Martin MAC 575 Krypton User manual

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 1 of 46
MAC 575 Krypton™ Low-Noise
Upgrade Kit Installation Guide
Introduction
This Installation Guide explains how to install the MAC 575 Krypton Low-Noise Upgrade Kit to convert a
standard MAC 575 Krypton to a Low-Noise model.
The MAC 575 Krypton Low-Noise Upgrade Kit has part number P/N 50300514.
For the latest documentation and information about this and all Martin Professional products, please visit
the Martin website at www.martin.com.
Warning! Read and follow the safety precautions in the MAC 575 Krypton user manual before installing the
Low-Noise Upgrade Kit. The user manual is supplied with the MAC 575 Krypton and is also
available for download from www.martin.com
Disconnect the fixture from power, allow to cool and place on a workbench before starting work.
The MAC 575 Krypton Low-Noise Upgrade Kit must be installed by qualified professional
technicians only. Read all of this Installation Guide carefully before starting to install the Upgrade
Kit. Martin Professional A/S and its affiliated companies cannot be held responsible for any
injury, damage, direct or indirect loss, consequential or economic loss or any other loss
resulting from failure to follow the instructions, respect the safety precautions and carry out the
safety tests listed in this Installation Guide.
If you have any questions about how to install the Upgrade Kit or use the MAC 575 Krypton
safely, please contact your local Martin distributor (see www.martin.com/distributors for details)
or call the Martin 24-hour service hotline on [phone], or in the USA on 1-888-tech-180.
Important!To avoid damage to PCBs and their sensitive electronic components, take precautions to avoid
ESD (electrostatic discharge) and carry out work at an ESD-free workstation. Do not get oil or
grease onto optical components. If necessary, clean components with 99.9% isopropyl alcohol.
© 2008 Martin Professional A/S. Olof Palmes Allé 18, DK-8200 Aarhus N, Denmark. Information subject to change without notice. Martin
Professional A/S and all affiliated companies disclaim liability for any injury, damage, direct or indirect loss, consequential or economic
loss or any other loss occasioned by the use of, inability to use or reliance on the information contained in this installation note. The
Martin logo, the Martin name and all other trademarks in this document pertaining to services or products by Martin Professional A/S or its
affiliates and subsidiaries are trademarks owned or licensed by Martin Professional A/S or its affiliates or subsidiaries.
P/N 35000602 Rev. B

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 2 of 46
Overview
The MAC 575 Krypton Low-Noise Upgrade Kit contains the following items:
ABCD
EFGH
IJKL
MNOP
QRST
Table 1

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 3 of 46
Tools required
Screw sizes given in this guide are indicative only.
The following tools are normally required to upgrade a
standard MAC 575 Krypton as described in this guide.
However, if screws have been replaced during service, for
example, you may find that other tools are required.
• wire cutters
• adjustable wrench
• 4 mm Allen key
• 2 x flathead screwdrivers
• Pozidriv PZ1 and PZ2 screwdrivers (all cross-head screws in MAC 575 Krypton fixtures are Pozidriv,
not plain Phillips type)
• 10 mm and 8 mm hex head screwdrivers
• Torx TX10 and TX20 screwdrivers
• Round (needle) file
• Gaffa tape
• Spirit marker pen
To help you avoid dropping screws into the fixture, we recommend that you magnetize tools. Use of a
powered screwdriver with correctly set torque will also save you time.
UVWX
Y Z AA AB
Table 1
A Wiring harness P/N 11850227
B Wiring harness P/N 11850228
C SMPS to DC/DC PCB leads P/N 11850230
D High-voltage wiring diagram P/N 33120093
E Base shell with fans P/N 62408570
F SMPS bracket P/N 62408580
G Ballast mounting bracket P/N 62408370
H Ballast mounting plate P/N 62408440
I Ballast mounting plate, terminals side P/N 62408400
J Inrush PCB P/N 62408390
plus P/N 62000144
K Vented panel for ballast-side
base side cover P/N 23912582
L Pan stop with switch P/N 62400815
M Grounding label for ballast P/N 33160051
N Ballast label P/N 33160050
O Voltaflex insulation for base side cover P/N 33001113
P Voltaflex insulation for pan frame P/N 33001114
Q Flexible cable retainer P/N 13101010
R M6x70 hex ballast mounting bolts x3 P/N 08111007
S M6 lockwasher P/N 08114401
T M3 lockwasher P/N 08054401
U M3x6 countersunk Torx screw x4 P/N 08050802
V M4x12 countersunk Torx screw x10 P/N 08070808
W M3x8 panhead Torx screw P/N 08050703
X M4x16 panhead Torx self-tap screw x3 P/N 08070703
Y M6 washer, stainless steel x3 P/N 08114302
Z M3x8 countersunk Torx screw x2 P/N 08050803
AA M4x10 phd. Torx tap + spike screw x6 P/N 08070701
AB Spacer Ø7/Ø4 x2 P/N 08261020
Parts list

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 4 of 46
Schematic wiring diagram

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 5 of 46
Replacement of components
To install the MAC 575 Krypton Low-Noise Upgrade Kit components in a standard MAC 575 Krypton
fixture:
1. Disconnect the fixture from
power, allow to cool, and place
on a workbench. Take
precautions against ESD
(electro-static discharge).
2. See Figure 1. Lay the fixture
on its side and remove the 14
Torx 20 pan frame retaining
screws (arrowed),
P/N 08070808, from the base.
Keep the screws for re-use.
3. See Figure 2. Stand the fixture
upright.RemovethethreePZ2
screws from the corners of
each base top cover (6 screws
total P/N 08070502) but do not
remove the ground (earth)
lead Torx screws that are set
slightly in from the corners of
the base covers. Keep screws
for re-use during reassembly.
Figure 1
Figure 2

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 6 of 46
4. See Figure 3. Remove the four
PZ2 screws Afrom the base
side cover on the ballast side.
Keep the screws for re-use.
Cut cable ties Bas necessary
to release the wiring to the
SMPS module and move the
cover away from the base.
5. See Figure 4. Remove the two
PZ2 screws Cfrom the top of
the base side cover and lift the
cover away from the SMPS
module. The screws are no
longer required.
Figure 3
A
A
A
A
B
Figure 4
C
C
Figure 4

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 7 of 46
6. See Figure 5. Cut cable ties as
necessary to release the base
side cover’s ground lead.
7. See Figure 6. Remove the
Torx 20 ground lead screw
(arrowed) from the base side
cover and disconnect the
ground lead. Keep the screw,
washer and ground lead for
re-use.
8. See Figure 7. Remove the
two PZ2 screws at each side
of the base cover and
remove the cover inner
panel. Keep the screws for
re-use.Thecoverinner panel
is no longer required.
Figure 5
Figure 6
Figure 7

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 8 of 46
9. See Figure 8. A new inner
panel with air vents,
P/N 23912582, is supplied in
the Upgrade Kit. Turn the
inner panel so that the tab
(arrowed) in one edge of the
inner panel is lined up with
the channel in the base side
side cover. Use the two
screws you have just
removed to fasten the new
inner panel into the base side
cover. You are screwing into
plastic, so do not overtighten.
Put the side cover and inner
panel assembly to one side.
10. See Figure 9. Remove the
nut and lock washer from the
phase compensation
capacitor. Keep the nut and
washer for re-use.
11. See Figure 10. Disconnect
the spade connectors from
the phase compensation
capacitor and remove the
capacitor. Keep the capacitor
for re-use.
Figure 8
Figure 9
Figure 10

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 9 of 46
12. See Figure 11. Remove the
Torx 20 ground lead screw
(arrowed) from the end of the
SMPS (switch-mode power
supply). The screw, washer
and ground lead are no
longer required.
13. See Figure 12. Note which
terminals the voltage Aand
frequency Btap leads on the
ballast are connected to and
use a small flathead
screwdriver to release the
tap leads from the terminals.
14. See Figure 13. Remove the
four Torx 10 screws from the
inrush PCB mounting posts,
using a wrench to hold the
mounting posts while you
loosen the screws. The
screws are no longer
required.
Figure 11
Figure 12
AB
Figure 13

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 10 of 46
15. See Figure 14. Remove the
four Torx 10 screws
(arrowed, one screw is
hidden behind the
technician’s hand in the
photo) from the DC/DC PCB
mounting posts. These
screws are no longer
required. Move the DC/DC
PCB to one side for access
to the SMPS mounting
screws.
16. See Figure 15. Remove the
three Torx 10 SMPS
mounting screws (arrowed)
from the SMPS bracket.
Keep the screws for re-use.
Figure 14
Figure 15

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 11 of 46
17. See Figure 16. Lift the SMPS
unit and the two PCBs out of
the bracket. The bracket is
no longer required, but keep
the other components.
18. See Figure 17. Disconnect
the plug Awith red and blue
leads from connector J2 and
plug Bwith blue and brown
leads from connector J1 on
the SMPS unit. Keep the
SMPS unit for re-use.
Figure 16
Figure 17
A
B

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 12 of 46
19. See Figure 18. Disconnect all
connectors from the DC/DC
PCB. The red/blue leads and
the brown/blue leads are no
longer required. Remove the
DC/DC PCB and keep it for
re-use.
20. See Figure 19. Disconnect
the data wiring connector
from connector PL1 and the
light-blue and black starter
(ignitor) leads shown in
Figure 19 from the inrush
PCB. Remove the inrush
PCB, leaving the remaining
leads connected to it. The
PCB and these remaining
leads (shown at bottom right
in Figure 19) are no longer
required.
Figure 18
Figure 19

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 13 of 46
21. See Figure 20. Cut the cable
ties on the wiring to the data
connector you have just
removed from the inrush
PCB and pull the wiring free.
22. See Figure 21. Using an 8
mmsocketdriver,removethe
three M5 ballast mounting
bolts and lift the ballast out of
the chassis. The bolts are no
longer required.
23. See Figure 22. Use a small
flathead screwdriver to lever
the plastic inserts out of the
ballast mounting bolt holes
on the top and the bottom of
the ballast. The inserts are
no longer required.
Important!The inserts are top-hat shaped,
with a sleeve inside the
mounting bolt hole and a collar
around the hole. If you break
off a collar, leaving the sleeve
stuck inside the hole, remove
the sleeve by knocking it out
with a bolt pushed through the
hole from the other side. Check
that all sleeves are removed
and holes are clear before
proceeding.
Figure 20
Figure 21
Figure 22

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 14 of 46
24. See Figure 23. Two new
ballast mounting plates, P/N
62408400 and P/N 62408440
an M6 star washer, P/N
08114401, three new M6
ballast mounting bolts, P/N
08111007 and three flat
washers, P/N 08114302, are
supplied in the Upgrade Kit.
On one plate there is a
countersunk recess. the star
washer must be installed
between the plate and ballast
here to ensure good electrical
continuity. Use a metal scraper
or sandpaper to clean the
surface of the ballast where
the star washer will sit. Use a
10 mm socket to install the
plates on the ballast as shown
in Figure 23 using the three
bolts supplied, with the star
washer sitting in its recess and
using flat washers under the
bolt heads.
25. See Figure 24. A label is stuck
on the side of the ballast next
to the terminals. Replace it
with the Elektrokov label C
supplied in the Upgrade Kit.
Apply the grounding label B
supplied in the Upgrade Kit
beside the Elektrokov label as
illustrated. This label indicates
that the ballast is grounded via
the bolt Aand star washer.
Important!To maintain electrical continuity,
the star washer must be
reinstalled in the same position
during future service operations.
Figure 23
A
Figure 24
CB
A

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 15 of 46
26. See Figure 25. Use a 7 mm
socket to remove the nuts
(arrowed) from the four screws
that hold the ballast mounting
brackets to the bottom of the
base. You will need to hold the
PZ2 screws in the base while
you loosen the bolts. Be
prepared to catch lockwashers
to avoid them falling inside the
fixture. One screw is hidden
under a label carrying patent
information. You will need to
scrape part of the label away
to free the screw. The brackets
and their screws and bolts are
no longer required.
27. Remove the four PZ2 retaining
screws from the display side
base cover and lift the cover
away from the fixture slightly.
Keep the screws for re-use.
Figure 25
Figure 26

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 16 of 46
28. See Figure 27. Disconnect the
display side base fan from the
top of the main PCB.
29. See Figure 28. Disconnect the
mains power leads (in a
braided sleeve) from the mains
filter PCB.
30. See Figure 29. Disconnect the
wiring to the DC/DC PCB from
its connector (arrowed) on the
bottom of the main PCB.
Figure 27
Figure 28
Figure 29

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 17 of 46
31. See Figure 30. The wiring
harness that includes the main
PCB-to-DC/DC PCB leads
should now be free. Remove it.
This wiring harness is no
longer required.
32. See Figure 31. Disconnect the
SMPS side base fan at its
cable connector behind where
the SMPS is installed.
33. See Figure 32. Disconnect the
ballast side base fan at its
cable connector behind where
the ballast is installed.
Figure 30
Figure 31
Figure 32

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 18 of 46
34. See Figure 33. Remove this
screw from the shield plate on
top of the pan frame. This
screw is no longer required.
35. See Figure 34. Remove this
screw and the cable retainer
mounted on it from the top of
the pan frame. This screw and
the cable retainer are no
longer required.
36. See Figure 35. Remove this
screw from the top of the pan
frame. This screw is no longer
required.
Figure 33
Figure 34
Figure 35

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 19 of 46
37. See Figure 36. Remove this
screw from the top of the pan
frame. This screw is no longer
required.
38. See Figure 37. Remove the
two screws that hold the
ground leads on the top of the
pan frame at both sides and lift
the base top covers away from
the fixture. Keep the screws
and covers for re-use.
Figure 36
Figure 37

MAC 575 Krypton Low-Noise Upgrade Kit Installation Guide – Page 20 of 46
Warning! To reduce the risk of injury to yourself or damage to the fixture, two people are required for the
next operation.
39. See Figure 38. While one
person lifts the head and yoke
assembly out of the fixture, the
other person must slide the
base out from underneath,
leaving the
display/connections panel and
main PCB connected to the
head and yoke. Do not discard
the base yet.
40. See Figure 39. Lay the head
and yoke assembly on its side.
Pull the light-blue and black
starter leads Aand data leads
Bin through the circular cutout
in the pan frame, pass them
back out through the
rectangular cutout C, pull to
remove any slack in the leads,
then tape them out of the way
Dagainst the side of the pan
frame.
41. See Figure 40. Pull the head
and yoke wiring harness out of
the pan frame, removing any
slack, and secure the harness
with an elastic band (see
arrow).
Figure 38
Figure 39
A
B
DC
Figure 40