KBL megaSun 7900 Service manual

Operating and Service Manual
megaSun 7900
megaSun Cadillac
BA_7900_GB_E (0707)

2
Operation and Service megaSun 7900
Printed in Germany
© Copyright 2004 KBL-Solarien AG
This documentation covers only products manufactured by KBL-
Solarien AG.
This documentation must not be duplicated, photocopied,
translated or stored on any electronic medium or in a machine-
readable form, neither in whole or in part, without prior written
consent by KBL-Solarien AG.
For instruction updates, please refer to http://www.kbl-support.de
For software versions:
without easyCare:• KBL4_64.exe
with easyCare: KBL4_ec_35.exe•
is a registered trademark of KBL-Solarien AG.
Certified according to DIN ISO 14001
Only original spare parts – especially tubes and burners – have
to be used, otherwise operating authorization and terms of
guarantee will become invalid.
KBL-Solarien AG ·
Ringstraße 24-26 · 56307 Dernbach · Germany
fon +49(0)2689.9426-0 · Fax [phone]
eMail [email protected] · Internet: www.megaSun.de
Copyright and Trademark

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Operation and Service megaSun 7900
Table of Content
1. General Safety Instructions................................................................................4
2. Service Plan .........................................................................................................5
3. Equipment ............................................................................................................6
4. Operation during the tanning session ..............................................................6
4.1 Operating panel.....................................................................................................................7
4.2 Functions...............................................................................................................................8
4.3 Tips for the studio operator .................................................................................................13
5. Maintenance of the apparatus .........................................................................14
5.1 Cleaning and care ..............................................................................................................14
5.2 Dismantling the acrylic panes .............................................................................................15
5.3 Filter panes..........................................................................................................................17
5.4 Tubes and facial tanners ....................................................................................................18
5.5 Dismantling the burners.......................................................................................................20
5.6 Unit lighting .........................................................................................................................21
5.7 Filter mats............................................................................................................................22
5.8 Canopy drive ......................................................................................................................22
5.9 Exhaust air system ............................................................................................................24
5.10 Air-conditioning unit and condensate pump ........................................................................24
5.11 Replacing the aquaCool nozzles.........................................................................................25
6. Technical data ....................................................................................................26
6.1 Data which all the apparatuses have in common................................................................26
6.2 Views...................................................................................................................................27
6.3 Special technical data ......................................................................................................28
7. Wiring diagrams.................................................................................................29
7.1 Mains voltage ......................................................................................................................29
7.2 megaVoice without music option .........................................................................................30
7.3 Internal music signal MP3-player ........................................................................................30
7.4 External music signal without channel selection ................................................................31
7.5 External music signal (100V) without channel selection .....................................................31
7.6 External music signal with channel selection .....................................................................32
7.7 External Timer .....................................................................................................................33
8. Service................................................................................................................34
8.1 General information and structures ....................................................................................34
8.2 Service level I ......................................................................................................................35
8.3 Service level II .....................................................................................................................42
8.4 Re-filling / Changing Aroma and aquaCool .........................................................................46
8.5 Colour codes for the pipes...................................................................................................47
8.6 Error messages ..................................................................................................................48
9. Tanning instructions ........................................................................................49
9.1 General tanning instructions................................................................................................49
9.2 Super Power, UV-Type 3, inductive.....................................................................................51
9.3 Super Power, UV-Type 3, CPI .............................................................................................51
9.4 Super Power, UV-Type 4, inductive.....................................................................................52
9.5 Super Power, UV-Type 4, CPI .............................................................................................52
9.6 Ultra Power, UV-Type 3, inductive.......................................................................................53
9.7 Ultra Power, UV-Type 3, CPI ...............................................................................................53
9.8 Ultra Power, UV-Type 4, inductive.......................................................................................54
9.9 Ultra Power, UV-Type 4, CPI ...............................................................................................54

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Operation and Service megaSun 7900
1. General Safety Instructions
Please observe the following safety instructions:
Tanning times
Timer
Please keep to the recommended tanning times see
Section 9
The apparatuses may only be operated with safety timers which
comply with the corresponding standards.
KBL-Solarien AG recommends the following timer:
megaTimer KBL-Article No. 9100025000.
Disconnecting Before opening the apparatus, switch off the fuses to disconnect
the system from the voltage supply!
Facial tanner Do not operate the sun bed if a filter pane is defective.
See Section 5.3
Attention! High light intensity, do not look into the radiators!
Technical
parameters
The data indicated in the tanning schemes are based on the
assumption that both tubes and burners are replaced at regular
intervals. (See Section 5.4)
When replacing tubes, remember to reset the CPI-control
system and the counter of the tube service hours.
Mechanics The canopy drive has to be serviced regularly with each tube
replacement.
This also includes the replacement of the drive rope after 3,000
hours of operation. (See Section 5.8)
Cleaning Do not use any cleaning agents other than the ones approved
by KBL Solarien AG. (See Section 5.1)

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Operation and Service megaSun 7900
2. Service Plan
Service intervals For a safe operation of the sun beds, regular service works are
essential and have to be documented. Cleaning works have to
be done when necessary and do not have to be documented.
Service hours What has to be done? see
Every day Check the filling level of the condensate tank and empty it if
necessary.
100 Change or clean filter mats 5.7
500 - 600 Change burners
For inductive apparatuses:
• Change tubes
• Change starters
• Reset counter of service hours
5.4
For CPI-apparatuses (with burners) in Power-mode:
• Change tubes
• Reset counters (8)
• Reset counter of service hours
Check and grease ropes of the canopy drive 5.8
Check all inner tubes and – if necessary – change them
Climatic apparatus:
• Clean heat exchanger
• Check the functioning of the condensate pump
5.10
800 For CPI-apparatuses (with burners) in Eco-mode or for CPI-
apparatuses (without burners) in Power-mode:
• Change tubes
• Reset counters (8)
• Reset counter of service hours
1000 For CPI-apparatuses (without burners) in Eco-mode or with
megaSun CPI-tubes in Power-mode:
• Change tubes
• Reset counters (8)
• Reset counter of service hours
8
Replace aquaCool nozzles. 5.11
1200 For CPI-apparatuses with megaSun CPI-tubes in Eco-mode:
• Change tubes
• Reset counters (8)
• Reset counter of service hours
3000 Replace all the ropes 5.8

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Operation and Service megaSun 7900
3. Equipment
4. Operation during the tanning session
General
information
When switching the apparatus on, the following information is
displayed for 2 seconds before the running text appears:
Firmware version of the display
Version of the control software
Sun bed type
Tube type
Running text
The start of the tanning program depends on the studio control
system. If a simple coin-operated system has been installed, the
tanning program is started by inserting coins or tokens. When
the warm-up time has elapsed the tanning lamps are turned on
automatically.
If the touch key “Start” is pressed during this warm-up time, the
lamps turn on immediately.
Feature S = standard
O = optional
pureAir S Fresh ionized air
ACS S Control of switch-on/switch-off behaviour
megaVoice S Acoustic user guidance
CPI S Electronic series equipment
activeFlex S Shoulder tanner
activeColor O Colour stimulation in red, green or blue
aquaCool O Misty water for refreshment
Aroma and
cabinBreeze
O Fragrances in the sun bed and in the cabin
AirCon O Air-conditioning
Music, MP3-player O with a 256MB-memory for music
Music, external signal O
Waste air tube O Ø 300 mm, 3 m
Central exhaust air
element
O
Warm air recirculation O
legTanner O

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67890
Operation and Service megaSun 7900
The facial tanners are always switched on only after a certain
delay.
Some of the basic features are set in service level I, such as
colour-stimulation, aroma therapy, time control etc. Studio staff
will set these options according to the customers’ wishes.
4.1 Operating panel
Illustr. 4-1
Main display The running text is displayed as long as the sunbed is in the
„waiting position“. When the coin-controlled signal appears, the
functions are displayed and the sunbed can be operated by
touching the corresponding keys. Any input will be confirmed by
a beep tone.
Operating panel
w/o aquaCool
The operating panel with aquaCool shows between the keys
3 ...8 a moving symbol (animation). If aquaCool is not present,
the symbol for the air conditioning will be displayed instead of
the aquaColl symbol.

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Operation and Service megaSun 7900
A function is switched on by pressing the plus sensor, which is
also used to increase the output stepwise. To set the maximum
value (e.g. fan speed) the sensor field has to be pressed again
and again until the maximum value has been reached.
A function is switched off by pressing the minus sensor, which
is also used to decrease the output step by step. To set the
minimum value (e.g. volume) the sensor field has to be pressed
again and again until the desired value has been reached.
4.2 Functions
You can use this touch key to switch the apparatus on during the
warm-up time.
If the tanning session has been interrupted by means of the
„Stop“ key, it can be continued after touching the „Start“ key
once again, provided the coin-operated counter has not run
down yet.
The numerical display shows the tanning time.
When the tanning time is over, the running text will appear again
By pressing this touch field for at least 2 seconds you can
terminate the tanning session prematurely.
During the tanning program the running time is displayed in this
field.
When adjusting the volume, the value set between 0 ... 99 % will
be displayed in this field for a short time.
When adjusting the fan speed, the value set between 20...99 %
will be displayed in this field for a short time
Running time
As soon as the tanning time is over a program to shut down the
sun bed will be started:
• a soft voice reminds you of the end of the tanning session
and says good-bye,
• burners, tubes and the ventilation system will be reduced
step by step,
• the LEDs (in apparatuses with activeColor) will shine in
the colour adjusted for another 20 seconds.
End of the tanning
session

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Operation and Service megaSun 7900
Extended menu These double arrows point to some more menus which can be
activated by pressing the „+“ or „-„ keys. The following menus
are available which will be explained in more detail below:
Music channel /
Air-conditioning /
Colour stimulation
Aroma
Acoustic user
guidance
By calling up these additional menu functions you can see which
functions are activated after switching on the apparatus (=1).
Special customer requests can be pre-selected in the service
menu (see Section 8.3ff.)
Volume You can adjust the volume of the music by touching the „+“ and
„-„ keys. The volume will be displayed in the numerical field as a
value between 0 – 99 %.
Press the corresponding sensor key
aquaCool
off on
Here you can activate the aquaCool water-atomisation func-
tion (plus button, symbol flashes) or deactivate it (minus button,
symbol does not flash). Default setting at start: as defined on
service level I in the AAC/Aqua menu.
If the aquaCool supply is running low, the message Aqua low•
is shown on the display between the tanning sessions. When
the message appears for the first time, the aquaCool supply
will last approx. another 2.5 hours of operation with aquaCool.
If the aquaCool supply is empty, the message Aqua 0% ap-•
pears and the symbol is crossed out. If the system is to be
used without aquaCool, you can switch off the messages
and the symbol. For this purpose, set the submenu Aqua
to “OFF”. To reach this menu, proceed to the AAC menu on
service level II.empty

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Operation and Service megaSun 7900
Facial tanners Level II Once the tanning program has been started, the facial
tanners are switched on automatically at maximum
setting.
Level I To reduce the output to level I, use the field “–”.
Level 0 To switch off the facial tanners completely, touch the “–”
field again for at least 3 seconds.
By touching the “+” field you can switch the facial tanners on
again or you can increase their output.
When the system has been switched off, there will be a time lag
before you can switch it on again due to the necessary cooling
of the burners.
Body fan The power of the body fan can be increased or reduced by
steps of 10 % by touching the fields „+“ or „–”.
After being switched on, the fan starts running at the power-level
value that has been entered for ACS/A.START on level II of the
service menu.
When changing the value, the current setting is displayed
as a two-digit number between “20%” (minimum) and “99%”
(maximum) in the numerical field for a short time.
In order to switch off the body fan completely, press the “−" field
several times until the value of 20% appears. Then press the "–”
field once again and keep the key pressed for 0.5 seconds. After
a short time lag the body fan is then switched off.
The body fan can be switched on again at any time simply by
touching the “+” field.
Channel selection With the help of this system you can choose the audio source,
e.g. change the CD or go to the next piece of music (MP3).
The MP3-player is equipped with a 256MB-chip, which can take
the volume of the 3 music CDs.
The MP3-player is designed in such a way that you only have to
change the chip for the music. As an optional feature, the music
of the MP3-player can be turned on during the tanning breaks.
Tip: The music of the MP3-unit can only be controlled by one
4.2.1 First sub-menu

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Operation and Service megaSun 7900
audio source, i.e. either by the chip of the MP3-player or by an
external music source.
The choose of an other music source may be done by a BCD
coded signal. It is possible to select up to 4 different sources.
Channel selection, continued
Air-conditioning By pressing the „+“ or „–” keys you can switch the air-
conditioning on or off during the tanning session. Once the air-
conditioning has been switched off, it can only be switched on
again after an interval of 3 minutes. A small star is displayed to
confirm this.
If the request to switch on the system is made earlier, it will be
registered (big star) and when the interval of 3 minutes is over it
will be executed automatically.
Exception:
In case that the system has been switched off by means of the
coin-controlled system, it can be switched on again immediately.
Note please: You will find this menu here, if there is no aquaCool.
Colour stimulation You can only switch on one colour. The colour of the colour
stimulation can be selected by means of the „+“ or „ - “ key.
48 power LEDs of each colour (R red, G green and B blue) are
mounted in the canopy of the tanning bed.

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Operation and Service megaSun 7900
Aroma
The „aroma“ function can be switched on by means of the
„+“ key above “0” and switched off by the „ - “ key below „1“.
The display flashes a signal when the function is not activated.
KBL can offer 2 aroma fragrances: „Sunrise“ and „Daydream“.
The apparatus holds only one fragrance which can be changed
very easily, however.
The fragrance is combined with a gel. Please note that the gel is
not completely used up but a small rest will remain. This status
is shown on the display so that the operator knows when to
change the gel.
The fragrance comes out at the foot of the bed. The air stream
leads the fragrance over the body to the face so that it can be
perceived intensively.
aroma and aquaCool are activated one after the other
(aroma – aquaCool – aroma) and start again and again in an
interval of 1 minute.
Note: pureAir and aroma exclude each other. As long as aroma
is given off pureAir will be switched off.
4.2.2 Other sub-menus
megaVoice
The „Voice“ function can be switched on by means of the
„+“ key above “0” and switched off by the „ - “ key below „1“.
The display flashes a signal when the function is not activated.
megaVoice informs the customer in a simple and short way
about the operating functions of the sunbed. If requested,
megaVoice can be switched off by the customer during the
tanning session.
pureAir The „pureAir“ function cannot be switched on or off by keys.
Note: pureAir and aroma exclude each other. As long as aroma
is given off, pureAir is switched off. During the tanning session,
nozzles at the foot of the bed produce cleared, ionized air which
is led over the whole body. Here as well, the air is led from
the foot of the bed over the whole body thus reducing tanning
odours.
Ionizer for the pureAir function is mounted in the foot.

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Operation and Service megaSun 7900
4.3 Tips for the studio operator
Daily checks and
basic settings
Please make sure
• that the tank for the condensed water is checked and
emptied every day
• that materials which have been used up are refilled (8.4)
and
• that the settings which can be executed in the service
levels (see 8.3) of operation, e.g. colour-stimulation,
aroma, time controls etc. are made.
Please observe Section 2 of the Service Plan.
Illumination after
use
The illumination (decorative) may be switched on or off if the
timer signal is not active by pressing the key sequence
„+“... „–”... “+“ of the body fan.
You have to press the individual buttons within a period of 1 sec.
Please also bear in mind the possibility of defining two different
illumination cycles for each day of the week (see 8.2 Service
level I).
Error message
„Abluft“
(exhaust air)
This error message is shown in the display and can be
acknowledged by pressing the „Stop“ key.
But before doing so, service people should repair the defect.
Possible reasons of this message can be:
• the temperature in the apparatus is too high or
• the exhaust vent system is defective
For more information see 8.5

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Operation and Service megaSun 7900
5. Maintenance of the apparatus
Preparatory works Before you open the apparatus, switch off the fuses to discon-
nect it from the mains supply!
Do not operate the tanning unit without the front panels, without
acrylic panes or with the base section opened, because other-
wise the tanner areas will overheat. This will destroy the filter
panes!
As far as CPI-equipped units are concerned, the electronic
switchboxes located under the bed are also exposed to the dan-
ger of overheating.
5.1 Cleaning and care
Plastic parts
Note
The bigger plastic parts are made of solid, high-quality ABS
material. On top of it you will find a hardwearing, transparent
PMMA-layer.
The surfaces and the acrylic glass must not be cleaned with
concentrated disinfectants or solvents or other liquids that
contain alcohol!
The manufacturer cannot be held liable for any damages caused
by chemically active agents such as inappropriate cleaning
agents.
To clean the varnished and plastic surfaces use a damp soapy
cloth.
It must be avoidted at any rate that cleaning fluid runs into the
apparatus.
Acrylic panes For a harmless cleaning of the acrylic panes use the special
cleaning and disinfectant fluid „ megaClean “ (to be obtained
from KBL) which has to be diluted in water at a ratio of 1:13
Fixing the canopy The canopy can be fixed in the upper position, to perform
service and maintenance works.
To do so, open the canopy and move the bolt at the right back
to the front. If you push the bolt to the back the canopy will be
released.
After removing the screws on the left and on the right, the bed
pane can be fastened to the canopy. For that purpose, use the
hook and hang it into the opening in the centre between the filter
mats.

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Operation and Service megaSun 7900
Illustr. 5-1 Fixing the
canopy
Illustr. 5-2 Releasing the
canopy
Illustr. 5-3 Opening for
hook
5.2 Dismantling the acrylic panes
Dismantling the
pane in canopy
and lateral part
Remove the screws and tilt down the panes.
Always put the pane frame with a soft padding (e.g. a head
cushion) on the bed.
For service works, it is possible to take out the complete frame
in the lower position from its support.
Mount the pane in reverse order. Make sure that the frame is
correctly positioned in the hinge.
When closing the pane, all air nozzles must be matching their
counterparts. If not, carefully push the nozzles concerned into
their proper position.
Illustr. 5-4 Loosen screws Illustr. 5-5 Opening the acrylic panes
Head cushion
used as a
padding
Base and duct
pane
The following table shows how to clean the base and duct pane.
The electronic parts installed underneath the bed must not get in
contact with any moisture.
Therefore, in order to clean the underside of the base pane, the
duct pane and the inner base section, use a slightly damp micro
fibre cloth only.

16
Sqaure bolt Bar
Operation and Service megaSun 7900
Illustr. 5-6 Placing the key Illustr. 5-7 Bar of the bed frame
Closing the base
pane
After cleaning the base pane, close it again. Make sure that the
duct pane is in the correct position.
Step Procedure Reference
1. Open the canopy, bolt it. see 5.1
2. Undo the two pan-head screws of the base pane.
Always make sure that you take the pane in the middle
and use the hook to hang the pane onto the fixed
canopy.
3. Take out the duct pane and lay it down in a safe place.
4. Open the bar to lift the complete base case, if
necessary.
Illustr. 5-6
5. In the centre of the lower front cover there is a square
bolt. Place the enclosed key onto this square element.
Illustr. 5-7
6. Unlock the bed by turning the key anti-clockwise. By
doing so, the bed will slightly go up.
Step Procedure Reference
1. If you have opened the bolt of the base case, re-bolt it
again:
Turn the key in the middle of the lower front cover as
far as possible clockwise. The bed is drawn to the
base part and is bolted firmly again.
2. Place the duct pane back into its place and make sure
that it is in the correct position
3. Release the base pane and tilt it down, fasten the
pane with screws.

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Operation and Service megaSun 7900
5.3 Filter panes
Safety function The facial tanners are equipped with an additional safety
function. Behind each of the filter panes there is a safety switch
that switches off the burner if a pane is missing or broken.
Do not operate the tanning system with a defective filter pane.
Carry out regular visual inspections!
Filter panes have to be replaced only by those of the same type!
The filter panes may be dismantled and replaced by trained
expert staff only.
Filter panes in the
canopy
The following table shows how to dismantle the frame of the
filter panes.
Illustr. 5-8 Dismantling the
tube cover
Illustr. 5-9 Dismantling the
filter pane frame
Filter panes in the
lateral part
This frame is to be dismantled as follows:
Step Procedure Reference
1 Dismantle the acrylic pane. Section 3.2
2 Undo the screws of the tube cover in the facial area to
remove the tube cover.
3 Undo the screw of the lower filter pane frame. Hold the
frame. Tilt it down and then take it out.
4 Also hold the front frame when undoing the screws.
Now you can take it out as well.
Step Procedure Reference
1 Completely dismantle the acrylic pane. Section 3.2
2 Undo the screws of the tube cover in the facial area to
remove the tube cover.
Section 3.3.
3 Lift the frame and swing it forward. Section 3.3.
4 Lift the base pane Section 3.2

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1
1
1
2
Operation and Service megaSun 7900
Illustr. 5-10 Dismantling the
tube cover
Illustr. 5-11 Dismantling the
filter pane frame
Cleaning For a harmless cleaning of the filter panes use the special
cleaning and disinfectant fluid „ megaClean “ which has to
be diluted in water in a ratio of 1:13. Or use a normal glass
cleaning agent with a soft cloth or a chamois leather.
5.4 Tubes and facial tanners
Dismantling In order to clean or replace the tubes and facial tanners, please
proceed as follows:
Cleaning intervals To make sure that the tanning effect is maintained, we
recommend you to clean the tubes and UV radiators with warm
water and a chamois after approx. every 200 hours of use. Do
not use any aggressive or alcoholic cleaning agents.
Tubes in the
shoulder tanner
The shoulder tanner „activeFlex“ is equipped with 7 tubes of
25 W each. In addition, the loudspeakers are located in this
element.
Step Procedure Reference
1 Completely dismantle the acrylic panes. Section 3.2
2 Remove the tube covers in the facial area. Section 3.3.
3 In apparatuses equipped with burners you will have to
dismantle the filter panes as well
Section 3.3.
4 Tilt up the base pane. Section 3.2

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Operation and Service megaSun 7900
Illustr. 5-12 Shoulder tanner with
loudspeaker (open)
Illustr. 5-13 Series apparatuses and
starter for shoulder tanner (open)
Illustr. 5-14 Shoulder tanner (closed)
Replacement
intervals
Tubes, facial tanners and starters have to be replaced only by
those of the same type!
When installing the tubes, make sure that the inscription is
visible, i.e. the reflector must be at the back.
For units equipped with CPI technology, it is essential to carry
out a reset after each tube replacement! (see Section 8.3)
For units equipped with inductive technology (shoulder tanner)
also install new starters when replacing the tubes!
Burner Tubes CPI Mode
Shoulder tanner Öko Power
750 hrs. 500 – 600 hrs. 800 hrs 500 hrs.
Exchange
Tubes and Starters
Perform CPI Reset

20
Illustr. 5-15 Dismantling the
burners
Illustr.. 5-16 Socket
Empty space
Operation and Service megaSun 7900
5.5 Dismantling the burners
Dismantling Attention! Only trained expert staff is allowed to install or
remove the burners.
Take the burners with a soft cloth and pull them out towards the
front. Do not touch the burner glasses or the reflector surface
with your bare hand (Illustr. 5-15).
If necessary, you can clean the glass bulb and the reflector sur-
face with an alcoholic cleaning agent.
The connecting elements of the burner are not all the same
thickness. When inserting the burner into the socket, the metal
clamp is directed to the right to the empty space in the middle of
the reflector. (Illustr.. 5-16)
During service, dirt accumulation and an incorrect positioning
may lead to damages of lamps and sockets. Therefore, when
inserting the burners please make sure that the contact surfaces
of both sockets and burners are clean. Insert the burners in a
straight position into their sockets.