Magnaflux ZB-100 Operating instructions

ZB-100 &
ZB-100F
BLACK LIGHTS
I N T R O D U C T I O N M A I N T E N A N C E I N F O R M AT I O N
This manual contains helpful maintenance tips,
plus troubleshooting instructions for correcting
problems. If you need additional information or
help, please call your local Magnaflux
Distributor or contact Magnaflux directly.
S A F E T Y I N F O R M AT I O N
If precautions are not taken, ultra-violet light
can injure eyes and skin. To assure operator
safety, please read and follow these guidelines:
•Connect the ZB-100 and ZB-100F only to
grounded electrical outlets.
• Avoid direct skin contact with the lens
when the light is on; the hot lens can
cause severe burns.
• Wear opaque gloves and protective clothing
during inspections to protect skin from
possible UV irritation.
•Never use a black light without the
glass filter.
•Never look directly into the lamp while
it is on.
• Avoid splashing liquid on hot lens; the
tempered glass may crack, allowing
unfiltered UV light to escape.
•The ZB-100 and ZB-100F use mercury
vapor gas bulbs, which must be handled
with care. If a bulb cracks, it should be
replaced immediately. If a bulb breaks,
sweep up the pieces without touching the
glass as the mercury can be harmful.
Dispose of the glass and mercury using
industry standard safety handling
procedures.
Although a wide variance exists, black light bulbs normally last 1,000 hours or longer. To maximize bulb life,
keep lamp ON for the entire day (or shift). Constant unplugging and restarting shortens bulb life.
Intensity of the bulb will drop steadily over its lifetime until the bulb eventually fails. Its usable life may be
extended by occasionally cleaning the lens with glass cleaner, or by replacing the lens entirely.
From the time the black light is plugged in, it takes about five minutes to reach full bulb intensity. When the
ZB-100 light is unplugged, the bulb must be allowed to cool for about 10 minutes before it will restart. The
ZB-100F should restart almost immediately.
BULB REPLACEMENT PROCEDURE
Before replacing a bulb or lens, allow the lamp to cool for at least 10 minutes.
•Remove the three screws around perimeter housing.
•Remove the bezel and lens assembly.
•Remove bulb by gently unscrewing.
•Screw in new bulb, being careful not to overtighten.
•Reinstall bezel and lens assembly.
LENS REPLACEMENT PROCEDURE
•Follow steps 1 & 2 from Bulb Replacement Procedure.
•Pull out any one of the three lens retainers and remove lens.
•Insert new lens into bezel and replace lens retainer.
•Reinstall bezel and lens assembly.
TRANSFORMER CONNECTIONS
Model ZB-100 (Hand-held, 115V)
A choice of two taps is provided to match input line voltage.
1. Connect neutral side of line to Lead #1 of transformer.
2. Connect white wire from lamp to Lead #1 of transformer.
3. Connect black wire from lamp to Lead #4 of transformer.
4. For 100-110V supply, connect line to Lead #2 of transformer. Cap Lead #3.
5. For 110-120V supply, connect line to Lead #3 of transformer. Cap Lead #2.
Model ZB-100F (Portable, 115V)
1. Connect black #1 from transformer, black #1 from lamp, and white wire from line together.
2. Cap-off black #2 from transformer.
3. Connect black #3 from transformer and black wire from line together.
4. Connect black #4 from transformer to black #2 from lamp.
5. Connect unnumbered black lead from transformer to black #4 from lamp.
6. Connect unnumbered red lead from transformer to black #3 from lamp.
7. Connect green ground lead from line, and green/yellow ground lead from lamp to transformer case ground.
M A I N T E N A N C E & T R O U B L E S H O O T I N G
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DescriptionQtyPart #Index #
M A I N T E N A N C E & T R O U B L E S H O O T I N G Z B - 1 0 0 & Z B - 1 0 0 F
CAUTION: BEFORE PERFORMING ANY SERVICE, DISCONNECT THE LIGHT FROM THE POWER SOURCE AND ALLOW COOL DOWN TIME.
*Input voltage must not be less than -15% or more than +5% of transformer input rating.
3624 West Lake Avenue, Glenview, IL 60026 USA • Phone: [phone] Fax: [phone] http://www.industry.net/magnaflux
Faraday Road, S. Dorcan Industrial Estate, Swindon, SN3 5HE, Wiltshire, England • Phone: [phone] Fax: [phone]
© 1997 MAGNAFLUX • Printed in U.S.A. • MX No. 30, 5M, SC/GI, 04/97
1a
1b
2
3
4
5
6
7
8
9
10a
10b
11
12
13
14
15
Bezel (ZB-100)
Bezel (ZB-100F)
Filter
Retaining clip
100 watt par 38 lamp
Shield (ZB-100 only)
Insulator shield (ZB-100 only)
Keps nut, #8-32
Socket assembly
Screw, 3.5 x 6 mm, pan hd
Lamp housing (ZB-100)
Lamp housing (ZB-100F)
Pop rivet (ZB-100 only)
Washer, #10 flat
Washer, #8 flat
Screw, #8-32 x 7/8", pan hd
Line cable assembly, #16-3 Cond. R.C. with
molded plug & GFCI
600036
600084
519227
600064
507320
600039
600014
99344
600063
8008535006
600011
600085
506690
N/A
8012508000
8008508087
520309
DescriptionQtyPart #Index #
16
17a
17b
18
19
20
21
22
23
24
25
26
27
28
29
1
1
1
1
1
2
1
1
1
1
1
1
1
2
4
One of the following transformers:
115V, 60 Hz (ZB-100 only)
115V, 60 Hz (ZB-100F only)
220V, 50 Hz (ZB-100 only)
220V, 60 Hz (ZB-100 only)
Cable, #16-3 Cond. R.C. (ZB-100 only)
Cable, #18-5 Cond. R.C. (ZB-100F only)
Handle
Strain relief brushing
Terminal lug, #16-22
Stakon lug
Keps nut, #10-32
Lock washer, #10 external tooth
Grd. Screw, #10-32 x 3/8", pan hd
Fan (ZB-100F only)
Fan bracket (ZB-100F only)
Fan guard (ZB-100F only)
Screw, #8-32 x 1-1/2" rd hd
Screw, #6-32 x 3/4" rd hd
1932
520704
1928
1929
423722A
620100
600013
519648
8478
2608
507434
511931
8008510037-B
520647
620101
520648
Corrective ActionPossible CauseProblem
Bulb goes out
or won't start
1. Allow 10 minute cool down
2. Tighten bulb
3. Replace bulb
4. Check outlet connection
5. Replace fuse
6. Tighten socket base screw
7. Replace socket
8. Repair as necessary
9. Check transformer connections
10. Keep away from magnetizing area
11. Reset in-line GFCI
1. Insufficient cool down
2. Loose bulb
3. Defective bulb
4. Bad plug connection
5. Blown fuse
6. Loose socket screw
7. Defective socket
8. Loose wiring
9. Wrong line voltage*
10. Magnetic field
11. GFCI tripped
Corrective ActionPossible CausePro b l e m
Low UV
intensity
1. Use glass cleaner,not solvent, or
replace
2. Replace UV filter
3. Replace bulb
1. Dirty UV filter
2. Worn UV filter
3. Old bulb
Short bulb life 1. Check transformer connections
2. Leave on all day/shift
1. Wrong line voltage*
2. Too many restarts
1
1
1
3
1
1
1
2
1
3
1
1
7
3
4
2
1
Fan not
operating
1. Check connection and wiring
2. Replace fan
1. Bad connection
2. Defective fan
Air blowing
out back of
housing
1. Reinstall fan in correct orientation1. Fan installed
backward
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