Martin MAC 500 User manual

MAC 500
service manual

© 1997, 1998 Martin Professional A/S, Denmark.
All rights reserved. No part of this manual may be
reproduced, in any form or by any means, without
permission in writing from Martin Professional A/S,
Denmark.
Printed in Denmark.
P/N 511000 Revision #980803-MA

03-08-1998 1MAC 500
section 1
INTRODUCTION
ABOUT THIS MANUAL .....................................................................................................2
SAFETY WARNINGS .......................................................................................................2
ADDITIONAL CAUTIONS ..................................................................................................3
SERVICE MATERIALS AVAILABLE FROM MARTIN .................................................................3
section 2
PARTS REMOVAL AND INSTALLATION
LOCTITE THREAD LOCK .................................................................................................4
REPLACING TAPTITES ...................................................................................................4
SEPARATING MAIN ASSEMBLIES ......................................................................................4
COLOR WHEEL MODULE .................................................................................................6
GOBO (AND IRIS/FOCUS/PRISM) MODULE ..........................................................................6
DIMMER MODULE ..........................................................................................................8
ROTATING PRISM MODULE .............................................................................................8
FOCUS MODULE ...........................................................................................................9
TILT MODULES ...........................................................................................................10
MAIN CIRCUIT BOARD ..................................................................................................10
PAN ASSEMBLY ..........................................................................................................11
BALLAST/TRANSFORMER ASSEMBLY (MAGNETIC BALLAST MODELS) ....................................12
BASE COOLING FAN ....................................................................................................12
CONTROL MODULE ......................................................................................................13
section 3
ADJUSTMENT
INDEXING METHODS ....................................................................................................14
ROTATING-GOBO WHEEL (MECHANICAL INDEX) ...............................................................15
FIXED-GOBO WHEEL (MAGNETIC INDEX) .........................................................................15
COLOR WHEELS (MAGNETIC INDEX) ...............................................................................15
SHUTTER/DIMMER (MECHANICAL INDEX) ........................................................................16
PRISM (MECHANICAL INDEX) ........................................................................................16
PAN SENSOR .............................................................................................................16
PAN (ELECTRICAL INDEX) ............................................................................................16
PAN MOTOR SYNCHRONIZATION ....................................................................................16
TILT MOTOR SYNCHRONIZATION ....................................................................................16
OPTIMIZING LAMP ALIGNMENT ......................................................................................17
section 4
TROUBLESHOOTING
GENERAL ..................................................................................................................18
SOFTWARE UPLOAD ....................................................................................................18
MOTORS ...................................................................................................................18
LAMP ........................................................................................................................18
COLOR WHEELS .........................................................................................................19
GOBOS .....................................................................................................................20
IRIS, FOCUS, AND PRISM .............................................................................................20
SHUTTER/DIMMER .......................................................................................................20
PAN/TILT ...................................................................................................................21
section 5
SOFTWARE LOG
..............................................................................................................................22
section 6
MAJOR HARDWARE CHANGES
..............................................................................................................................24
section 7
TYPICAL SPARE PARTS
911360-000000 MAC 500 IN CARDBOARD; 230V,50HZ; ; MSR 575 ; BLACK ..................26
section 8
BLOCK DIAGRAM
.............................................................................................................................29

1998-08-032 MAC 500
section 1
INTRODUCTION
1.1 ABOUT THIS MANUAL
1.1.1 PURPOSE
Since its introduction at PLASA in the fall of 1997, the MAC 500 has proven to be an extremely reliable luminaire. Thorough
attention to detail has resulted in a robotic light that is both compact and portable, and yet able to withstand the thumps and
bumps of touring.
Under the extreme conditions of heat and light, components do, however, occasionally wear out or require adjustment. This
manual is a guide to the most common service requirements. It is not intended as an exhaustive reference on how to trouble-
shoot and replace every single part.
1.1.2 DISTRIBUTION
The MAC 500 Service Manual is available free of charge from the Martin Professional web site at http://www.martin.dk.
1.1.3 ADDITIONAL SERVICE RESOURCES
• The user manual contains basic troubleshooting, maintenance, and service information.
• The Martin Professional web site at http://www.martin.dk provides a library of information including the user manual, the
latest software updates, control protocols and more.
• A global network of qualified Martin technicians is available to provide service and parts and to answer your technical ques-
tions. A list of distributors is maintained on the Martin Professional web site.
• Technical assistance is also available 24 hours a day from the Martin Service Hotline. The number is [phone]. In the
United States call 1-888-TECH-180.
1.2 SAFETY WARNINGS
Read the warnings and cautions below before servicing the fixture. Some adjustment procedures require that the case and/or
shell is removed while the MAC 500 is under power and the lamp is lit. They shall only be performed by qualified technicians
who are aware of, and can protect themselves from, the hazards involved in working with live circuits and discharge lamps.
IFYOU ARE NOT SURE OF HOW TO PROTECT YOURSELF FROM ELECTRIC SHOCK
AND UV RADIATION, ALWAYS DISCONNECT THE FIXTURE FROM AC POWER BEFORE
AND WHILE SERVICING OR REFER THE WORK TO AQUALIFIED TECHNICIAN.
1.2.1 RISK OF ELECTRICAL SHOCK
Removal of any cover exposes connectors that carry lethal electric currents. While working on a fixture under power:
• Make sure the fixture is electrically grounded.
• Use a supply with ground-fault-interrupt protection.
• Keep one hand in your pocket.
• Never touch any connector that carries voltage.
• Be careful with tools that conduct electricity.
1.2.2 RISK OF UV RADIATION AND LAMP EXPLOSION
Discharge lamps emit harmful ultraviolet (UV) light which can cause eye and skin burns. In addition, they work under high
temperature and pressure: lamps can and do explode. The explosion risk increases as the lamp ages and the quartz envelope
weakens. To reduce the risk of injury while working on a fixture with the cover removed:
• Never operate the lamp outside the reflector unit.
• Protect eyes with UV-blocking safety goggles. Do not look directly into the light.
• Protect exposed skin with a high factor sun-block.

1998-08-03 3Introduction
1.3 ADDITIONAL CAUTIONS
1.3.1 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS
The following parts are classified as ESD sensitive:
• Motherboard PCB and the individual ICs.
• Keyboard/display PCB and the individual ICs.
• Hall-sensors.
To avoid damaging ESD sensitive parts:
• Ensure that you and your tools have the same potential (ground) as the fixture before and when handling any of the above
components.
• Always store PCBs in antistatic (electrically conducting) bags and store ICs in antistatic foam.
• Always power off the fixture, and allow capacitors do discharge before removing or inserting any components on the PCBs.
1.3.2 INDUCTIVE LOADS
Always power off the MAC 500 before connecting or disconnecting any of the step motors. Otherwise, damage to the motor
drivers may occur.
1.4 SERVICE MATERIALS AVAILABLE FROM MARTIN
1.4.1 PROTECTION DEVICES
• UV protection glasses, clear .....................................................................................................402010
• ESD table mat, 750 x 610 mm...................................................................................................402020
• Snap button connector, female, type 4730, for ESD table mat....................................................402022
• ESD ground (earth) wire w/2 banana sockets, 4710 ..................................................................402023
• Adjustable ESD wrist band........................................................................................................402024
• Spiral wire for ESD wrist band...................................................................................................402025
• Antistatic bag, 200 x 300 mm....................................................................................................453801
• Antistatic bag, 100 x 125 mm....................................................................................................453802
1.4.2 TOOLS
• 2 mm T-shaft allen key ..............................................................................................................402001
• ESD IC pin straightener combi..................................................................................................402030
• Light duty maintenance tool for AMP MTA 100 sockets..............................................................402011
• Heavy duty pistol grip for AMP MTA 100 sockets (requires head, below)....................................402012
• Heavy duty termination head for AMP MTA 100 sockets (requires grip, above)...........................402013
1.4.3 LUBRICANTS
• High temperature synthetic oil, 0.5 liter.....................................................................................400003
• Silicone lubricant, 0.5 liter.........................................................................................................400119
• Silicone lubricant, 0.2 liter in dispenser with closable valve .......................................................400118
1.4.4 ADHESIVES
• High temperature (300 - 375° C) silicone glue, red....................................................................400002
• Loctite 243 thread lock, 10 ml ...................................................................................................400531
• Loctite 290 thread lock, 10 ml ...................................................................................................400533

1998-08-034 MAC 500
section 2
PARTS REMOVAL AND INSTALLATION
2.1 LOCTITE
THREAD LOCK
2.1.1 EXTENT OF APPLICATION
Loctite thread lock is used on all machine screws (this does not include self-tapping or sheet metal screws) to lessen the prob-
lems due to the loosening of screws under transport and with time. The thread lock must be reapplied if the screws are loosened
or removed for service.
Two types of Loctite are in use, and are available from Martin Professional. Set screws securing wheels to motor shafts are
secured with the lighter, green, Loctite 290 (P/N 400533). All other screws are treated with the heavier, blue, Loctite 243 (P/N
400531). Both are available in 10 ml tubes.
2.1.2 METHOD OF APPLICATION
Be careful to avoid getting any material on shafts or axles. A needle and syringe makes an idea application tool.
Long set screws: Start the screw and turn it until it contacts the shaft. Back the screw 2 turns, apply a small drop or 2 of Loctite
290 to the threads, and then tighten the screw as you normally would.
Short set screws: Back the set screw out of the adaptor until 2 threads stick out of the shaft. Apply a small drop or 2 of Loctite
290 to the threads, and then tighten the screw within 60 minutes.
Other metric screws: Apply a drop of Loctite 243 (blue) to 3 or 4 threads, or spread a thin stripe with a syringe, before starting
the screw.
2.2 REPLACING TAPTITES
Taptites are not fully round and thus do not have the same strength as regular metric hardware. They are selected, after careful
consideration by R&D, for their excellent thread-cutting abilities.
Taptites shall not be reused in critical locations. Problems can be avoided with the following practice:
Change to metric hardware of the same size when reinstalling used parts originally held with taptites. For the pan/tilt motors,
use M5 x 16 mm allen head bolts, P/N 360855.
Use new taptites when installing new parts. Do not use old taptites to cut new threads! For pan/tilt motors use M5 x 12 mm tap-
tites, P/N 361800.
If the threads in the motors are stripped, use a smaller screw (M4) and a lock nut.
2.3 SEPARATING MAIN ASSEMBLIES
2.3.1 REMOVE HEAD FROM YOKE
1. Remove color and gobo modules. Refer to sections 2.4 and 2.6.
2. Disconnect wires from starter.
3. Cut the ties holding wires to the chassis; pull the wires out through the tilt bearings on both sides.
4. Remove the screws holding the head to the tilt bearings and remove the head. These screws are locked with
Loctite and may be difficult to remove - use a screwdriver in good condition.
5. Installation is the reverse of the above.
2.3.2 REMOVE YOKE FROM BASE
1. Remove the plastic covers from both arms.
2. Disconnect the lamp wires from the connection block.
3. Clip the tie holding the lamp wires to the wire bundle leading into the head.
4. Unplug all wires leading into the base from both sides of the yoke.
5. Remove the tilt-reset switch wires and cut the tie binding them to the wires leading into the head.

1998-08-03 5Parts Removal and Installation
6. Remove the tilt-sensor circuit board.
7. Remove the bottom row of 5 screws from both sides of the yoke base and lift off the yoke.
2.3.3 INSTALL YOKE ON BASE
1. Set the base on a work table with the circuit-board side facing you.
2. Turn the yoke base fully clockwise to the mechanical stop; then turn it back 270° counter-clockwise.
3. Arrange the wires. Lay the bundle with the sensor, fan, rotating-gobo, gobo wheel 1, color wheel 2, dimmer, and
tilt motor and reset switch wires to the left (as the fixture faces you). Lay the bundle with the focus, iris, prism,
rotating prism, color wheel 1, and gobo wheel 2 along with the bundle of 3 lamp wires (black, blue, and yellow/
green) to the right.
4. Tie the wire bundles to the base using the pair of holes on each end. The wires can be damaged by the shaft
collar if they are tied too tightly. They are too tight if, with power off, there is increased resistance or a slight
spring action at the extremes of the pan range.
5. Find the side of the yoke with the plastic lamp wire connection block. Place the yoke on the base with the con-
nection block on the right side. Install the 10 screws that hold the yoke to the base.
6. Connect all wires on both sides of the yoke. When connecting the tilt reset switch wires, it makes no difference
which wire is on top. Replace the tilt-sensor circuit board under the tilt motor.
7. Tie the wire bundles together where they pass the tilt motors. Do not tie them to the arm. Replace the plastic
arm covers.
Figure 2-1

1998-08-036 MAC 500
2.4 COLOR WHEEL MODULE
2.4.1 REMOVE MODULE
1. Refer to figure Figure 2-1. Working from the top of the head, remove the top air flow plate (A) and Hall sensor
module (B). There is no need to cut the tie holding the wires to the Hall sensor module.
2. Unplug the motor wires. Unscrew 2 screws from the bottom of the chassis first and then the screw on the top of
the module.
3. Clip the tie attaching the prism and focus motor cables to the color module and carefully lift it out.
4. Installation is the reverse of the above procedure. Make sure the ground wire is connected to the chassis after
installing the module.
2.4.2 REMOVE COLOR WHEELS
1. Remove the color wheel module.
2. Loosen the adaptor set screws and remove the color wheels.
2.4.3 INSTALL COLOR WHEELS
1. Remove scratches in the motor axles with a fine file or sandpaper.
2. Refer to Figure 2-1. First install color wheel 2 (C) as shown. Color wheel 2 has 4 CTC filters and its adaptor is
on the side as the color filters. Position the face of the wheel 2 mm from the face of the motor and tighten a set
screw slightly to fix the position along the shaft.
3. Install color wheel 1 (D) on the other motor as shown. The adaptor on color wheel 1 is on the opposite side as
the color filters. Position the face of the adaptor 2 mm from the face of the motor and tighten a set screw slightly
to fix the position along the shaft.
4. Check that the inside wheel turns freely.
5. Replace the color wheel module and adjust the wheels as described in section3.4.
2.5 GOBO (AND IRIS/FOCUS/PRISM) MODULE
2.5.1 REMOVE MODULE
1. Refer to Figure 2-1. Working from the top of the head, remove the top air flow plate (A) and Hall sensor module
(B). There is no need to cut the tie holding the wires to the Hall sensor module.
2. Remove the bottom air flow plate and unplug the bottom Hall sensor. Unplug all motors on the module.
3. The gobo module is secured to the bottom of the chassis with 2 screws. Hold it as you remove the screw. Care-
fully lift out the module and place it upside down on the work table.
4. Installation is the reverse of the above procedure. When plugging in the bottom Hall sensor, the side of the plug
where the wires attach faces down, towards the circuit board.
2.5.2 REMOVE ROTATING-GOBO WHEEL
1. Remove the gobo module.
2. Refer to Figure 2-2. Unscrew the 3 screws (I) and remove the wheel (J).
2.5.3 INSTALL ROTATING-GOBO WHEEL
1. Turn the gobo wheel adaptor (G) clockwise until it stops.
2. Place the wheel (J) over the adaptor as shown with the open position centered in the light path.
3. Align the holes and screw in the 3 screws (I).
4. The rotating-gobo wheel does not normally require adjustment after replacement.
2.5.4 REMOVE FIXED-GOBO WHEEL
1. Remove the rotating-gobo wheel.

1998-08-03 7Parts Removal and Installation
2. Loosen the 2 set screws on the adaptor (H) and pull off the wheel.
2.5.5 INSTALL FIXED-GOBO WHEEL
1. Remove scratches and grooves in the motor axle with a fine file or sandpaper.
2. Place the wheel on the motor shaft with the black side facing the module. Position the inside face of the wheel
10 mm from the face of the motor. Tighten a set screw slightly to hold the position along the shaft.
3. Reinstall the rotating-gobo wheel. Replace the gobo module and then adjust the fixed gobo wheel. See proce-
dure 3.3.
2.5.6 REMOVE GOBO-ROTATION GEAR
1. Refer to Figure 2-3. Remove the rotating-gobo wheel (J).
2. Loosen the 2 set screws and pull the adaptor (K) off the axle.
3. Use a gear puller to remove the drive gear (N) and bearing (M). There is no need to remove the locking ring (L).
2.5.7 INSTALL SILICONE DRIVE GEAR
1. Remove scratches in the axle with a fine file or sandpaper.
2. Refer to Figure 2-3. With the locking ring (L) facing the gobo wheel, press the silicone gear (N) and bearing (M)
onto the shaft together, all the way to the gear (P).
3. Install adaptor (K). The end of the shaft should be flush with the face of the adaptor. Do not tighten the set
screws.
4. When replace the rotating-gobo wheel, make sure the set screws are accessible between the gobos.
5. Refer to procedure 3.2 to adjust the rotating-gobo wheel.
2.5.8 REPLACE ROTATING-GOBO BEARING
If the bearing requires lubrication, use silicone lubricant, available from Martin in 0.5 liter containers as P/N 400119. Clean the
bearing thoroughly before lubricating.
Figure 2-2
2
3
4
5
1

1998-08-038 MAC 500
1. Remove the rotating-gobo wheel.
2. Refer to Figure 2-3. Remove the outer ring (T).
3. Remove the retaining spring (not shown) from the back of the gobo holder (U) and remove the holder.
4. Remove the bearing (S) from the outer ring (T).
5. Reassembly is the reverse of the above.
2.6 DIMMER MODULE
2.6.1 REMOVE MODULE
1. Remove the gobo module.
2. Unplug the dimmer motors.
3. Remove 2 screws from the bottom and 1 screw from the top of the dimmer module and remove the module.
4. Installation is the reverse of the above procedure.
2.6.2 REPLACE DIMMER BLADES
1. Loosen the set screws and remove the dimmer blades.
2. Remove scratches in the motor axles with a fine file or sandpaper.
3. See Figure 2-1. Install a dimmer blade on the right motor (as seen from the rear) with the adaptor facing the
front.
4. Install the left dimmer blade with the adaptor facing the motor.
2.7 ROTATING PRISM MODULE
2.7.1 REMOVE MODULE
1. Remove the gobo module.
Figure 2-3