Accuprint AP42CL 8000 User manual

PP
AP42CL 8000 Closed Loop
High Resolution Printer
Service Manual
94MS42 Rev. B1 S/W 2.06 O

94MS42 Rev.B1 S/W Ver 2.06
This manual is designed for technical personnel
and should only be used by authorized Dealer
service personnel.
This manual is written to provide an
understanding of the equipment, as
well as a plan for troubleshooting.

94MS42 Rev.B1 S/W Ver 2.06 0-1
0. Contents
1. Specifications
Crated Dimensions ......................................................................1-1
Shipping Weight ..........................................................................1-1
Actual Dimensions ......................................................................1-1
Effective Exposure Frame Area...................................................1-2
Intensity .......................................................................................1-2
Typical Room Requirements .......................................................1-2
Electrical specifications and connections .................................... 1-2
Connecting power to printer ........................................................1-4
Cooling Requirements .................................................................1-5
2. Cooling System
Connecting the Evaporator ..........................................................2-1
Connecting the chiller.................................................................. 2-2
Filling the Closed Loop System ..................................................2-4
Checking the chiller.....................................................................2-4
Closed Loop Cooling Assembly..................................................2-6
3. Integrator Functions and Features
Integrator .....................................................................................3-1
Feature Quick Reference ............................................................. 3-3
Operator Control Panel ................................................................3-4
Table Showing the 12 Calibration Positions ............................... 3-4
Calibration Procedures ................................................................3-5
Changing the Calibration Number............................................... 3-6
Matching Exposure Surfaces .......................................................3-7
Splitting Steps.............................................................................. 3-8
Matching with a meter................................................................. 3-8
4. Integrator Program Set Up
To Enter the Select Mode ............................................................4-1
Lock Level Feature ......................................................................4-1
Lock Level Description and Operation .......................................4-2
Setting or Changing your Lock Code feature ..............................4-3
To Clear Lamp Statistics ............................................................. 4-3
To Clear Memory and Exposure Statistics ..................................4-3
Two Value Exposure Mode.........................................................4-4
Split Exposure Mode ...................................................................4-4
Single Surface Mode ...................................................................4-5
Board Count Display Mode.........................................................4-5
Frame Control Interface Mode ....................................................4-6
Automatic Vacuum Mode ........................................................... 4-6
Auto Step Mode...........................................................................4-7
Set Default Vacuum Delay..........................................................4-7
Tray Mode ...................................................................................4-8

0-2 94MS42 Rev.B1 S/W Ver 2.06
Type Mode................................................................................... 4-8
Exposure Statistics (Elapsed Hours)............................................4-9
Exposure Statistics (Total Exposures).........................................4-9
Selecting a Memory Location....................................................4-10
Quick Keypad ............................................................................4-10
Entering an Exposure Time .......................................................4-10
Setting the Light Intensity .........................................................4-11
Making an exposure...................................................................4-11
Blank frame cycle...................................................................... 4-11
Error Handling System ..............................................................4-12
5. Diagnostics
Output Diagnostics ......................................................................5-1
Output Functions Check .............................................................. 5-1
Functions Table ...........................................................................5-2
Input Diagnostics......................................................................... 5-3
Typical values that you will see when all switches are good. .....5-3
Typical values that you will see when a fault occurs. .................5-4
6. Lamp Changing Instructions
Lamp Changing Instructions ....................................................... 6-1
7. Preventive Maintenance
Preventive Maintenance Daily.....................................................7-1
Preventive Maintenance Monthly................................................ 7-1
Preventive Maintenance Semi-Annually.....................................7-1
8. Vacuum System
Vacuum Pumps............................................................................8-1
Flushing the Pump.......................................................................8-1
Pump Disassembly ......................................................................8-2
Pump Check.................................................................................8-2
Pump Replacement ......................................................................8-3
Tubing/Fitting Replacement ........................................................ 8-4
Vacuum Gauge Replacement ......................................................8-4
Vacuum Seal Replacement..........................................................8-5
Phototool Wiring Diagram (optional).......................................... 8-7
9. Nose Assembly
Removing the Left and Right Rail Covers ..................................9-1
Replacing the Display and Keypad PC Board.............................9-1
Replacing the zEmergency Stop Button..................................9-1
Replacing the Sand GButtons ..........................................9-1
Replacing the Glass Tool Vacuum Buttons.................................9-2
Replacing the Vacuum Gauges....................................................9-2
Nose Section Autoformer ............................................................9-2
Work Lights................................................................................. 9-3
Nose Fans ....................................................................................9-3
Cleaning or Replacing Nose Filters.............................................9-3

94MS42 Rev.B1 S/W Ver 2.06 0-3
Nose Assembly Drawings ...........................................................9-4
Nose Assembly Left and Right Covers ....................................... 9-6
10. Exposure Trays
Mylar® Replacement ................................................................10-1
If Mylar® Pulls Out of the Frame. ............................................ 10-1
Outer Frame Replacement .........................................................10-1
Tray Assembly Drawing............................................................10-3
Outer Frame Assembly..............................................................10-5
Inner Frame Assembly...............................................................10-6
Gas Spring Removal and Replacement .....................................10-7
Replacing the Linear Bearings ..................................................10-7
Frame Glass Replacement .........................................................10-8
11. Center/Drive Assembly
Center/Drive Assembly Diagram ..............................................11-1
Tray Transport System .............................................................. 11-3
Tray Drive Motor Replacement.................................................11-3
Tray Drive Clutch Adjustment ..................................................11-3
Tray Speed Adjustment .............................................................11-4
Light Block Assembly...............................................................11-6
Lower Light Block (insert section) Assembly Drawing............ 11-7
Replacing Light Block Springs ................................................. 11-8
12. Diagrams
Control Box Front View Typical............................................... 12-1
Control Box Wiring Diagram ....................................................12-2
Base Assembly Diagram ...........................................................12-4
Unit Cabling Diagram (new style).............................................12-7
Unit Cabling Diagram (old style) ..............................................12-8
13. Light Source
Component Layout ....................................................................13-1
Ballast/Tap Switch Wiring ........................................................ 13-3
Path of Power to the PC Board.................................................. 13-4
Interlock System ........................................................................13-4
Lamp Voltage ............................................................................13-5
Lamp Power Path....................................................................... 13-5
Trigger Board ............................................................................13-6
Capacitors and Level Switching ................................................13-6
Opening the Lamp Head............................................................ 13-9
Shutter........................................................................................13-9
Shutter Switch .........................................................................13-10
Shutter Brake ...........................................................................13-10
Shutter Motor...........................................................................13-10
Installing the Motor .................................................................13-11
Shutter Removal ......................................................................13-12
LT8 Shutter Assembly Drawing..............................................13-13

0-4 94MS42 Rev.B1 S/W Ver 2.06
Idle Setting...............................................................................13-14
Lamp Head Blowers ................................................................13-15
Blown Fuse on PC Board ........................................................ 13-15
Lamp Head Signals.................................................................. 13-16
Light Function States...............................................................13-18
Printed Circuit Board Layout .................................................. 13-19
Signal Description ................................................................... 13-20
Circuit Diagram (64MV407 60Hz) ........................................13-22
Lamphead for all Lights ..........................................................13-23
AL 84 Power Supply 60Hz....................................................13-24
AL 84-480 Power Supply 60Hz ............................................13-25
AL 94 Power Supply 50Hz....................................................13-26
Interconnect Cable................................................................... 13-27
14. Printing Light Check List
Check List for Printing Light Troubleshooting and Service .....14-1
15. Fault Trees
No Strike Fault Tree ..................................................................15-1
Shutter Rotation Fault Tree ....................................................... 15-2
Drive Motor Fault Tree..............................................................15-3
16. Parts List
Parts List ....................................................................................16-1
17. Warranty
Limited Warranty ......................................................................17-1
Lamp Warranty..........................................................................17-1

94MS42 Rev.B1 S/W Ver 2.06 1-1
1. Specifications
48"51"
99"
61"
58"
96"
66" 110"
51"
Upper Tray
Lower Tray
Crated Dimensions
Length Width Height
130" 78" 85"
330cm 198cm 216cm
Shipping Weight
Crated 2,400 lbs. 1089kg
Uncrated 2,000 lbs. 907kg
Actual Dimensions
Cabinet, welded heavy gauge steel construction, with access doors on
both sides.
Length Width Height
110" 61" 99"
279cm 155cm 251cm
Note: The AP42CL can be disassembled (see Base Assembly Diagram)
into 4 pieces if required to pass through most doorways or
hallways. Pleasemakesurethereisadequateroomforitspassage.

1-2 94MS42 Rev.B1 S/W Ver 2.06
Effective Exposure Frame Area
Width 42" 107cm
Depth 34" 86cm
Intensity
AP42CL-8000Lamps can be operated at 8 kW, 5 kW, and 2 kW.
Typical Room Requirements
TOP VIEW
Rear
Front
36"
Circuit
Breaker
36"
36"
Electrical specifications and connections
3 phase (Wye) See Figure A 3 wires + neutral + ground 380/415V~ 50 Hz, 24 amp.
3 phase (Delta) See Figure B 3 wires + ground 208/240V~ 60 Hz, 44 amp.
3 phase (Delta) See Figure C 3 wires + ground 480V~ 60 Hz, 18 amp.
Single phase See Figure D 2 wires + ground 480V~ 60Hz, 35 amp.

94MS42 Rev.B1 S/W Ver 2.06 1-3
Earth
Ground
L1 L2
L1 L2 L3
Figure A
380 / 415V~ 50Hz Connection
Wye: 3 Wires + Neutral + Ground
Terminal Block
N
380 / 415V~
OLITE
Power Supply
Blowers
Vacuum
Pumps
Electronics
Drives
Etc.
L3
N
Earth
Ground
L1 L2
L1 L2 L3
Figure B
208/240V~ 50Hz Connection
DELTA: 3 Wires + Ground
Terminal Block
N
208V~
OLITE
Power Supply #1
Blowers
Vacuum
Pumps
Electronics
Drives
Etc.
L3
208V~
OLITE
Power
Supply #1
Earth
Ground
L1 L2
L1 L2 L3
Figure C
480V~ 60Hz Connection
DELTA: 3 Wires + Ground
Terminal Block
480V~
OLITE
Power Supply #1
Blowers
Vacuum Pumps
Electronics
Drives, Etc.
L3
X1 X2 X3
480V~
OLITE
Power
Supply #2
X1
X2
X3
X4 H1 H2
H3
H4
L1 L2 L3
Blowers
Vacuum Pumps
Electronics
Drives, Etc.
X1 X2 X3
X1
X2X3
X4
H1 H2 H3 H4
480V~ OLITE
Power Supply #1
Earth
Ground
L1 L2
Figure D
480V~ 60Hz Connection
Single Phase: 2 Wires + Ground
Terminal Block
480V~ OLITE
Power Supply #2

1-4 94MS42 Rev.B1 S/W Ver 2.06
Connecting power to printer
We recommend installing a circuit breaker box within easy reach of the
operator.
•Install and run the main power cord through a strain relief then into the
channel on the lower right rear of the printer and up to the power control
box on the left side (see diagram below).
•Connect the main leads to the 4 position or 6 position terminal block and
connect the ground lead to the single ground terminal (see Figures
A,B,C,D).
•Reinstall the lower side door.
Z
Feed power
through here
•Energize the main power circuit. You should hear the lamp head and
power supply cooling fans go into a cool-down cycle. Ensure that the
voltage select switch on the hinged control panel is switched to the lit
LED.
•Installthe lower front and rear black trim pieces over the forklift channels,
using a 5/32" Allen wrench.