Coatmaster Atline V4 User manual

Operation manual
Maintenance coatmaster
Atline / Inline V4
These operating instructions describe the individual steps of an annual Atline / Inline coatmaster
maintenance based on a photo documentation.

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Index
1 Introduction..................................................................................................................................... 3
2 Material........................................................................................................................................... 4
2.1 Protection equipment (supplied by CM AG)......................................................................... 4
2.2 Parts to be replaced (supplied by CM AG)............................................................................. 4
2.3 Special tools (supplied by CM AG)....................................................................................... 4
2.4 Miscellaneous tools (Not supplied by CM AG)................................................................... 5
3 Coatmaster Atline............................................................................................................................ 6
3.1 Safety instructions................................................................................................................... 6
3.2 Remove the cover.................................................................................................................... 7
3.3 Empty the cooling circuit......................................................................................................... 8
3.4 Complete emptying............................................................................................................... 10
3.5 Excitation unit removal ......................................................................................................... 11
3.6 Hoses replacement................................................................................................................ 14
3.7 Connect new hoses ............................................................................................................... 15
3.8 Install new excitation unit..................................................................................................... 16
3.9 Cooling liquid refill................................................................................................................. 18
3.10 Replace filter mat .................................................................................................................. 20
3.11 Close the device..................................................................................................................... 21
4 Coatmaster Inline .......................................................................................................................... 23
4.1 Safety instructions................................................................................................................. 23
4.2 Empty the cooling circuit....................................................................................................... 24
4.3 Head cover removal .............................................................................................................. 25
4.4 Excitation unit removal ......................................................................................................... 26
4.5 Head hoses replacement....................................................................................................... 29
4.6 Install new excitation unit..................................................................................................... 31
4.7 Close the head....................................................................................................................... 33
4.8 Open the cooling unit............................................................................................................ 34
4.9 Cooling unit hoses replacement............................................................................................ 34
4.10 Close cooling unit .................................................................................................................. 36
4.11 Cooling liquid refill................................................................................................................. 36
5 Testing and updates ...................................................................................................................... 37
5.1 Update the service date ........................................................................................................ 37

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5.2 Reset the lamp status............................................................................................................ 38
6 Harting flex cable for drag chain ................................................................................................... 40
6.1 Material................................................................................................................................. 40
6.2 Assembling ............................................................................................................................ 41

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1Introduction
Read this maintenance instructions completely and carefully before starting the maintenance work.
The maintenance work described in this document may only be carried out by personnel who have
been trained for the maintenance of the coatmaster by coatmaster AG.
To ensure your own safety, the steps described in chapter 3.1 and 4.1 must be carried out in a
focused and conscientious manner. No respecting of the safety instructions can lead to serious
injuries and / or death by electric shock. In addition, only the work described in this document may
be carried out. Any extensions or changes to the hardware or software are forbidden.
If, after you have studied this manual and have received personal training from an employee of
coatmaster AG, you are unable to properly perform the work described, contact coatmaster AG.
coatmaster AG
Flugplatzstrasse 5
CH-8404 Winterthur
T [phone]
F [phone]
[e-mail]
www.coatmaster.com
Any liability is refused.
.

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2Material
2.1 Protection equipment (supplied by CM AG)
odischarge resistor
2.2 Parts to be replaced (supplied by CM AG)
o1 x tubes replacement set
o1 x complete light excitation unit
o1 x isolation ring
o8 x plastic screws M6
o1 x filter mat
o3L of mineral no sparkling water with low
calcium content (e. g. Volvic or Evian)
2.3 Special tools (supplied by CM AG)
oSpecial 16-side key
oSpecial 4-pin key
oFunnel
oCap for blank measurement
oSuction cup ø≤40mm
oFilling / emptying tubes set for all
coatmasters types

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2.4 Miscellaneous tools (Not supplied by CM AG)
oMultimeter (1000 VDC/Cat. III)
oTorx screwdrivers set
oSlotted screwdrivers (5 pieces)
oHex keys-Set
oTorque wrench
oCombination pliers
oProtective goggles
oElectrical safety gloves
oCable ties 10mm
oCable ties 14mm
oElectronic side pliers
oBucket
oCleaning paper
oSpecial round head hex key 2 x 80mm
oIf present: clean compressed air gun
oIf present: cable tie pliers

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3Coatmaster Atline
3.1 Safety instructions
Before beginning the maintenance on the coatmaster, the following steps must
be carried out according to the safety rules of electrical engineering:
3.1.1 Disconnect completely!
Switch off the coatmaster and wait until the LED turns off.
3.1.2 Secure against reconnection!
Disconnect all cables from the device and tie them together.
Wait at least 2 minutes (so the flash generator has enough
time to fully discharge).
3.1.3 Short-circuiting!
After the coatmaster has been uncovered (see chapter 3.2
Remove the cover):
Wear protective equipment (protective goggles and protective
gloves)!
Carefully pull straight off the light connectors (red and black
one) from the electrodes (do not twist, do not jerk, otherwise
the electrodes may break!).
Connect the discharge resistor between the two light
connectors and wait at least 2 minutes.
3.1.4 Verify the absence of voltage!
Use the multimeter (1000 VDC setting) to check that the flash
generator is not powered (<10 VDC). If there is no current the
protective equipment can be removed.

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3.2 Remove the cover
3.2.1 Unscrew the coatmaster
Unscrew the 6 x M4 screws on underside of the unit with torx screwdriver.
3.2.2 Remove the cover by sliding
Slide gently the cover to the front, take out the rubber cover on the back side and slide the cover
back as shown in the picture. Only on one third of the length!
3.2.3 Disconnect the grounding wire
Disconnect the grounding wire from the bottom of the cover
3.2.4 Completely remove the cover from the back side
At that stage, it is possible to completely remove the cover by fully sliding it to the back side.
3.2.5 Interior cleaning
If necessary, remove dust and dirt particles with compressed air (not oiled).
Attention: work with compressed air, only with safety glasses on!
Attention: high pressure can damage the device! Max. air pressure 1 bar.

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3.3 Empty the cooling circuit
After you have uncovered the coatmaster(see chapter 3.2 Cover remove) and verified the absence of
voltage (see chapter 3.1.4 Verify the absence of voltage) is possible to continue with the following
steps.
3.3.1 Disassemble the reflector
You can unscrew the reflector on the front of the device by turning it counterclockwise by hand.
3.3.2 Flip the coatmaster on the right side
3.3.3 Unscrew and remove the water tank cap.

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3.3.4 Connect the water drain hose and place the other side into the bucket.
At this stage, it is possible to connect the water drain hose: turn back the coatmaster on a laying
position and position the other side of the hose into the bucket.

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3.4 Complete emptying
3.4.1 Unscrew the ventilation cap on the top of the tank
The water tank should automatically empty.
3.4.2 Screw on the ventilation cap
Once there is no more water in the tank, the ventilation cap can be screwed back on and tightened.
3.4.3 Pull off the water supply hose and close the hose connection
Cut off the cable tie, carefully pull off the hose and seal the water tank with a hose plug as shown in
the picture.
Attention: Danger of injury due to sharp edges in the device!
3.4.4 Emptying of the water circuit
By carefully supplying clean compressed air, into the water supply hose, the entire cooling circuit is
drained. This step is carried out until there is no more water in the excitation unit.
It can be helpful to move the coatmaster to different angles during the emptying.
Once the cooling system is empty, unscrew the water drain hose and screw on the water tank cap.
Attention: work with compressed air, only with safety glasses!
Attention: high pressure can damage the device! Max. air pressure 1 bar.

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3.5 Excitation unit removal
3.5.1 Disassemble the fasting ring and the front panel
Using the special 4-pin washer, the mounting ring is unscrewed, and the front panel can be removed.
3.5.2 Disconnect hoses from the head
If the hoses are not marked, take a picture or mark them with a waterproof marker to not forget the
right positioning.
Disconnect the two hoses from the excitation unit using a quick-release coupling.
3.5.3 Cut the IR sensor cable ties
3.5.4 Unscrew the grounding wire
With a torx screwdriver, unscrew the grounding wire from the left side board.

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3.5.5 Disconnect all the cables connected to the IR sensor
By pulling the sockets, it is possible to disconnect the two cables connected to the IR sensor.
3.5.6 Unscrew the M6 screws
Unscrew 8 x M6 slotted screws with a screwdriver.
Caution: Electrodes of the flash can break off at low mechanical loads.
Attention: When the head is completely unscrewed do NOT take it out from the coatmaster!
3.5.7 Unscrew the ignition coil cable
Carefully turn the head on its axis and unscrew the ignition coil cable positioned on the bottom of
the excitation unit. At this stage, it is possible to remove the entire excitation unit and the insulation
ring by hand.
Caution: Lay the excitation unit on the fasting ring to prevent scratches on the lens.

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3.5.8 Disassemble the IR sensor holder
Unscrew the 2 x M3 plastic slotted screws from the head.
Loosen 4 x M3 grub screws with a round head hex key until the sensor holder can be removed.
It is then possible to change the excitation unit.

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3.6 Hoses replacement
3.6.1 Remove old hoses
Take a picture of the hoses positioning or mark them with a permanent marker so that you do not
forget the right positioning.
3.6.2 Remove cable ties
Cut and remove all 6 cable ties used to secure the hoses using an electronic side cutter.
3.6.3 Remove hoses
Remove all 3 transparent hoses by pulling them off from the connection in a controlled manner.
Attention: Danger of injury due to sharp edges in the device!

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3.7 Connect new hoses
3.7.1 Put hoses on connections
Reconnect the cooling system as shown in the following illustration and tie together loosely with
3 cable ties (14 mm). If necessary, shorten the hoses to such an extent that no kinks or to large radii
are created.
3.7.2 Secure the connections
Secure all 6 connections with cable ties (10 mm) and shorten the excess tie with electronic side
pliers. If present, use cable tie pliers.

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3.8 Install new excitation unit
3.8.1 Mount the IR sensor holder
Insert the sensor holder together with the sensor on the new excitation unit. Be sure, that the whole
surface of the sensor holder is leaning on the excitation unit. Tighten the 4 x M3 grub screws with the
round head hex key. Tighten the 2 x M3 plastic slotted screw to the excitation unit.
The plastic screws must be tightened with a torque of 0.5 Nm. (the screw head must not deform)
3.8.2 Position back the excitation unit and screw the ignition coil cable
With a torx screwdriver, screw the ring cable lug with a M4 screw, fan disc and spring washer.
Caution: Electrodes of the flash can break off at low mechanical loads.
3.8.3 Screw on the excitation unit
Insert the new excitation unit with the new insulation ring into the device and secure it with the new
8 x M6 plastic screws. The plastic screws must be tightened without deforming them.

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3.8.4 Connect the IR sensor
Plug in the two IR sensor connectors. With a torx screwdriver, screw on the grounding wire with
spring washer on the left side board. Do not forget to tie all the cables!
3.8.5 Coupling hoses
Connect the two hoses in the right position to the excitation unit with the quick-release coupling.
3.8.6 Fit front panel and mounting ring
Position the front panel and screw on the mounting ring using the special 4-pin washer and tighten
firmly. However, it is important to ensure that the fasting ring is not tightened until the correct
thread clearance has been reached (the ring can be screwed in without much effort), otherwise the
thread could be damaged.

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3.9 Cooling liquid refill
3.9.1 Disconnect the flash generator
Disconnect the power supply cable from the flash generator on the power distribution board.
3.9.2 Fill the water tank
Unscrew the ventilation cap and fill the water tank with descaled tap water up to the upper edge
using the funnel.
ATTENTION:DURING THE FOLLOWING STEPS THE COATMASTER IS UNDER MAINS VOLTAGE.
→WEAR PROTECTIVE GOGGLES AND DO NOT TOUCH ANY ELECTRICAL CABLES.RISK OF DEATH.
3.9.3 Connect the power cable and switch on the coatmaster
As a result, the pump starts to pump the water into the cooling circuit and the water tank begins to
empty.
3.9.4 Add water into the tank
Use the funnel to fill the water tank to the top with descaled tap water. Repeat this procedure until
the water circuit is filled and the water level in the water tank has reached a stable value.
→If the pump draws in too much air, there is a possibility that the water will no longer be pumped.
In this case, turn off the coatmaster, wait 10 s, and then turn the coatmaster back on.
→It is advisable to check the water level every 3 –4 months and top up with water if necessary.

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3.9.5 Switch off the coatmaster and unplug the power cable
Switch off the coatmaster and wait until the LED turns off.
Disconnect all cables from the device and tie them together. Wait at least 2 minutes.
3.9.6 Screw on the ventilation cap
Tighten the ventilation cap with the slot screwdriver.