29 (VIOLET).

COM

120 CAP

COM

120 CAP

(VIOLET)

NO. 20 (ORANGE TO CAP. PACK).

BALLAST #2

BALLAST #4

BALLAST #1

BALLAST #3

CAP 240 208 COM

CONTACTOR

(RED)

(BLK)

VOLTAGE SELECTOR SWITCH

ORANGE TO CAP. PACK

BALLAST

COM

#2 208 240

CAP

BALLAST #4

COM 208 240 CAP

YELLOW TO

AUTOFORMER

RED TO FUSE

AUTOFORMER

240 VOLT

4-4 94MS20 Rev. B4

AL 35 Ballast / Tap Switch Wiring

D3328A

TERMINAL STRIP

BLK

1234567891011121314151718 16

RED

BALLAST #1

CAP 240 208 COM

AL23 and AL20 Ballast Wiring

CONTACTOR

VOLTAGE SELECTOR SWITCH

ORANGE TO CAP. PACK

BALLAST #2

COM 208 240

CAP

YELLOW TO AUTOFORMER

RED TO FUSE

AUTOFORMER 240 VOLT

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

TERMINAL STRIP

BLK

AC IN

VIOLET

WHITE

CONTACTOR

(BLK)

(RED)

CAP

BALLAST

240 COM

ORANGE TO CAP. PACK

94MS20 Rev. B4 4-5

AL 19 and AL15 Ballast Wiring

1618 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

TERMINAL STRIP

BLK

CONTACTOR

AC IN

(BLK)

VIOLET

WHITE

(RED)

CAP

BALLAST

120 COM

ORANGE TO CAP. PACK

4-6 94MS20 Rev. B4

5. General

Path of Power to the PC Board

This section is useful when there is no power reaching the PC board (no LEDs lighted). Before tracing the power, check the fuse on the PC board and the incoming power.

The power cord enters the rear of the unit. The two hot conductors are connected by wire nuts to wires that are in turn connected to the front of a terminal strip. One of these two wires passes through a fuse and on 208/240V~ 60Hz units is then connected to a voltage selector switch, then is connected to taps on a step-down autotransformer. This transformer is located under the terminal strip on the component bracket near the dividing wall. The transformer tap marked 120V~ becomes the unit common and returns to the terminal strip. The other line wire is connected to the transformer common and becomes the hot 120V~ lead to the PC Board and also returns to the terminal strip. The power is distributed from the strip and a pair of wires goes to the PC board.

Interlock System

The internal interlock system serves two purposes. The first is for operator safety by insuring the safety glass is in place before operation. This glass filters short UV radiation and covers the high voltage lamp terminals. This interlock also protects from overheating by traveling through two thermostats in the lamp head. There is also an outlet on some equipment marked “interlock” and is not used in this equipment.

The internal interlock is a loop that travels through the light head, passing through the glass switch and two thermostats. This interlock is in series with the control circuit of the large relays in the power supply. When the interlock is opened, the relays will open and cut the power to the lamp terminals. The PC board senses the drop in voltage and closes the shutter.

The first place to check is the glass switch. The switch lever is located near the edge of the glass on the end of the lamp where the cable enters. By releasing the glass, the lever can be seen. If the lever can slip past the glass, it should be bent slightly toward the reflector. If the switch is closed, the loop can be traced. First measure the voltage between lamp wires (#4 V~ Common) and wire (#10 Interlock). The presence of voltage between these terminals indicates an open loop. This loop travels to the lamp head on wire (#10), then to the glass switch, the far end thermostat, the near end thermostat and terminates on wire (#4). The thermostats are mounted in the air tubes leading to the lamp. There are no splices in the air tubes.

94MS20 Rev. B4 5-1

Lamp Voltage

The lamp voltage measurement can provide useful information for lamp striking, lamp output, and level switching information. The meter used to measure can cause different results. We use caution when using digital meters in our factory, due to the trigger pulses on the lamp before striking. The waveforms are not sinusoidal, so different meters may produce different results. Here is a chart with typical measurements:

MODEL IDLE LOW MED HIGH TRIG. IDLE/LOW MED. HIGH TRIG.

AL15 w/L1150A 180 180 ---- 230 500+ 65-90 --- 110-125 110-125

AL15 w/L1250 180 180 --- 230 500+ 65-90 --- 110-125 110-125

AL19/20 w/L1150A 205 190 210 225 500+ 65-90 80-95 110-125 110-125

AL19/20 w/L1250E 210 205 215 235 500+ 65-80 70-90 80-95 110-125

AL23 w/L1250 205 190 210 225 500+ 65-90 80-95 110-125 110-125

AL23 w/L1252 210 205 215 225 500+ 65-80 70-90 80-95 110-125

AL23 w/L1261 215 210 215 220 500+ 65-80 70-90 80-95 110-125

AL25/25-2 w/L1250 190 190 --- 230 500+ 45-80 --- 100-125 110-125

AL35 w/L1250 190 190 205 235 500+ 60-80 75-95 110-125 110-125

AL35 w/L1252 207 200 *195 235 500+ 65-90 *60-85 100-125 110-125

AL35 w/L1261 200 195 *195 235 500+ 65-90 *60-85 100-125 110-125

AL50 w/L1250 190 185 --- 270 500+ 60-90 --- 110-125 110-125

AL50 w/L1252 207 200 --- 270 500+ 65-90 --- 110-125 110-125

AL50 w/L1261 200 200 --- 270 500+ 65-90 --- 110-125 110-125 AL53/54/54-480/55/

55-480 w/L1250 AL53/54/54-480/55/ 55-480 w/L1252 AL53/54/54-480/55/ 55-480 w/L1261

AL56/56-480 w/L1280 360-380 360-380 380-410 415-445 500+ 80-95 90-120 115-125 115-125

AL56/56-480 w/L1281 400-430 400-430 420-490 440-510 500+ 80-90 90-120 115-125 115-125

AL56/56-480 w/L1282 400-430 400-430 420-490 440-510 500+ 80-90 90-120 115-125 115-125 AL83/84/84-480/85

w/L1280 AL83/84/84-480/85 w/L1281 AL83/84/84-480/85 w/L1282

190 185 225 270 500+ 60-90 95-115 110-125 110-125

207 200 225 270 500+ 65-90 85-125 110-125 110-125

200 200 225 270 500+ 65-90 85-125 110-125 110-125

370 360 390 425 700+ 80-105 90-125 110-125 110-125

415 395 425 485 700+ 80-115 90-125 110-125 110-125

422 395 430 510 700+ 80-105 90-125 110-125 110-125

*When using the L1252 or L1261 the AL35 has only high and low power.

Lamp Power Path

The basic path that the power to the lamp takes is almost identical for all units. The basic path is incoming line, main power relay, ballasts, capacitors, trigger board, and then the lamp. See the point to point wiring diagrams for each light source in section 7.

5-2 94MS20 Rev. B4

Trigger Board

A trigger board is provided in the light head to start the lamp. This board operates on demand by sensing the lamp voltage. This board can be heard when it is functioning, although the sound is faint. By turning the unit on and off, the sound can be compared during trigger and cool-down. In both situations, the fans are running full speed. The fans may be disabled by pulling the blue wire from terminal #5 to aid in determining if the trigger board is functioning.

C Use caution that the lamp doesn’t run without cooling. The trigger board is located in the lamp head, in the end where the cable

enters. It is located in the cool air path inside the air plenum. One lamp lead is in series with the trigger transformer [(1) input (3) output], the other lamp lead (2) is used to sense the lamp voltage. Outside the unit, the board can be tested by putting 350-750V~ between terminals [(1) and (3)], and causing an arc from terminal (3) to terminal (1). This arc should be .015" or greater.

AL 15, AL 19, AL 20, AL 23, AL 25, AL 25-2, AL 35, AL 50, and AL 53

Lead to Lamp (3)

(High Temp Wire)

TRIGGER BOARD #64MV414 FOR AL 83 and AL 100

TRIGGER BOARD #64TR408 for

Lamp Current (1) (Purple Wire)

Lead to Lamp (3)

(High Temp Wire)

Other Lamp Lead (2)

Lamp Current (1)

Other Lamp Lead (2)

(Yellow Wire)

(Violet Wire)

94MS20 Rev. B4 5-3

Capacitors and Level Switching

The capacitors pass all the current that flows through the lamp. They are also used to switch power levels.

The capacitors for the light sources are divided into two or three sections. All units have one or two idle capacitors, they are connected with a yellow wire. There are one or two medium power capacitors (in tri-level light sources only) connected with a brown wire. There are one or more high power capacitors connected with a blue wire. All capacitors have an orange wire which acts as a common.

The capacitors for high and medium levels are pulled in with relays during warm-up and exposures. The medium relay will pull in to select medium power. In all lights the medium relay will also always pull in for high power exposures.

The capacitors set the operating current of the lamp. If the lamp output has changed rapidly, inspect the capacitors for swelling. The design of capacitor we use will burn open if it begins to short. A swollen capacitor should be replaced, and the unit should be tested to see that the capacitor did not damage the high or medium relay. To test the unit’s ability to switch power levels, make a manual exposure, then switch between the power levels, noting the change in intensity. When switching down in power, allow the unit three seconds to respond.

Capacitor Assembly 62D127-83

BLACK BLUE

AL 83 Capacitor Assembly

D3309A

16 µƒ

8 µƒ

10 µƒ

12 µƒ

16 µƒ

WIRE COLORS

Blue / White1

Blue

Brown Yellow

4 5 Orange

CAPACITOR SWITCH

A B C

REAR PCB 64MV422-83

Blue Black

3 2 1

FRONT PCB

1234

Wires to Capacitors

5-4 94MS20 Rev. B4

AL 84 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D2652A00

12µƒ

10µƒ

12µƒ

16µƒ

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

AL 84-480 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D3533A00

12µƒ

10µƒ

12µƒ

10µƒ

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

94MS20 Rev. B4 5-5

AL 85 Capacitor Assembly

BLACK

BLUE

SWITCH

YELLOW

WIRE COLOR

BLUE / WHITE 2 BLUE 3 BROWN

413 2 1

4 YELLOW 5 ORANGE

POS. 1

SWITCH

REMOVE

64MV422V00

WIRES TO CAPACITORS

FRONT VIEWBOTTOM VIEW

AL 56 Capacitor Assembly

CAPACITOR ASSEMBLY #62D2726A00

16µƒ

10µƒ

8 µF

16µƒ

BLACK

WIRING INSTR., CAPACITOR, 8K, 60HZ - AL85

64MV422V00

16µF

10 µF

WIRES

FROM

HARNESS

12 µF

BLUE

321

POS. 2

16µF

C1 C2

14 AWG ORANGE WIRE (FROM BALLASTS)

1 2 3

FRONT

VIEW OF

PC BOARD

WIRES TO

CAPACITOR

TOP

5-6 94MS20 Rev. B4

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

AL 56-480 Capacitor Assembly

CAPACITOR ASSEMBLY #62D3083A00

WIRES

FROM

HARNESS

1 2 3

FRONT

VIEW OF

16µƒ

10µƒ

16µƒ

10µƒ

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

PC BOARD

WIRES TO

CAPACITOR

2 1

TOP

AL 54, AL 55 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D1048

WIRES

16µƒ

12µƒ

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

6) BLACK

CAUTION

DO NOT SWITCH

WHILE UNIT IS ON

12µƒ

16µƒ

1 2 3

SWITCH ON CAPACITOR

4 3 2 1

REAR VIEW OF

PC BOARD

FROM

HARNESS

FRONT

VIEW OF

PC BOARD

WIRES TO

CAPACITOR

TOP

MOUNTING BRACKET

94MS20 Rev. B4 5-7

AL 54-480, AL 55-480 Capacitor Assembly

CAPACITOR ASSEMBLY PART # 62D3654A00

WIRES

12µƒ

10µƒ

CAUTION

DO NOT SWITCH

12µƒ

WHILE UNIT IS ON

12µƒ

1 2 3

SWITCH ON CAPACITOR

FROM

HARNESS

FRONT

VIEW OF

PC BOARD

WIRES TO

CAPACITOR

TOP

MOUNTING BRACKET

AL 53, AL 50 Capacitor Assembly

Capacitor Assembly 62D127

YELLOW BLACK BLUE

12µƒ

16µƒ

WIRE COLORS

1) YELLOW

2) BROWN

3) BLUE

4) BLUE WITH WHITE STRIPE

5) ORANGE

6) BLACK

16µƒ

12µƒ

Blue Black

Yellow

3 2 1

FRONT PCB

1234

Wires to Capacitors

4 3 2 1

REAR VIEW OF

PC BOARD

Wire Colors

Blue / White1

Blue

Brown

Yellow

5 Orange

CAPACITOR SWITCH

A B C

REAR PCB 64MV422-53

NOTE: on AL 50 you MUST install a jumper between these two terminals.

5-8 94MS20 Rev. B4

Old Style AL 53, AL 50 Capacitor Assembly

Old Style AL 53

8µƒ

Wire Colors

Blue

2 3

Brown Yellow

Orange

8µƒ

Old Style AL 50

8µƒ

AL 35 Capacitor Assembly

Capacitor Assembly 62D127-35

YELLOW BLACK

8 µƒ

12 µƒ

16 µƒ

Black Yellow

3 2 1

FRONT PCB

1234

Wires to Capacitors

Wire Colors 2

Blue / White1

Blue

Brown

Yellow

5 Orange

CAPACITOR SWITCH

A C

REAR PCB 64MV422-53

94MS20 Rev. B4 5-9

AL 25, AL 25-2 Capacitor Assembly

Capacitor Assembly 62D126 (New Style)

12µƒ

Capacitor Assembly 62D2753A00

D2753A

Yellow

Blue

3 Orange

FRONT PCB

Wires to Capacitors

AL 23 Capacitor Assembly

12 µƒ

9 µƒ

3 µƒ

Old Style

8µƒ

1250/1261

BLUE

BROWN

YELLOW

ORANGE

12 µƒ

9 µƒ3 µƒ

12 µƒ

1250/1261

5-10 94MS20 Rev. B4

BROWN

BLACK

AL 20, AL 19 Capacitor Assembly

ORANGE

10µƒ 10µƒ

ORANGE

YELLOW

3µƒ 9µƒ

BLUE

10µƒ

YELLOW

AL 15 Capacitor Assembly

Old Style

AL 15 with L1150A Lamp

8µƒ

AL 15 with L1150B Lamp

8µƒ

Old Style

8µƒ

55SW01

8µƒ

WIRES

FROM

HARNESS

YELLOW

BLUE

New Style

AL 15 with L1150A Lamp

WIRES FROM HARNESS

1 35

16µƒ

CAPACITOR ASSEMBLY PART # 62D139

New Style

AL 15 with L1150B Lamp

WIRES FROM HARNESS

1 35

16µƒ

8µƒ

94MS20 Rev. B4 5-11

8µƒ

WIRES

FROM

HARNESS

16µƒ

CAPACITOR ASSEMBLY PART # 62D139

16µƒ

Opening the Lamp Head

• Unplug the unit.

• Remove the glass and the four screws attaching the large outer reflector section.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

Bottom View

Remove the 2 center screws from the bottom side and the 2 screws from the top side of the lighthead.

Bottom View

Top View

Remove the 6 screws from each side of the lamphead and remove the two endcaps. On 8kW lampheads you can now access the trigger board and shutter position switch that are located at the opposite end from the shutter motor under the air plenum plate.

Side View

On 5kW lampheads remove the 5 screws from the air plenum plate to remove it. The trigger board and shutter position switch are located at the opposite end from the shutter motor under the air plenum plate.

5-12 94MS20 Rev. B4

End View

Shutter

The shutter is controlled by the PC board, with information from a switch in the lamp head to provide position information. During cool-down and exposure, the shutter is open and during warm-up and idle, the shutter is closed.

The PC board compares the shutter position with the requested position. The shutter motor will run until the switch position matches. The shutter motor has a brake that is magnetically operated. Whenever the power is released from the motor, the brake falls into a slot. There is an LED on the PC board that lights whenever the shutter is being energized. (Look in the PC board pin section for a diagram of the LEDs).

Shutter Switch

The switch provides shutter position information to the PC board. This switch is in the lamp end where the cable enters, inside the manifold cover. The cam is in the chamber with the shutter. A failure of the switch can cause the shutter to rotate continuously or erratically. Similar problems may be due to the shutter motor brake, the idle setting, or the PC board.

The switch contacts close when the shutter is fully open and remain closed until the shutter closes. This level can be measured on the terminal strip from terminal 9 (+) to terminal 7 (-). The level is 12 VDC when the shutter is closed, and 0 V when the shutter opens. The switch is in the lamp head on the end where the cable enters inside the air manifold on older units. On newer units we use the normally open contacts, COM contact and the center contact. We use the normally closed contacts, the two outside leads, not the center contact. This switch is adjustable on older units. We recommend scribing a line around the switch and the bracket, if replacement is necessary, to return to the same position. The switch roller should be centered on the cam and closed when the cam pushes the wheel on the switch halfway.

Shutter Brake

The motor that drives the shutter has a brake that is magnetically operated. When the motor core magnetizes, it pulls a lever to release the brake. If the shutter coasts or rotates continuously, look at the shutter LED on the PC board. On early boards, where there are three LEDs in a row near the front of the power supply, it is the third from the front of the power supply. On the newer models, there are five in a row; it is the fourth from the front of the power supply. When this light goes out, the shutter brake should engage. If the shutter coasts, the brake may have failed. The shutter may coast to the point where the switch will switch again to cause the motor to energize. The LED on the board will flash if this occurs.

94MS20 Rev. B4 5-13

Shutter Motor

The shutter motor is located in the lamp head on the side with the shutter drive chain. We recommend checking the power and signals from the switch and to the motor coil, before entering the lamp head. These items are covered in the preceding sections. Changing the shutter motor requires

a Phillips screwdriver and a

• Remove the glass and outer reflector from the light head.

• Open the end of the light head, where the drive chain and the sprocket are located.

• There are four screws that hold the motor; two of them require access through holes in the sprocket. The shutter can be turned counterclockwise to access these screws, by pushing the brake on the motor.

C Turn the shutter only counterclockwise (looking from the

motor end) or you may damage the shutter switch on the other end of the light.

• Remove the chain from the sprocket with care to keep tension. The chain has shortened links and will separate if slackened. If the chain opens, attach an end to the sprocket with tape or wire and revolve the shutter.

/32" Allen wrench.

• Remove the motor sprocket by loosening the set screw.

• Remove the two wire nuts from the motor coil wires.

• Remove the four motor screws.

Installing the Motor

• Mount the motor with four screws.

• Install the sprocket in line with the shutter sprocket and tighten.

• Install the chain on the sprockets.

• Set the chain to where it has 3/8" side travel and tighten the two accessible motor screws lightly.

C Turn the shutter only counterclockwise (looking from the

motor end) or you may damage the shutter switch on the other end of the light.

• Rotate the sprocket to tighten the other two screws and attach the wires.

• The shutter can be tested with the unit open by disconnecting one of the lamp leads and holding the interlock switch.

C DO NOT light the lamp without the safety glass or when

you are close to the bulb.

5-14 94MS20 Rev. B4

Shutter Removal

LT1 lampheads

• Remove the 2 screws holding the air flow deflectors and remove them.

Then reach through the air tube and remove the thermostat, then the high temp lamp lead (reaching through the bottom of the light a pair of needlenose pliers to remove it from the lamp support assembly makes this easier).

END VIEW

• Remove the 4 screws holding the rear reflector to the air tubes and remove

the reflector and lamp from the lamphead.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

BOTTOM VIEW

• Remove the top screw from the cooling tube on both sides. Compress

the air tubes into the shutter assembly, remove the chain from the motor sprocket, then remove the shutter assembly.

END VIEW

• Reassemble in reverse order.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

94MS20 Rev. B4 5-15

LT1 Shutter Assembly Drawing

DETAIL

REF.

2 PL

25172

8 PL

2 REF.

21 2

REF.

EDETAIL

18810 28

REF.

SECTION I-I

DETAIL

DETAIL A

4 PL

18 25

4 PL4 PL

2 PL

DETAILH

2 PL

REF.

DETAIL

26427

REF. DETAIL

SECTION

2 PL

2 PL2 PL

H-H

REF.

DETAIL

2 PLACES

16 13

DETAIL

2 PL

NOTE: Older shutters have one straight and one curved linear spring. If the straight spring needs to be replaced it is upgraded to the curved

spring

CDETAIL

#8 WASHER, SPLIT LOCK

#8-32X.25 SCREW, PHIL,PN.HD.

#6 WASHER, SPLIT LOCK

#8 X .250 ROUND SPACER

8 #6 FLAT WASHER

1 21 20

4 #6-32X.62 SCREW, 100° FLAT HD. 41B06SHF.62 19 18

13 #6-32X.37 SCREW, PHIL.PN.HD. 41-06PPS.37 17 16

2 #4-40 NUT HEX 41-04NHX 15

2 #4-40X3/16 PPMS ZINC 41-04PPS.18 14 13

2 FUSE CLIP 43CLP02 12 11

2 LAMP SUPPORT ASSEMBLY 63D0142B00 10

1 SPROCKET, DRIVE (MACHINED) 12D1998A99

IDLER ARM, SHUTTER 63D3530A62 7 6

2 AIR TUBE LT-1, AL25-53 12D0217A62

#6 X .180 ROUND SPACER 42HHS8500

4 4 3

1 11D2206SHUTTER ASSEMBLY LT1

TIMING DISC, LT-1 11D210A621

2 11D1949A71

SHUTTER END

ITM

QTY

41-08WLS4 41-08PPS.25 41-06WLS

42HHS8521

41-06WFR 11D878BAFFLE, SHUTTER ASSEMBLY 41B06SHF.432 6-32 X 7/16 SOC FLAT

41-06PF0.37 #6-32X.37 SCREW, 100° FLAT HD.3

41B06PPS.25 #6-32X.25 SCREW, PHIL PN.HD.8

42HHS8347#6-32X1.000 RD.THD SPACER3

41-06WLI#6 WASHER, LOCK INTERNAL3

12D3515A00BALL, BEARING 6

12D2060A072 SPRING, SHUTTER AL83

11D886REFLECTOR, INNER RF531

PART NO.DESCRIPTION D3214B

5-16 94MS20 Rev. B4

THERMOSTAT

#6-32 NUT, FLEX LOCK

#8-32 X 1/2 PPMS ZINC

2 3

12SPACER, TUBING (SHORT)

30 29

1 SPACER, TUBING (LONG)

BUSHING, IDLER ARM 12D3550A62

QTY

ITM

DETAIL

2 PLACES

DESCRIPTION

REF.

1 18

56THM01

41-06NLM 41-08PPS.50 42HHS8761W#6-32 X 1.7 STANDOFF

12D3588B07 12D3588A07

PART NO.

DETAIL

2 PLACES

DETAIL

18 18

18 25 28 10 21

DETAIL

REF.REF.

4 PLACES

REF.

182530 8 14

101

LT8 lampheads

• Remove the four hex nuts mounting the blowers, disconnect the blower and thermostat wires.

End View

• Remove the four screws holding the rear reflector to the cooling tubes and remove the reflector and lamp from the lamp head.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

Bottom View

• Remove the three screws from the blower mounting plate to the cooling tubes on both sides. Compress the cooling tubes into the shutter assembly, remove the chain from the motor sprocket, then remove the shutter assembly.

End View

• Reassemble in reverse order.

C DO NOT TOUCH THE REFLECTOR SURFACE WITH

YOUR HANDS.

94MS20 Rev. B4 5-17

LT8 Shutter Assembly Drawing

DETAIL

REF.

REF. DETAIL

219

REF.

1 25

DETAIL

G-GSECTION

2 PL

17 25 8 PL

11 2518

4 PL

4 PL 4 PL

GDETAIL

REF.

DETAIL

27 26

REF.

H-HSECTION

DETAIL

REF.

16 13

REF.

DETAIL

REF.

#8 WASHER, SPLIT LOCK #8-32X.25 SCREW, PHIL,PN.HD.

42726

21 4 #6-32 NUT, FLEX LOCK

24 23

4 #6 FLAT WASHER

IDLER ARM, SHUTTER 63D3530A62

2 20 19

3 #6-32X.37 SCREW, 100° FLAT HD. 41 06PF0.37 18 17

8 #6-32X.25 SCREW, PHIL PN.HD. 41B06PPS.25 16 15 14

6 #6-32X.687 RD. SPACER 42HHS8779 13 12

3 #6 WASHER, LOCK INTERNAL 41 06WLI 11 10

6 BEARING, BALL SEE BOM 9 8 7

SPRING, SHUTTER AL832 12D2060A07 6 5

1 REFLECTOR, INNER, RF83-SW-G 11D1876B99

LT8 SHUTTER-REFLECTOR ASS'Y 11D22161 2

1 11D0210A62TIMING DISC, LT-1

SHUTTER END, PHOTOCELL, SLOT

ITM

QTY

DESCRIPTION D4358A PART NO.

DETAIL

56THM012 THERMOSTAT29 12D3550A622 BUSHING, IDLER ARM28

41 08WLS4 41 08PPS.25 41 06WLS#6 WASHER, SPLIT LOCK 41 06NLM 41 06WFR

41B06SHF.432 6-32 X 7/16 SOC FLAT

41B06SHF.62 #6-32X.62 SCREW, 100° FLAT HD.4

41B06PPS.37#6-32X.37 SCREW, PHIL.PN.HD.13

41 04NHX#4-40 NUT HEX2 41B04PF025#4-40X.25 SCREW, 100° FLAT HD.2

43CLP02FUSE CLIP2

63D0142B03LAMP SUPPORT ASSEMBLY2

12D1998A99SPROCKET, DRIVE (MACHINED)1 12D1874A621 AIR TUBE, FRONT

12D1873A62AIR TUBE, DRIVE 1 42HHS8500#6 X .187 ROUND SPACER

11D3974A712

DETAIL

A B

DETAIL DETAIL 2 PLACES 2 PLACES

19 181

REF.

14 Newer units

have fixed spacer

here

252

2 PL

DETAIL

182525 1021 28 2218

REF.

2 APPLY LOCTITE 242 TO THREADS WHERE INDICATED.

REF.

91 1818

2525 14

DETAIL

4 PLACES

DETAIL

REF.

1 10

5-18 94MS20 Rev. B4

Idle Setting

The idle level occurs between exposures and low power exposures. The idle setting determines the power and temperature of the lamp, while at idle. It also allows for much lower idle power than was ever attainable before.

This lower power level provides a wider light output range, low power consumption, lower heat generation, and increased lamp life. At low power levels, the lamps normally become unstable. If over cooled, they begin to dissipate less energy, which causes them to cool more. This can continue until they extinguish. When lamps become hotter at idle, they become more efficient and dissipate more energy, making them hotter still. This becomes stable, and is commonly done in conventional light sources, but will shorten the life of the lamp and wastes energy. We have chosen to servo the cooling, by sensing the lamp condition and adjusting the cooling to regulate the idle temperature.

The idle setting is done at the factory and is rarely necessary in the field. Always check all other causes of problems before changing the setting.

If the lamp becomes too cool during operation, the board will sense this level and initiate a warm-up cycle. During warm-up, the shutter will close and will not open until the unit is sufficiently warm. A symptom of this is: after an exposure is started, the shutter will open, then close again for several seconds, before finishing the exposure. This should only happen if the unit is left in idle for a period of time. Successive rapid exposures would not fail, since it takes many minutes for the unit to over cool. This over cooling situation could also be due to a bad idle capacitor, which would not allow sufficient energy to the lamp to keep it warm.

After checking the capacitors, mark the factory setting of the trimpot that is located on the back side of the PC board. The trimpot sets the power level that the lamp idles at. Turning the trimpot counterclockwise will first slow the lamp blowers. As the lamp reaches the new idle setting, the blowers will speed up to hold the new level. Setting with a meter is done by measuring the lamp voltage on terminals 2 and 3. See Lamp Voltage for proper idle voltage setting. The voltage will increase with a counterclockwise and decrease with a clockwise direction. This voltage change is a secondary effect after the lamp has responded to the change in cooling. The changes should be done in small increments, waiting between adjustment for the voltage to stabilize the lamp temperature.

The idle setting affects the power that the lamp attains on warm-up cycle, before switching to idle and the idle temperature of the lamp. If the setting is too high (too far counterclockwise), the unit will run at high power, with no cooling until the thermostats switch the unit off. The idle temperature of the lamp affects its life and reliability. If the idle setting is too low (too far clockwise ), the lamp will be slow to come to power for exposures, and the unit may close the shutter, after the unit has begun to expose to warm back to power. For these reasons, please take care when making this adjustment and check for other problems first.

94MS20 Rev. B4 5-19

Lamp Head Blowers

The lamp head blowers are controlled by the printed circuit board to provide the correct cooling to the lamp. During warm-up, the blowers are off or run very slowly. At idle and during low exposure, the blowers vary in speed. Both at high exposure and cool-down the blowers run at full speed.

A symptom of a defective blower would be: during high power exposure, after approximately 10 seconds, the lamp extinguishes and requires 2 to 4 minutes to restart. One blower will speed up to compensate for the defective blower or low power. When the unit switches to high power, the additional heat causes one of the lamp thermostats to open. (See also Interlock System for information on the thermostats.)

To test the blowers, turn the power supply main switch on then off. During the cool-down cycle, place a piece of paper over each intake vent located on the lamp end. The paper should be drawn to the lamp end. If one lamp end does not draw, that blower is suspect.

To replace the blower in the lamp head, see Opening Lamp Head.

Blown Fuse on PC Board

If the fuse blows on the printed circuit board, check if the fuse is a 5 amp fuse.

The printed circuit board drives five or six circuits: the lamp head blowers, shutter motor, power supply blower, and the relays. To find the cause:

• Unplug the unit and replace the fuse; then disconnect the wires to the lamp head on terminals 5 (blue wire) and 6 (red wire), and disconnect one of the wire nuts connecting the blower in the power supply. The relay coils rarely cause any problem.

• Plug in the unit and turn on the power switch for 10 seconds.

• If the fuse blows, the problem is either: the p.c.board or in one of the relay coils.

• If the fuse does not blow the problems is either: the power supply blower, lamphead blower or shutter motor.

• Unplug the unit and reconnect the red wire to the terminal strip #6.

• Plug in the unit and turn on, then off. The shutter should now turn. If the fuse blows, the problem is in the shutter motor or wiring to the motor.

• Unplug the unit and connect the blue wire to the terminal strip. Turn on the unit, then off for the cool-down cycle to test the lamphead blowers. If the fuse blows during this test, the problem could be with either of the two blowers in the lamp head. Normally, when the coil on a blower fails, the coil will become discolored. See section Opening Lamp Head.

• If the fuse has not blown throughout the test, the power supply blower is suspect.

5-20 94MS20 Rev. B4

Lamp Head Signals

Signals at the Terminal Strip (Cable to the Lamp Head) A great deal of information about the operation of the lamp may be found

at the terminal strip, in the power supply that connects to the lamp head. The terminals are counted number 1 at the end where the cable begins, and wire number 18 is the last wire. Terminal number 1 is closest to the dividing wall in the power supply.

Terminal# Description

#1 Ground to lamp head #2 Lamp #3 Lamp #4 V~ common #5 Lamp fans #6 Shutter motor #7 Shutter position switch #8 Not currently used #9 Shutter position switch

#10 Interlock and thermostat switching

#11 Not currently used #12 Incoming voltage #13 Autoformer #14 Incoming voltage

• #1 The ground terminal is for safety purposes and carries no current.

• #2#3 Lamp terminals 2 and 3 carry the power to the lamp. If the lamp is hot or fails to start, the voltage should be 600 to 950V~. During this time, there are voltage pulses that may damage a sensitive voltmeter. Immediately after the lamp strikes, the voltage will drop as low as 20V~, then rise as the lamp warms to the operating voltage, between 180 and 240V~.

• #4 V~ common terminal is the V~ return for the lamp fans, the shutter motor, and the interlock switch. On 120V~ equipment, this is the V~ common from the power line. This potential is generated on 208/240V~ equipment and may be 60V~ from the line common.

• #5 The voltage applied to the lamp fan varies as cooling is required.

94MS20 Rev. B4 5-21

The voltage is measured referenced to terminal 4 and terminal 5. This voltage starts at 0V~ during unit warm-up and when the lamp temperature rises it increases. As the lamp reaches temperature, the fans speed increases to regulate the lamp. At idle, this voltage is typically 45 - 90V~

and depends on the lamp age and ambient temperature. When an exposure at high power is initiated, the lamp voltage rises to the maximum. The voltage remains there after the lamp returns to low power, until the lamp temperature again stabilizes.

• #6 The shutter voltage is present during the rotation of the shutter. The shutter motor runs on 120V~ measured to terminal 4.

• #7 Shutter position DC common (see terminal 9)

• #8 Not presently used

• #9 The shutter position switch reports the position of the shutter to the printed circuit board. This switch is open when the shutter is closed, and closes when the shutter opens. This signal is low voltage DC and can be measured (+) on terminal 9, (-) on terminal 7. The meter will read +12 VDC when the shutter is closed, and 0 VDC when the shutter is opened.

• #10 Interlock and thermostat switching. During normal operation, terminal 10 is shorted to terminal 4 (V~ common). An V~ voltage present would indicate the glass switch or one of the two thermostat switches open.

• #11 Not presently used.

• #12#14 Incoming voltage. To get load voltage, meter between terminals 12 & 14 while power is on. On 208/240V~ equipment set voltage selection switch accordingly, (low=219V~ or below, high=220V~ or above).

• #13 a. Autoformer

5-22 94MS20 Rev. B4

Light Function States

Model Warm-Up Idle Low Exp. Med Exp. High Exp. Cool Down Trigger

Unit Fans On / On On / On On / On On / On On / On On / On On / On

Power Relay On / On On / On On / On On / On On / On Off / Off Off / Off

Shutter Closed / Off Closed / Off Open / Off Open / Off Open / Off Open / Off * / Off

Lamp Fans Off / Off Var.Slow / On Slow/Med. / On Med./Fast / On Fast / On Fast / On

Off / Off High Relay On / On Off / Off Off / Off Off / Off On / On * / *

* / * Medium Relay On / On Off / Off Off / Off On / On On / On * / *

Warm-Up - Occurs after the lamp ignites and ends when the lamp has warmed to operating temperatures. The lamp fans are held off and the unit goes to high power. Due to the technology of the power supply, the units do not draw large amounts of current during warm-up. Due to the restrictive cooling, the lamps warm up rapidly, without surge current. The shutter will not open until the unit reaches temperature.

Idle - Between exposures, the lamp is held in idle. During this period, the lamp fans vary in speed to maintain the proper lamp temperature. This allows the unit to consume less power on idle, and provides a wider range of exposure capabilities, since this same low power level is available for exposures. The lower idle saves power, generates less heat, and extends the lamp life.

Expose - The units allow exposures at three levels. At high power, the high and medium relays are activated. At medium power, the medium relay is activated.

Cool-Down - When the unit is switched off, all fans are turned on to cool the equipment. After the cooling period, the unit disables all of its functions until it is started again.

Trigger - If the lamp is turned on before the unit has fully cooled, the fans will run at full power and a trigger pulse is created. This mode will release itself when the lamp strikes. The unit is responding to conditions to provide these functions. It is therefore not possible to confuse the unit. If there is a momentary loss of power, the unit will cool the lamp until it strikes. It is recommended that the unit be shut off and allowed to cool, rather than turning off the power supplied to the unit.

94MS20 Rev. B4 5-23

Printed Circuit Board Layout

This is a description of the signals and voltages present on the pins of the printed circuit board.

64MV407V03 Control Board layout. Used on all BUT 8kW light sources 64MV407V04 Control Board layout. Used on all 8kW light sources

Note: Graphic of the new style p.c.board is shown. Relay style p.c.board

has the same connector hookups and pin outs, however the LEDs are on the component side of the p.c.board not on the solder side as on the new style. The old style board is replaced by the new style and is interchangeable.

64MV407V

REV.

U101

R105

TR101

R106

32TRN02

R102

R101

U102

C101

R108

R107

TR102

C102

R103

R109

C103

TR105

R104

U103

R110

TR103 TR104

L K

HS101

REV. 64MV504V

D C B

U104

J I H G

R112

R111

C104

COIL1

COIL2

P1 Power Connector 1 AC Hot 2

AC Common

Lamp Fans

Shutter Motor

High Relay

Medium Relay

7 8

Unit Fan Power Relay

Not Connected Aux Terminal DC Common Position

Check Idle Voltage on Board or on Terminal Strip Lugs #2 and #3

1 AC Hot 2

AC Common

Not Connected

Aux Terminal

DC Com/Ground

Power Switch

R10

R11

120K

R59

8.2K

470K

R50

U8 U9 U6

P2 Switch Connector

7 8 9

10 11

22K

High Switch Low/Med Switch Manual Expose Interlock

Not Connected +12 VDC

Front View of Control Board

Triacs & Relay

TR101

TR102

TR103 TR104

TR105

Unit Power

Shutter Motor High Relay Medium Relay

Main Contactor

Lamp head fans

LED's

D18 Lamp head fans

Power Supply Fan

D13

Shutter Motor

D17

High Relay

D15

Medium Relay

D16

Power Relay

D14

Switch Connector

Idle Voltage Adjustment

Back View of Control Board

5-24 94MS20 Rev. B4

Power Connector

D17

D15

D16

D14

D13

D18

Signal Description

Power Connector

P1) V~ Hot: Supply to board approximately 125V~.

V~ Common: Common to board is the common also for relays, shutter fans,

P2)

P3) Lamp Fans: V~ proportional drive output for the blowers in the lamp head. P4) Shutter: V~ output to drive the shutter motor.

and the internal lamp head interlock. (This may not be at ground potential and should be measured with caution).

P5)

P6)

P7) Unit Fan: V~ Output to drive the power supply blower or fans.

P8)

P9) Not currently used.

P10)

P11)

P12)

High: V~ Output to drive the high relay, which engages the high power

capacitor bank during warm-up and high power exposures.

Medium: V~ Output to drive the medium relay which engages the medium

capacitor bank during warm-up and both high and medium level exposures.

Power Relay: V~ Output to drive the main relay. This provides power to the lamp circuit.

Aux: Terminal connects to the signal connector for accessories (Not used in most equipment).

DC Common: Circuit common for low voltage signals from the lamp (this may not be the same potential as V~ Common connection and should never be interchanged).

Position: Shutter switch active signal from the lamp head - Low voltage when the shutter is open and 12VDC when closed.

Switch Connection

94MS20 Rev. B4 5-25

S1) V~ Hot: Output, V~ supply for internal accessories. S2) V~ Common: Output, V~ common for internal Accessories. S3) Not currently used.

S4)

S5)

Aux: Terminal connects to the power connector for accessories (Not used in most equipment).

DC common: DC circuit common for switches (Not the same as V~

Common).

Power Switch: Switch to turn on power. Low (0V) for power on. The power

S6)

can also be turned on by the integrator through the outlet. (Only a signal !

Power is always present on the PC Board).

Continued on next page

S7) High Switch: Switch to select high power level. Low (0V) for high.

S8)

S9) Manual Switch: Manual expose switch. Low (0V) to cause exposure.

S10)

S11) Not currently used. S12) +12V: Output for internal accessories (Not used in most equipment).

Low/Med Switch: Switch to select power level when high switch is off. Low

(0V) for medium power, High (12VDC) for low power.

Interlock: External interlock outlet. Line must be connected to DC common to allow an exposure. (Outlet is normally shorted when plug in not inserted).

DIN Connection

Expose: High expose when connected to a compatible integrator. High /

D1)

D2) DC Common: Common for all signals. D3) Low Exp: Low expose input. D4) Power: Signal from integrator to turn on the power. D5) Medium Exp: Medium expose input.

Medium / Low expose depending on the unit switches when connected to an

older style integrator or other manufacturer’s equipment.

LEDs

The LEDs are an indicator of an acting command that you are asking the control board to do. For a list of which commands activate which LEDs, look at the chart above, labeled LED indicators. The LEDs light when they detect a ground or negative going pulse.

5-26 94MS20 Rev. B4

Circuit Diagram (64MV407 60Hz)

Lamp Signal

110 VAC

12 V Power Supply

AC Common

Lamp Fans

Output for Shutter

Output for Lamp

Blowers

D18,U4,U5

High Relay

Shutter Motor

Output for High

Relay

Motor

D17,Q6,K5

Medium Relay

D15,Q4,K3

Output for Medium

Relay D16,Q5,K4

Unit Fan

Power Relay

Connector P1

Output for Power

Relay

Output for Power

Supply fan

D13,Q2,K1

Not Connected

D14,Q3,K2

Aux Terminal

DC Common

AUX

AC Source

Ouput Type "B"

Signal

Output

Shutter Position

Output

D18

110 VAC

AC Common

AUX

Not Used

Aux terminal

Connector P2

Power Switch*

DC Common

Lamp Cooling Logic

Input Filters

High Switch*

Manual Expose Switch*

Low/Medium Switch*

Not Used

Safety Interlock*

+12 V

AC Source

Shutter and Intensity Logic

Ouput Type "A"

1 High Expose

4 Power On

*No Switches on Models

AL55, 65, 75, 95, 96

K__

D__

Input Filters

2 DC Common

3 Low Expose

5 Medium Expose

Q__

Signal

94MS20 Rev. B4 5-27

Old Style (64MV210A) Control Board Layout

Although there are very few old boards in the field, there are some, therefore we must address them also. To determine if you have an old board, look at the serial number. For the AL 25 the serial number is 2550 and below. For the AL 50, the serial number is 5400 and below. For the AL 53 the serial number is 7100 and below. If your control board has a serial number below those just stated, you have an older board.

Note: This pertains only to the models mentioned, and no others.

Lamp Signal

Low Expose

Connector

14------------------------1

3 4

LED's

Control Board connector pins and pin signals.

14 Pin Power Connector 1 AC Hot 8 Shutter Switch DC Common 2 AC Common 9 Optical Coupler 3 Lamp Fans 10 Shutter +12VDC

4 Shutter Motor 11 Power Supply Blower 5 High Relay 12 External Expose High/Low 6 Power Switch 13 External Expose Return

7 High/Low Switch 14 Manual Expose Switch

Control Board LEDs.

5-28 94MS20 Rev. B4

LED's

1 Lamp Fans 2 Shutter Motor 3 High/Low Relay 4 Power Relay

Signal Description (64MV210A)

Lamp Signal: V~ going to lamp. Low Expose: Input of 110V~ from timer/integrator activates a low

powered exposure.

Power Connector

P1)

P2)

P3) Lamp Fans: V~ proportional drive output for the blowers in the lamp head. P4) Shutter: V~ output to drive the shutter motor.

P5)

P6) Power: Switch 110V~ output to power on off switch.

P7)

P8)

P9) Optical Coupler: Not used.

P10)

P11)

AC Hot: Supply to board. It is equal to the line voltage on 110V~

equipment, an approximately 130V~ on the 208/240V~ equipment.

AC Common: Common to board, also is common for relays, shutter fans, and the internal lamp head interlock. (This may not be at ground potential and should be measured with caution).

High: V~ Output to drive the high relay which engages the high power capacitor bank during warm-up and high power exposures.

High/Low: Switch 110V~ output to high/low intensity switch. Switch must be at high power to be controlled externally from an integrator.

Power Relay: V~ Output to drive the main relay. This provides power to the

lamp circuit.

Aux: Terminal connects to the signal connector for accessories (Not used in

most equipment).

DC Common: Circuit common for low voltage signals from the lamp (This

may not be the same potential as V~ Common connection and should never

be interchanged).

Input: 110V~ from timer/integrator activates a low or high powered

P12)

P13)

P14) Manual Expose: Switch 110V~ output to manual expose switch.

exposure (Intensity switch on power supply must be set on high power to get a high powered exposure).

Input: 110V~ from timer/integrator activates a low or high powered exposure (Intensity switch on power supply must be set on high power to get a high powered exposure).

94MS20 Rev. B4 5-29

5-30 94MS20 Rev. B4

6. Check List for Printing Light Troubleshooting and Service

Check List for Printing Light Troubleshooting and Service

C In order for this check list to be effective it must be followed

1) Disconnect the integrator/timer from the power supply. This will make sure that a faulty integrator or QC15 cable are not

responsible for the malfunction and also eliminate a bad DIN socket on the board.

2) Check the tap switch (208/240V~ power supplies only. If the top LED is lit, make sure the switch is in the UP position, and if the bottom LED is lit, make sure the switch is in the DOWN position (see Printing Light Installation Manual). Improper setting will most likely cause blower, capacitor, and/or PC board failure and will prematurely age the lamp.

The LEDs next to the switch are not controlled by the switch, the LEDs tell you where to put the switch.

C You MUST NOT flip this switch with the power supply

step by step.

turned on! You will arc the contacts inside and this will damage the switch.

• If the tap switch is set for 240V~ and you have 208V~ coming in, the light source is going to draw excess amperage (as voltage goes down amperage draw has to go up). If when you open the power supply you notice right off burnt wires or connectors, one of the most likely causes is the tap switch in the wrong position. This condition usually take months and sometimes years (depending upon the degree of voltage discrepancy) to show up. When the burnt wire is on the tap switch itself or on the bottom side of the power relay it is very difficult to see the burnt wires without some disassembly of the power supply.

• If the tap switch is set for 208V~ and you have 240V~ coming in, the p.c.board and the blowers are usually the two items to get damaged. Over voltage to the blowers will burn them out and are usually the first to component damaged, the p.c.board will also be damaged under extended usage in an over voltage condition.

• If the voltage fluctuates there is a line that you can not cross 219V~ 220V~ the voltage must always stay 220V~ or above or always stay 219V~ or below.

If the switch itself is bad with no external signs of burning make sure that the user is not flipping the switch with the power supply on. Flipping the switch with the light source turned on will cause damage to the switch that may take time to show up.

94MS20 Rev. B4 6-1

3) Check the safety glass for proper installation. The long dimension of the glass goes parallel with the long dimension of the lamphead. Improper installation can cause the glass to shatter and/or an 'open' in the safety interlock circuit.

• You must be able to reach up, place your fingers against the safety glass and there must be play front to back and side to side. Otherwise the glass does not have room for expansion and will more than likely shatter under use.

C NEVER operate the light source without the safety glass in

place.

4) Check the beau plug at the lamphead. Make sure it is pushed in all the way. The most likely problem caused by a loose beau plug is an erratic shutter operation or an open safety interlock circuit.

Just push in on the beau plug while rocking it up and down to make sure it is in all the way.

5) Check the lamphead interlock circuit. Remove or lower the safety glass. Turn the power supply on. Check for 120V~ from terminal 4 to terminal 10; when the glass is reinstalled, the voltage should go low. (See Interlock System for operation.)

With the interlock open what should happen is the shutter should close and the power supply blower should come on, that's all. After you remove the glass and you turn on the power supply, if the light source comes on turn power off immediately and determine what is shorting out and bypassing the safety interlock circuit. If this does happen it is possible that the safety interlock circuit is shorting to ground. On older light sources this condition would burn up the autoformer. On newer light sources this condition will blow the 3A slow blow fuse on the dividing wall below the wiring harness.

6) Check input voltage with the power off at terminals 12 & 14. Then with power on, intensity level on high, and manual expose set on, check the voltage again. If the voltage drops more than 6 V~, the incoming power is most likely a problem.

You can do checks 6 and 7 at the same time. Write down the voltage that you get before turning power on and after turning power on but before the light source completes the warm up cycle. This is maximum amperage draw so the voltage will show maximum drop.

If the voltage in check 6 drops more than 6V~ the incoming power is a problem and it can not be corrected in the power supply (there is nothing you can do in the power supply to correct bad voltage from the wall).

7) Check input voltage to the PC board with the power off at pins 1 & 2 (see p.c.board layout for pin location). Then with power on, intensity level on high, and manual expose set on, check the voltage again. If the voltage drops more than 6 V~, the autoformer is most likely a problem.

• If and only if the voltage on 12 and 14 in step 6 is good can you say that

6-2 94MS20 Rev. B4

the autoformer is definitely bad, if the voltage on 12 and 14 in step 6 is bad you can not get a correct reading for step 7.

8) Check capacitors and relay circuit by:

The capacitors and relays are checked by watching the voltage changes that take place at the different intensity levels. If a capacitor is not in the circuit the voltage readings on input and output will be the same. If the capacitor is pulled into the circuit the input and output voltages will be hundreds of volts apart. Now the tricky part, if a capacitor is pulled into the circuit the way it is supposed to be then we need to look at the voltage itself to see if we see an increase in the overall voltage to make sure that the capacitor is adding voltage to the circuit. If the capacitor is pulled into the circuit when it is supposed to be but the overall voltage does not increase then the capacitor is defective.

9) Check voltage from terminal 3 to the capacitor input (orange wire on top

of the capacitors). The voltage should be 500+ V~. If voltage is lower, check the power path to the tap switch and ballasts. 500+V~ is typical for AL 19 through AL53 light sources, 450+ V~ for 1.5 kW light sources and 700+ V~ for the 8kW light sources. If the voltage on a 208/240V~ is low then not all the ballasts are being powered properly. This is usually caused by a bad tap switch or a burnt connector at the tap switch, however any of the wiring between ballast and tap switch is suspect. If the voltage is zero then a burnt wire at the power relay or a bad power relay is most likely the problem. There is a possibility that if there is zero V~ that you might have a grounded safety interlock circuit.

• At idle, check voltage from terminal 3 to the capacitor outputs (yellow,

brown, and blue wires on top of the capacitors). On the chart following step 6.8.5 find the Wattage of the unit you are

working on and then for the lamp installed into the unit, these are the general voltages you should read. These voltages are a ball park figure depending upon several factors and the actual voltage is not as important as to whether or not the voltages change on the capacitors according to intensity level. For instance on a 5kW light with an L1250 lamp at low intensity one capacitor will be about 200V~ and three capacitors will be over 500V~. Now when you go to medium intensity you should see two capacitors at about 230V~ and two capacitors at over 500V~. NOTE the number of capacitors at the lower voltage (i.e. in the circuit) and the voltage increase from the previous intensity 200V~ at low and 230V~ at medium.

• At low power, manual expose on, check voltage from terminal 3 to the

capacitor outputs (yellow, brown, and blue wires on top of the capacitors).

• At medium power, manual expose on, check voltage from terminal 3 to

the capacitor outputs (yellow, brown, and blue wires on top of the capacitors).

• At high power, manual expose on, check voltage from terminal 3 to the

capacitor outputs (yellow, brown, and blue wires on top of the capacitors).

94MS20 Rev. B4 6-3

• SEE CHART FOR PROPER VOLTAGE READINGS (ALL VOLTAGES ARE READ TO TERMINAL 3).

1.5kW with L1150A or L1150B LAMP ORANGE YELLOW BLUE

a. IDLE/LOW 450+ 180 450+

b. HIGH 450+ 230 230

1.5kW with L1250E LAMP ORANGE YELLOW BLUE

a. IDLE/LOW 450+ 180 450+

b. HIGH 450+ 230 230

2kW (AL25 and AL25-2 only) with L1250 LAMP

ORANGE YELLOW BLUE

a. IDLE/LOW 500+ 190 500+

b. HIGH 500+ 230 230

1.9kW and 2kW (other than AL25 and AL25-2) with L1150A LAMP ORANGE YELLOW BROWN BLUE

a. IDLE 500+ 205 500+ 500+ b. LOW 500+ 190 500+ 500+ c. MEDIUM 500+ 210 210 500+ d. HIGH 500+ 225 225 225

1.9kW and 2kW with L1250E LAMP ORANGE YELLOW BROWN BLUE

a. IDLE 500+ 210 500+ 500+

b. LOW 500+ 205 500+ 500+

c. MEDIUM 500+ 215 215 500+ d. HIGH 500+ 235 235 235

2.3kW with L1250 LAMP ORANGE YELLOW BROWN BLUE

a. IDLE/LOW 500+ 190 500+ 500+ b. MEDIUM 500+ 210 210 500+ c. HIGH 500+ 235 235 235

6-4 94MS20 Rev. B4

2.3kW with L1252 LAMP

ORANGE YELLOW BROWN BLUE a. IDLE/LOW 500+ 205 500+ 500+ b. MEDIUM 500+ 215 215 500+ c. HIGH 500+ 225 225 225

2.3kW with L1261 LAMP

ORANGE YELLOW BROWN BLUE a. IDLE/LOW 500+ 210 500+ 500+ b. MEDIUM 500+ 215 215 500+ c. HIGH 500+ 225 225 225

3.5kW with L1250 LAMP

ORANGE YELLOW BROWN BLUE a. IDLE/LOW 500+ 200 500+ 500+ b. MEDIUM 500+ 215 215 500+ c. HIGH 500+ 240 240 240

3.5kW with L1252 or L1261 LAMP ORANGE YELLOW BROWN BLUE

a. IDLE/LOW 500+ 195 195 500+ b. HIGH 500+ 230 230 230

5kW with L1250 LAMP

ORANGE YELLOW BROWN BLUE #1 BLUE #2 a. IDLE/LOW 500+ 200 500+ 500+ 500+ b. MEDIUM 500+ 225 225 500+ 500+ c. HIGH 500+ 270 270 270 270

5kW with L1252 or L1261 LAMP

ORANGE YELLOW BROWN BLUE #1 BLUE #2 a. IDLE/LOW 500+ 200 500+ 500+ 500+ b. MEDIUM 500+ 230 230 500+ 500+ c. HIGH 500+ 270 270 270 270

94MS20 Rev. B4 6-5

6kW with L1280 LAMP

ORANGE YELLOW BROWN BLUE #1 BLUE #2

a. IDLE/LOW 500+ 360-380 500+ 500+ 500+

b. MEDIUM 500+ 380-410 380-410 500+ 500+

c. HIGH 500+ 415-445 415-445 415-445 415-445

6kW with L1281 or L1282 LAMP

ORANGE YELLOW BROWN BLUE #1 BLUE #2

a. IDLE/LOW 500+ 200 500+ 500+ 500+

b. MEDIUM 500+ 230 230 500+ 500+

c. HIGH 500+ 270 270 270 270

8kW with L1280 LAMP

ORANGE YELLOW BROWN BLUE #1 BLUE #2

a. IDLE 700+ 360 700+ 700+ 700+

b. LOW 700+ 360 700+ 700+ 700+

c. MEDIUM 700+ 390 390 700+ 700+ d. HIGH 700+ 425 425 425 425

8kW with L1281 LAMP

ORANGE YELLOW BROWN BLUE #1 BLUE #2

a. IDLE 700+ 395 700+ 700+ 700+

b. LOW 700+ 395 700+ 700+ 700+

c. MEDIUM 700+ 425 425 700+ 700+ d. HIGH 700+ 485 485 485 485

8kW with L 1282 LAMP

ORANGE YELLOW BROWN BLUE #1 BLUE #2

a. IDLE 700+ 395 700+ 700+ 700+

b. LOW 700+ 395 700+ 700+ 700+

c. MEDIUM 700+ 430 430 700+ 700+ d. HIGH 700+ 510 510 510 510

IF VOLTAGES CHECK GOOD, SKIP TO STEP 9, OTHERWISE CONTINUE.

‡ The voltage readings described in the following are typical of 5kW light

6-6 94MS20 Rev. B4

sources see voltage chart to find high and low values for others.

10)If a reading remains high (500V~ or more see note ‡) and it should be low (less than 300V~ see note ‡), the capacitor is not being pulled into the circuit. Check the respective relay, resistor, and wiring for an open.

11)If a reading remains low (less than 300V~ see note ‡) and it should be high (500V~ or more see note ‡), the capacitor is locked into the circuit. Check the respective relay, wiring, and PC board for a short.

12)If the readings show voltage changes from high to low and from low to high, but the overall low reading does not increase from the previous power level, then the capacitor being pulled into the circuit has failed.

13)Check the blowers using a piece of paper held up to the intakes at each of the lamphead during a cool-down cycle. The paper should get held up to each intake, if it doesn’t, the blower is bad.

Blowers speed can not be checked until this point because all previous checks affect the operation and can make them appear to be operating incorrectly. Also check blower voltage at terminals 4 & 5 for most lights this voltage should be a MINIMUM of 45V~ some lights this voltage will be higher depending on lamp used and lamp condition.

14)Check for cooling obstructions on intakes and exhausts. If any are found, remove them.

15)Check lamp idle voltage at terminals 2 & 3. This voltage should match the voltage chart above, if not, YOU MUST install a new lamp and recheck (see Idle Setting if adjustment is necessary).

C DO NOT ADJUST idle voltage with a used lamp. Lamp voltage can be effected by all the checks in the check list to this

point. So if this check list is used properly (followed step by step) if at this point the lamp voltage is out of specification it can now be adjusted if the lamp is less than two weeks old AND "not or" has no sign of deformation otherwise a new lamp must be installed before adjusting. Adjusting lamp idle voltage without first checking other causes of the lamp voltage deviation can damage the equipment.

16)If used, check the power supply safety interlock jack next to the power supply power on/off switch. A failure in this circuit will not allow the unit to do an exposure, the only time the shutter will rotate if this circuit is open, is when the power is turned on or off.

If you suspect this circuit is faulty, turn the manual expose switch on, then short the blue and white wires on the jack together with a screwdriver (make sure you do not short to ground) and see if the shutter opens, if it opens the circuit is at fault.

17)Check for smooth shutter rotation. If the shutter rotates smoothly, skip to step 20, otherwise continue.

18)If the shutter does not rotate smoothly, it may not stop in the correct

94MS20 Rev. B4 6-7

position and the bearings must be greased.

19)If the shutter fails to rotate at any time, then check the following:

20)When the shutter is supposed to be moving. Check for 120V~ between terminals 4 & 6. If there is voltage, go to the lamphead and check for voltage at the shutter motor then skip to step 22.

21)If there is no voltage between terminals 4 & 6, check the PC board output for voltage at pins 2 & 4 (see PC Board Layout for pin location).

22)Check to make sure the shutter stops immediately in the correct position.

23)If the shutter stops immediately, but in the wrong position, check the shutter position switch.

24)If the shutter coasts to a stop in the wrong position, check the shutter brake.

25)If you run into a situation were you are not getting voltage at the terminal strip, relay, blower, etc. make sure you go to the PC board itself and Double check the PC board outputs before replacing it.

26)Before you reassemble everything it is a real good idea to: Check the manual operations of the light source. Just to make sure everything is back together.

27)Reconnect all wires to the integrator and then: Check the remote operations of the light source from the integrator.

6-8 94MS20 Rev. B4

7. Wiring Diagrams

Lamphead for AL 83, 84, 84-480, 85, 56, 56-480, 53, 54, 54-480, 55, 55480, 50, 35, 25, 25-2, 23

Shutter Position Switch

Thermostat Thermostat

Safety Glass Switch

Shutter Motor

Blowers

Lamp

94MS20 Rev. B5 7-1

Trigger Board

Lamphead for AL 100

Note: AL100 uses two AL 53 power supplies

1 2 3 4 5 6 7 8 9 10 11 12

Safety Glass

Thermostats

Shutter Position Switch

Switch

Thermostats

Blowers

Lamp

Trigger Board Trigger Board

Lamp

Shutter Motor

Blowers

7-2 94MS20 Rev. B5

AL 83 Power Supply

208/240 VAC

Tap Switch

COM COM

Safety Interlock

Power

High

Din

Socket

12 11

P O W E

R C

O N T R O L

O A

2 1

9 8 7 6

4 3 2 1

7 6

4 3

blu

wht

gry

org brn

red/wht org/wht

brn/wht blu/wht red blu

wht blk

Medium

Expose

Power Supply Blower

Ballast

10µƒ

Medium

Relay

240 208240208 240 208

Ballast

8µƒ 16µƒ12µƒ16µƒ

2 Position 1

High Relay

120 0

3 Amp

Slow Blow

Fuse

INPUT

Power Relay

Voltage

Selection

Board

Toward

front of unit

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

7 org

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Interconnecting

Beau Plug Connector

94MS20 Rev. B5 7-3

Safety Interlock

AL 84,85 Power Supply

Tap Switch

208

COM COM

240

240 208

220 VAC 50HZ

INPUT

Voltage

Selection

Board

Toward

front of unit

P O W E R

C O N T R O L

B O A R D

Din

Socket

12 11 10 blu

9 8 7 6 5 wht 4

3 2 1

12 gry 11 org 10 brn

8 red/wht

7 org/wht 6 brn/wht

5 blu/wht

4 red

3 blu 2 wht 1 blk

Power Supply Blower

Ballast

Medium

Relay

Fuse

Power Relay

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

Ballast

12µƒ 12µƒ16µƒ10µƒ

High

Relay

120 0

3 Amp

Slow Blow

7 org

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Interconnecting

Beau Plug Connector

7-4 94MS20 Rev. B5

Safety Interlock

AL 84-480 Power Supply

277

480 VAC 60HZ

INPUT

120 VAC 60HZ

INPUT

Toward

front of unit

P O W E R

C O N T R O L

B O A R D

Din

Socket

12 11 10 blu

9 8 7 6 5 wht 4 3 2 1

12 gry 11 org 10 brn

9 8 red/wht 7 org/wht 6 brn/wht 5 blu/wht 4 red 3 blu 2 wht 1 blk

Power Supply Blower

Ballast

Medium

Relay

Ballast

12µƒ 12µƒ10µƒ10µƒ

High

Relay

Power Relay

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

7 org

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Interconnecting

Beau Plug Connector

94MS20 Rev. B5 7-5

Safety Interlock

AL 56 Power Supply

Tap Switch

COM COM

240 208240208 240 208

208/240 VAC

INPUT

Voltage

Selection

Board

Toward

front of unit

P O W E R

C O N T R O L

B O A R D

Din

Socket

12 11 10 blu

9 8 7 6 5 wht 4

3 2 1

12 gry 11 org 10 brn

8 red/wht

7 org/wht 6 brn/wht

5 blu/wht

4 red

3 blu 2 wht 1 blk

Power Supply Blower

Ballast

Medium

Relay

16µƒ 10µƒ16µƒ16µƒ

Ballast

High Relay

120 0

3 Amp

Slow Blow

Fuse

Power Relay

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

7 org

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Interconnecting

Beau Plug Connector

7-6 94MS20 Rev. B5

Din

Socket

Safety Interlock

AL 56-480 Power Supply

277

10µƒ 10µƒ

Ballast

Com

Ballast

16µƒ 16µƒ

277

480 VAC 60Hz

INPUT

Power Relay

120 VAC

INPUT

Toward

front of unit

12 11

10 blu

9 8

O W

5 wht

C O

T R

1 O L

12 gry

O A

11 org

R D

10 brn

8 red/wht

7 org/wht

6 brn/wht

5 blu/wht

4 red

3 blu

2 wht

1 blk

Power Supply Blower

Medium

Relay

High Relay

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

7 org

6 red

5 blu

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

Interconnecting

Beau Plug Connector

94MS20 Rev. B5 7-7

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Safety Interlock

AL 54,55 Power Supply

Tap Switch

COM COM

240 208240208 240 208

208/240 V~

INPUT

Voltage

Selection Board

Toward

front of unit

P O W E R

C O N T R O L

B O A R D

Din

Socket

12 11 10 blu

9 8 7 6 5 wht 4 3 2 1

12 gry 11 org 10 brn

8 red/wht

7 org/wht 6 brn/wht

5 blu/wht

4 red

3 blu 2 wht 1 blk

Power Supply Blower

Ballast

Medium

Relay

Position 2

12µƒ 16µƒ12µƒ16µƒ

Ballast

Position 1

High Relay

120 0

3 Amp

Slow Blow

Fuse

Power Relay

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

7 org

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Interconnecting

Beau Plug Connector

7-8 94MS20 Rev. B5

Din

Socket

Safety Interlock

AL 54-480,55-480 Power Supply

277

10µƒ 10µƒ

Ballast

Com

Ballast

16µƒ 16µƒ

277

480 VAC 60Hz

INPUT

Power Relay

120 VAC

INPUT

Toward

front of unit

12 11

10 blu

9 8

O W

5 wht

C O

T R

1 O L

12 gry

O A

11 org

R D

10 brn

8 red/wht

7 org/wht 6 brn/wht

5 blu/wht

4 red

3 blu 2 wht 1 blk

Power Supply Blower

Medium

Relay

High

Relay

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

7 org

6 red

5 blu

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

Interconnecting

Beau Plug Connector

94MS20 Rev. B5 7-9

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

P O

E R

C O N T R O L

B O A R D

Din

Socket

12 11 10

9 8 7 6 5 4 3 2 1

12 11 10

7 6

3 2 1

blu

wht

gry

org brn

red/wht org/wht

brn/wht blu/wht red blu

wht blk

Safety Interlock

Power

High

Medium

Expose

AL 53 Power Supply

Note: AL100 uses two AL53 power supplies

Tap Switch

COMCOM

Ballast

16µƒ

Medium

Relay

Power Supply Blower

240 208240208 240 208

Ballast

2 Position 1

High

Relay

120 0

3 Amp

Slow Blow

Fuse12µƒ 16µƒ12µƒ

208/240 VAC

INPUT

Power Relay

Voltage

Selection

Board

Toward

front of unit

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

7 org

6 red

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

Interconnecting

Beau Plug Connector

7-10 94MS20 Rev. B5

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

P O

E R

C O N T R O L

B O A R D

Din

Socket

12 11 10

9 8 7 6 5 4 3 2 1

12 11 10

9 8 7 6 5 4 3 2 1

blu

wht

gry

org

brn

red/wht

org/wht

blu/wht

red blu

wht

blk

Safety Interlock

Power

High

Medium

Expose

AL 50 Power Supply

Tap Switch

COMCOM

Ballast

High Relay

Power Supply Blower

240 208240208 240 208

Ballast

2 Position 1

Relay

High

120 0

3 Amp

Slow Blow

Fuse12µƒ 16µƒ12µƒ16µƒ

208/240 VAC

INPUT

Power Relay

Voltage

Selection

Board

Toward

front of unit

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

7 org

6 red

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

Interconnecting

Beau Plug Connector

94MS20 Rev. B5 7-11

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

AL 35 Power Supply

208/240 VAC

Tap Switch

COM COM

Safety Interlock

Power

High

Din

Socket

12 11

W E

C O

R O L

O A

7 6

3 2 1

Medium

Expose

blu

wht

Power Supply Blower

gry

org

brn

red/wht org/wht

brn/wht blu/wht red blu

wht blk

16µƒ

Ballast

8µƒ

2 Position 1

Medium

Relay

240 208240208 240 208

Ballast

120 0

12µƒ

16µƒ

High

Relay

3 Amp

Slow Blow

Fuse

INPUT

Power Relay

Voltage

Selection

Board

Toward

front of unit

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

7 org

6 red

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

Interconnecting

Beau Plug Connector

7-12 94MS20 Rev. B5

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

AL 25-2 Power Supply

208/240 VAC

Tap Switch

COM COM

Safety Interlock

Power

High

Din

Socket

12 11

E R

T R O L

12 11

3 2 1

Medium

Expose

blu

wht

Power Supply Blower

gry

org brn

red/wht org/wht

blu/wht red blu wht blk

Ballast

12µƒ

240 208240208 240 208

Ballast

120 0

12µƒ

High Relay

INPUT

Power Relay

Voltage

Selection

Board

Toward

front of unit

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

7 org

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Interconnecting

Beau Plug Connector

94MS20 Rev. B5 7-13

Din

Socket

Safety Interlock

Power

High

Medium

AL 25 Power Supply

COM COM

Ballast

12µƒ

Ballast

12µƒ

208/240 VAC

INPUT

120120

Power Relay

Toward

front of unit

9 8 7 6

4 3 2 1

7 6

3 2 1

blu

wht

gry

org

brn

red/wht org/wht

blu/wht red blu wht blk

Expose

Power Supply Blower

High

Relay

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

7 org

6 red

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

12 11

P O W E R

C O N T R O L

12 11

B O

10 A R D

Interconnecting

Beau Plug Connector

7-14 94MS20 Rev. B5

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

AL 23 Power Supply

220 VAC

INPUT

2 1

240

120 0

3 Amp

Slow Blow

Fuse

Power Relay

240

Safety Interlock

Power

High

Din

Socket

12 11

Medium

Expose

blu

9 8

P O

wht

5 4

C O

T R

O L

gry

O A

org

brn

red/wht

org/wht

brn/wht

blu/wht

red

blu

wht

blk

COM

Ballast

COM

12µƒ 3µƒ 9µƒ9µƒ12µƒ

Power

Supply

Fan

3µƒ

12µƒ

Position Position

1 2

Medium

Relay

CAP

High

Relay

Toward

front of unit

14 blk

13 wht

12 red

10 blk

9 clear

8 brn

P O W E R

S U P P L Y

T E R M I N A L

S T R I P

7 org

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

Interconnecting

Beau Plug Connector

94MS20 Rev. B5 7-15

P O W E R

C O N T R O L

B O A R D

Din

Socket

12 11

9 8 7 6

4 3 2

12 11

9 8 7 6

4 3 2 1

blu

wht

gry

org

brn

red/wht

org/wht brn/wht blu/wht

red blu

wht

blk

Safety Interlock

Power

High

Medium

Expose

Thermostat

Shutter

Motor

Blower

Trigger Board

AL 20 Power Supply

COM

240

Ballast

COM

9µƒ 10µƒ 3µƒ

10µƒ

Medium

Relay

Power

Supply

Fan

Safety Glass

Switch

Shutter Position

Switch

Lamp

CAP

10µƒ

2 1

Position

High

Relay

L A M P

H E A D

T E R M I N A L

S T R I P

208/240 VAC

INPUT

Toward

front of unit

240

Power Relay

120 0

3 Amp

Slow Blow

Fuse

14 blk

O W E

wht

S U

red

P L

Y T

blk

M I N

9 clear

A L

brn

T R I

org

6 red

5 blu

wht

3 pur

2 yel

1 grn/ yel

Toward

center of unit

7-16 94MS20 Rev. B5

Din

Socket

Safety Interlock

Power

High

Medium

AL 19 Power Supply

COM

120

CAP

10µƒ

Ballast

9µƒ 10µƒ 3µƒ

COM

10µƒ

120 VAC

INPUT

Power Relay

Toward

front of unit

P O W E R

C O N T R O L

B O A R D

12 11 10

12 11

Expose

blu

9 8 7 6

wht

4 3 2

gry

org brn

red/wht

org/wht

brn/wht

blu/wht

red

blu

wht

blk

Shutter

Motor

Power

Supply

Fan

Thermostat

Shutter Position

Switch

Blower

Trigger Board

Lamp

Medium

Relay

Safety Glass

Switch

2 1

Position

High

Relay

L A M P

H E A D

T E R M I N A L

S T R I P

P O

blk

E R

wht

red

P P L

T E

blk

R M

clear

N A L

8 brn

S T

org

I P

6 red

5 blu

4 wht

3 pur

2 yel

1 grn/

yel

Toward

center of unit

94MS20 Rev. B5 7-17

P O W E R

C O N T R O L

B O A R D

Din

Socket

12 11 10

9 8 7 6

4 3 2

12 11 10

9 8 7 6

4 3 2 1

blu

wht

gry

org

brn

red/wht

org/wht brn/wht blu/wht

red blu

wht

blk

Safety Interlock

Power

High

Expose

Thermostat

Shutter

Motor

Blower

Trigger Board

ALI 15 Power Supply

16µƒ

Jumper installed when

using L1150A lamp.

Jumper removed when

using L1150B lamp.

Switch

Ballast

Power Supply

Fan

Lamp

16µƒ

Shutter Position

Switch

COM

Exposure Integrator

Board

Safety Glass

16µƒ

COM

L A M P

H E A D

T E R M I N A L

S T R I P

High

Relay

120

CAP

120 VAC

INPUT

Toward

front of unit

16µƒ

Power Relay

P O

blk

E R

wht

red

P P L

T E

blk

R M

clear

N A L

8 brn

S T

org

I P

red

5 blu

4 wht

3 pur

2 yel

1 grn/

yel

Toward

center of unit

7-18 94MS20 Rev. B5

AL 15 Power Supply

P O W E R

C O N T R O L

B O A R D

Din

Socket

12 11 10

9 8

7 6

4 3 2

12 11 10

9 8 7 6

4 3 2

blu

wht

gry

org brn

red/wht org/wht

brn/wht blu/wht red blu

wht blk

Safety Interlock

Power

High

Expose

Thermostat

Shutter

Motor

Blower

Trigger Board

Power Supply

Fan

Lamp

16µƒ

Shutter Position

Switch

16µƒ

Jumper installed when

using L1150A lamp.

Jumper removed when

using L1150B lamp.

Safety Glass

Switch

Ballast

16µƒ

Relay

L A M P

H E A D

T E R M I N A L

S T R I P

High

COM

120 CAP

120 VAC

INPUT

Toward

front of unit

16µƒ

Power Relay

P O

blk

E R

wht

red

P P L

T E

blk

R M

clear

N A L

8 brn

S T

org

I P

red

5 blu

4 wht

3 pur

2 yel

1 grn/

yel

Toward

center of unit

94MS20 Rev. B5 7-19

Interconnect Cable for AL23, AL25, AL25-2, AL35, AL50, AL53, AL83

WHITE

YELLOW

RED

BROWN

HEAT SHRINK

GREEN

VIOLET

BLUE

ORANGE

BLACK

10 BLACK

9 HEAT SHRINK

8 BROWN

7 ORANGE

6 RED

5 BLUE

4 WHITE

3 VIOLET

2 YELLOW

1 GREEN

7-20 94MS20 Rev. B5

Interconnect Cable for AL85, AL84, AL84-480, AL56, AL56-480, AL55, AL55-480, AL54, AL54-480

WHITE

YELLOW

RED

BROWN

HEAT SHRINK

4 3

GREEN

VIOLET

BLUE

ORANGE

BLACK

WHITE

GREEN

YELLOW

RED

BROWN

HEAT SHRINK

4 3

VIOLET

BLUE

ORANGE

BLACK

94MS20 Rev. B5 7-21

7-22 94MS20 Rev. B5

8. Fault Trees

No Strike Fault Tree

No Strike

Yes

Is there 0 VAC across pin

#3 purple on terminal

strip and orange com. on

capacitor pack?

Is there less than 500VAC but more

than 0 VAC across#3

purple on terminal

strip and orange

com. on capacitor

pack?

Yes

Check wiring from

voltage selector

assy through

ballasts to capacitors-

Verify

operation

500+ VAC:

Check wiring from

capacitors, through

resistor board, to

terminals #2 and #3. If

wiring is O.K., check across terminal strip pins 1 to 2 and 1 to 3. If either

is less than 50 VAC, that

pin is shorted to ground.

Replace lamp-

Verify

operation.

Yes

Repair or replace

wires at power

relay or replace

power relayVerify operation

Does shutter rotate

when power is turned

Is safety glass

installed and lever

Yes

Is power relay

pulling in?

Yes

Is the lamp new?

Yes

Is there 500+ VAC

on pins #2 yellow

and #3 purple?

Yes

Faulty lamp

or trigger

boardVerify

operation.

on?

Yes

actuated?

Is there 190 to 245

VAC on #12 red &

#14 black to top of

power relay?

Yes

Is there 0 VAC across

pins #4 and #10?

Yes

Is there 120 VAC on PCB connector pins

#2 white and #8

Yes

Verify

operation

red?

Repair or

replace

wires-

Are there any LED's

lit on the PC board?

Yes

Is the PC board fuse

operation

good?

Replace

fuse-

verify

Repair or

replace

wires-

Verify

operation.

Replace

thermostats, safety switch or associated

wiring-

Verify

operation.

Replace

PCB

Verify

operation

Yes

94MS20 Rev. B4 8-1

Shutter Rotation Fault Tree

No Shutter Rotation

Yes

Yes Yes

Does the shutter seem to

bind during rotation?

screw on the shutter motor gear and the

shutter position

Is the chain too tight

or bearings worn?

Yes

Adjust shutter

motor and/or

replace bearings

and air tubes.

Check the set

switch.

Possible

faulty shutter motor.

Does the shutter rotate at any time?

Is LED #3 lit on PC

Board?

Yes

Check for 120 VAC on

terminal 4 white and

terminal 6 red on the

terminal strip when

shutter should be

rotating.

Yes

Check for 120 VAC

at shutter motor.

Is the lamp lit?

Yes

The shutter will not open for an exposure without the lamp being lit. Go to the No Strike Fault Tree.

If LED #3 is lit, check

for 120 VAC at pins

2 and 4 at power

connector on

PC board.

Yes

Power Supply PCB-Rear View

LED #3

8-2 94MS20 Rev. B4

Replace

shutter

motor.

Yes

Repair or

replace wiring

from terminal

strip to shutter

motor.

Repair or

replace wiring

from PC Board

to terminal

strip.

Replace

PC board

9. AL 13 / AL 9

AL 13 Component Layout

*Capacitors for 220~ units are different values see AL 13 (220~) Wiring Diagram for values.

39BLO03

Blower

32BAL09

Ballast

31MOT11

Shutter Motor

*34CAP18-S

Capacitor

*34CAP15-S

Capacitor

L900 / L902

Lamp

56THM03

Thermostat

63D0142B02

Lamp Support

Assembly

55SW02

Safety Interlock

Switches

90RF13

Reflector

64MV461V00 Resistor Board

55SW02-1

Safety Interlock

Switches

93MV427C2

Control Board

94MS20 Rev. B4 9-1

AL 13 Control Board (64MV427C2)

10 11 13 14 15 16 17 18 19

10 Amp Fuse

1 2

3 4

5 6 7 8

1) AC COM

2) Ballast COM

3) Lamp COM

4) Blower COM

5) Blower HOT

6) Medium Cap Input

7) High Cap Input

8) Low Cap Input

9) Lamp Lead HOT

10) Ballast AC HOT

DS1 DS2

DS3 DS4

11) Incoming AC HOT

12) **Voltage Selection Jumpers** see NOTE A

13) Ground

14) Shutter Motor +

15) Shutter Motor -

16) Shutter Switch 2 +

17) Shutter Switch 2 -

18) Shutter Switch 1 +

19) Shutter Switch 1 -

JP2

JP1

DS5

DS1) POWER DS2) BLOWER DS3) MED POWER DS4) HIGH POWER DS5) SHUTTER MOTOR A) Idle Adjustment B) External Interlock C) **External Operation Switches** see NOTE B D) Control Din (to integrator)

JP3

NOTE A: TERMINAL 12 Voltage Selection Switch

Connector must be in this position for 120V

JP1 JP2 JP3 JUMPER SETTING

9-2 94MS20 Rev. B4

Connector must be in this position for 220V

JP1 UP DOWN JP2 UP DOWN JP3 UP DOWN

NOTE B Test Switches OFF ON 1 Power ON/OFF 2 High Expose 3 Medium Expose 4 Low Expose

Duel Shutter Switch Operation Single Shutter Switch Operation Not Using External Interlock Using External Interlock 50Hz Operation 60Hz Operation

AL 13 (120V~) Wiring Diagram

BALLASTT1

SW3-SW4

SW1-SW2

M1 MOTOR, DRIVE 12VDC 31MOT11

REF. DESIGNATIONS

THERMOSTATTHERM SWITCH,(SAFETY) SWITCH,(SHUTTER) 55SW02-1

RESISTOR 1M Ohm 1WR1-R4

CAPACITOR 15µƒ 400VC1,C3 RESISTOR BOARDPCBA2 CONTROL BOARDPCBA1

32BAL08 120V 60HZ

56THM03

55SW12

39BLO03MOTOR, BLOWERM2

26S6-10

34CAP18-SC2,C4 CAPACITOR 20µƒ 400V

34CAP15-S

64D1477

64MV427 CX

PART NO.DESCRIPTION

(YEL)

(BLK)

SW1

SW2

N.O.

COM

(BLK)

(RED)

(BLK)

(RED)

(BLK)

JP1

JP2

F1 10A

J1 J2 J3 J4

J5 J6 J7 J8

SLO BLO

J11

J14 J16 J18J19J17J15J13

220V

J12

120V

J10

JP3

3 2 1

64MV427C2

(ORG.HI-VOLT)

(RED)

120V

(BRN)

(YEL)

(BLU)

(YEL)

COM

PCBA2

R6 R5

(YEL)

(BRN)

(BLU)

(ORG)

(GRN/YEL)

(ORG. HI-VOLT)

(ORG)

(RED)

(BLK)

SW4

CAP

THERM

SW3

(GRN/YEL)

(BLK)

(RED)

P1-2 P1-1

(BLU)

(BRN)

LAMP

94MS20 Rev. B4 9-3

AL 13 (220V~) Wiring Diagram

FUSE, 4 AMP 250V SBFUSE BALLASTT1

SW3-SW4

SW1-SW2

M1 MOTOR, DRIVE 12VDC 31MOT11

REF. DESIGNATIONS

THERMOSTATTHERM SWITCH,(SAFETY) SWITCH,(SHUTTER) 55SW02-1

RESISTOR 1Meg 1WR1-R4

CAPACITOR 15µF 400VC1 RESISTOR BOARDPCBA2 CONTROL BOARDPCBA1

220~ 60HZ 56FUS23 32BAL09 56THM03 55SW12

62D2483A00MOTOR, BLOWERM2

26S6-10 34CAP18-SC2, C3, C4 CAPACITOR 20µF 400V 34CAP15-S 64D1477 64MV427 CX

PART NO.DESCRIPTION

(YEL)

(ORG.HI-VOLT)

THERM

(YEL)

(BLK)

(RED)

(BRN)

(BLU)

(YEL)

F1 10A SLO BLO

J1 J2 J3 J4

J5 J6 J7 J8

(RED)

J11J10

J13 J15 J17 J19

J12

(BLK)

R7 R6

SW1

SW2

N.O.

COM

(BLK)

(RED)

(BLK)

JP1

JP2

JP3

3 2 1

J18J16J14

(YEL)

(BRN)

(BLU)

FUSE

(YEL)

(ORG)

(GRN/YEL)

(ORG. HI-VOLT)

(RED)

(BLK)

CAP

220V

COM

THERM

LAMP

SW3 SW4

(BLK)

(RED)

P1-2 P1-1

(GRN/YEL)

(BLU)

(BRN)

220VAC

50/60HZ

9-4 94MS20 Rev. B4

AL 9, AL 9-PLUS Component Layout

39BLO03

Blower

56THM03

Thermostat

32BAL09

Ballast

55SW02

Safety Interlock

Switches

31MOT11

Shutter Motor

64CT474-T

Shutter Drive Board

(AL 9 Plus Only)

64MV461V00 Resistor Board

34CAP15-S

Capacitor

64MV427-T for AL 9

64MV427-Plus for AL 9-Plus

18D718-W

Photocell Rod

Control Board

L900 ONLY

Lamp

63D0142B02

Lamp Support

Assembly

94MS20 Rev. B4 9-5

90RF13

Reflector

55SW02

Shutter Position

Switch

55SW02

Shutter Position

Switch (AL9-Pus Only)

64MV427-Plus Board Layout for AL 9-Plus

10 11

1 2 3

4 5 6

Fuse 10 Amp

DS4

DS3

DS1 DS2

12 13

DS5

14 15

EFGH

1) Ballast COM

2) AC COM

3) Lamp COM

4) Blower COM

5) Blower HOT

6) Medium Cap Input, brown

7) High Cap Input, blue

8) Low Cap Input, yellow

9) Lamp Lead HOT

10) Ballast AC HOT

DS6

11) Incoming AC HOT

12) Not Used

13) Not Used

14) Shutter Switch -

15) Shutter Switch +

16) Ground A) Idle Adjustment B) External Interlock C) Photocell Din (to integrator) D) Control Din (to integrator) E) Overall Photocell adjust

F) Photocell A(high) adjust G) Photocell B(low) adjust H) Photocell DS1) Power DS2) Blower DS3) MED Power DS4) HIGH Power DS5) Not Used DS6) Shutter Motor W1) Shutter Motor (-) W2) Shutter Motor (+)

9-6 94MS20 Rev. B4

INCOMING

AC COM

AL 9-Plus Wiring Diagram

INCOMING

AC HOT

SHUTTER DRIVE BOARD 64CT474

SAFETY

GLASS

SWITCH

COM

THERMOSTAT

N.O.

1 2

4 5

6 7

COM

10 11

SAFETY

GLASS

SWITCH

12 13

NOT

USED

SHUTTER

MOTOR

N.O.

14 15

COM

SHUTTER

POSITION

SWITCH #2

SHUTTER

POSITION

SWITCH #1

N.C.

COM

INTERCONNECT

CABLE

64MV427

BOARD

LOW

MED

HIGH

94MS20 Rev. B4 9-7

LAMP

15µf 15µf

CAPACITORS

15µf 15µf

BLOWER

CHASSIS GROUND

BALLAST

64MV247 Board Layout for AL 9

10 11

2 3

Fuse 10 Amp

4 5 6

DS3

DS4

1) Ballast COM

2) AC COM

3) Lamp COM

4) Blower COM

5) Blower HOT

6) Medium Cap Input, brown

7) High Cap Input, blue

8) Low Cap Input, yellow

9) Lamp Lead HOT

10) Ballast AC HOT

DS5

DS1 DS2

12 13

11) Incoming AC HOT

12) Shutter Motor -

13) Shutter Motor +

14) Shutter Switch -

15) Shutter Switch +

16) Ground A) Idle Adjustment B) External Interlock C) Photocell Din (to integrator) D) Control Din (to integrator)

14 15

EFGH

E) Overall Photocell adjust F) Photocell A(high) adjust G) Photocell B(low) adjust H) Photocell DS1) POWER DS2) BLOWER DS3) MED POWER DS4) HIGH POWER DS5) SHUTTER MOTOR

9-8 94MS20 Rev. B4

AL 9 Wiring Diagram

SAFETY

GLASS

SWITCH

INCOMING

AC COM

COM

INCOMING

AC HOT

THERMOSTAT

N.O.

4 5

1 2

COM

10 11

SAFETY

GLASS

SWITCH

N.O.

COM

12 13

14 15

SHUTTER POSITION

SWITCH

64MV427

BOARD

MED

HIGH

LOW

LAMP

BLOWER

15µf

CAPACITORS

15µf

CHASSIS GROUND

BALLAST

94MS20 Rev. B4 9-9

AL 9, AL 13 Cover Removal

• Place the light on its top and remove the hood and filter assembly.

• Place the light on a table with the shutter flat against the table and remove the safety glass. Then remove the two screws from each of the four sides and remove the cover.

OLITE AL13

Screws

Safety Glass Thumbscrews

Path of Power to the P.C.Board

The power circuit can be easily traced from where the power cord enters the corner of the unit and immediately connects with 2 (two) wire nuts to black (V~ hot) and white (V~ common). The circuit travels through the black wire to the thermostat, then through the safety glass switch and returns as a brown wire to the P.C. Board as incoming V~ (HOT). The V~ common circuit travels through the white wire to the other safety glass switch and returns as a yellow wire to the P.C. Board as incoming V~ common.

Interlock Systems

The internal interlock system serves two purposes. The first is for operator safety by protecting the safety glass. This glass filters short UV radiation and covers the high voltage lamp terminals. This interlock also protects from overheating, by traveling through the thermostat by the reflector. There is also an outlet on the side marked “INTERLOCK”. This external interlock inhibits exposures when installed. It is not, however, related to the internal interlock.

The internal interlock is a loop that travels through the light, passing through two safety glass switches and a thermostat. This interlock is in series with the input power to the P.C. Board. When this interlock is open all power is cut to the P.C. Board.

The first place to check for an opening in the circuit is the glass switches (see Component Layout Diagram for location). If both switches check good, then check the thermostat. This is a closed loop and can be traced with an Ohmmeter with the AL9/AL14 unplugged.

9-10 94MS20 Rev. B4

Lamp Voltage

The lamp voltage measurement can provide useful information for lamp striking, lamp output and switching information. The meter used to measure can cause different results. The waveforms are not sinusoidal, so different meters may produce different results.

Here is a chart with typical measurements, (see P.C. Board Layout Diagrams for the location of the test points).

See Shrouding The Lamp before continuing.

Lamp voltage measured from lamp lead common to:

Low Med. High Trigger

Low (Yellow) 130 140 150 270

Medium (Brown) 270 140 150 270

High (Blue) 270 270 150 270

Path Of Power To The Lamp

The basic path is incoming line, safety interlock, P.C. Board, ballasts, capacitors, back to the P.C. Board, then to the lamp.

In detail first see Path of Power to the P.C. Board. Then see P.C. Board Layout, showing ballast power (yellow 120V) and

ballast common (yellow COM). This is the feed to the ballast and should be 120 V~. The ballast then

feeds the capacitors with the wire labeled "CAP" (see Capacitors and Level Switching for detailed wiring).

From the capacitors the power feeds back to the P.C. Board on the yellow, brown, and blue wires. The P.C. Board does the electronic switching of the capacitors and sends the power to the lamp.

Capacitors and Level Switching

The capacitors pass all the current that flows through the lamp. They are also used to switch power levels. The capacitors are divided into three sections. The unit has two low power (idle) capacitors connected with a yellow wire. There is one medium power capacitor connected with a brown wire. There is one high power capacitor connected with a blue wire. All capacitors have an orange feed wire coming from the ballast.

The low power (idle) capacitors are always in the circuit. The medium power capacitor gets pulled into the circuit for warm-up, medium power exposures, and high power exposures. The high power capacitor gets pulled into the circuit for warm-up and high power exposures.

94MS20 Rev. B4 9-11

AL 9, AL 9 Plus Capacitor Wiring

64MV461V00 RESISTOR BOARD

BLUE

YELLOW

15µƒ

34CAP-AL9

AL 13 Capacitor Wiring

ORANGE

15µƒ

TO BALLAST

64MV461V00 RESISTOR BOARD

15µƒ

BROWN

34CAP-AL9

BROWN

15µƒ

BLUE

20µƒ

15µƒ

YELLOW

ORANGE

20µƒ

34CAP-AL13

TO BALLAST

34CAP-AL13

C See Shrouding The Lamp before continuing.

The capacitors set the operating current of the lamp. If the lamp output has changed rapidly, inspect the capacitors for swelling. The design of the capacitors we use will burn open if it begins to short. A swollen capacitor should be replaced and the unit should be tested to see that the capacitor did not damage the P.C. Board.

To test the unit’s ability to switch power levels, make a manual exposure at low power, note the voltage between the lamp lead common and the low yellow (about 130V~, see diagram). Then switch to medium brown (about 140V~, see diagram). Then switch to high power and note the

9-12 94MS20 Rev. B4

Olec OLITE Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual