Olec OLITE User manual

94MS20 Rev. B4
OLITEOLITE 60Hz
Printing Light
Service Manual
O

94MS20 Rev. B4
This manual is designed for technical personnel
and should only be used by authorized dealer
service personnel.
This manual is written to provide an understand-
ing of the equipment, as well as a plan for
troubleshooting.

94MS20 Rev. B4 0-1
0. Contents
1Introduction
Introduction .................................................................................1-1
2Safety
The Nature of UV ........................................................................2-1
UV, Source of Health ..................................................................2-1
Bad UV ........................................................................................2-1
UV in Nature ...............................................................................2-1
Ozone, UV“B” and UV“C” .........................................................2-2
Safety Glass .................................................................................2-2
Light Leaks ..................................................................................2-2
Overexposure to UV....................................................................2-2
3Component Layout
Lamphead for AL 83, 84, 84-480, 85, 56, 56-480......................3-1
Power Supply for AL 83..............................................................3-1
Power Supply for AL 84..............................................................3-2
Power Supply for AL 84-480 ......................................................3-2
Power Supply for AL 85..............................................................3-3
Power Supply for AL 56..............................................................3-3
Power Supply for AL 56-480 ......................................................3-4
Lamphead for AL 53, 54, 54-480, 55, 55-480, 35, 25, 25-2, 23 .3-4
Power Supply for AL 53, AL 50 .................................................3-5
Power Supply for AL 54, 55........................................................3-5
Power Supply for AL 54-480, 55-480 .........................................3-6
Power Supply for AL 35..............................................................3-6
Power Supply for AL 25-2, AL 25 ..............................................3-7
Power Supply for AL 23..............................................................3-7
Lamphead for AL 15, 19, 20 .......................................................3-8
Power Supply for AL 19, 20........................................................3-8
Power Supply for AL 15..............................................................3-9
Lamphead for AL 100 .................................................................3-9
4Ballast / Tap Switch Wiring
AL 83 Ballast / Tap Switch Wiring ............................................. 4-1
AL 84, 85 Ballast / Tap Switch Wiring ....................................... 4-1
AL84-480 Ballast Wiring ............................................................4-2
AL 56 Ballast / Tap Switch Wiring ............................................. 4-2
AL56-480 Ballast Wiring ............................................................4-3
AL54 / AL55 Ballast / Tap Switch Wiring..................................4-3
AL54-480 / AL55-480 Ballast Wiring ........................................ 4-4
AL53/50 Ballast / Tap Switch Wiring......................................... 4-4
AL 35 Ballast / Tap Switch Wiring ............................................. 4-5
AL23 and AL20 Ballast Wiring .................................................. 4-5
AL 19 and AL15 Ballast Wiring ................................................. 4-6

0-2 94MS20 Rev. B4
5General
Path of Power to the PC Board....................................................5-1
Interlock System ..........................................................................5-1
Lamp Voltage ..............................................................................5-2
Lamp Power Path.........................................................................5-2
Trigger Board ..............................................................................5-3
Capacitors and Level Switching .................................................. 5-4
AL 83 Capacitor Assembly .........................................................5-4
AL 84 Capacitor Assembly .........................................................5-5
AL 84-480 Capacitor Assembly..................................................5-5
AL 85 Capacitor Assembly .........................................................5-6
AL 56 Capacitor Assembly .........................................................5-6
AL 56-480 Capacitor Assembly..................................................5-7
AL 54, AL 55 Capacitor Assembly.............................................5-7
AL 54-480, AL 55-480 Capacitor Assembly ..............................5-8
AL 53, AL 50 Capacitor Assembly.............................................5-8
Old Style AL 53, AL 50 Capacitor Assembly.............................5-9
AL 35 Capacitor Assembly .........................................................5-9
AL 25, AL 25-2 Capacitor Assembly........................................5-10
AL 23 Capacitor Assembly .......................................................5-10
AL 20, AL 19 Capacitor Assembly...........................................5-11
AL 15 Capacitor Assembly .......................................................5-11
Opening the Lamp Head............................................................5-12
Shutter........................................................................................5-12
Shutter Switch ...........................................................................5-13
Shutter Brake .............................................................................5-13
Shutter Motor.............................................................................5-14
Installing the Motor ...................................................................5-14
Shutter Removal ........................................................................5-14
LT1 Shutter Assembly Drawing................................................5-16
LT8 Shutter Assembly Drawing................................................5-18
Idle Setting................................................................................. 5-19
Lamp Head Blowers ..................................................................5-20
Blown Fuse on PC Board .......................................................... 5-20
Lamp Head Signals....................................................................5-21
Light Function States................................................................. 5-23
Printed Circuit Board Layout .................................................... 5-24
Signal Description ..................................................................... 5-25
Circuit Diagram (64MV407 60Hz) ..........................................5-27
Old Style (64MV210A) Control Board Layout.........................5-28
Signal Description (64MV210A) ..............................................5-29
6Check List for Troubleshooting and Service
Check List for Printing Light Troubleshooting and Service .......6-1

94MS20 Rev. B4 0-3
7Wiring Diagrams
Lamphead for AL 83, 84, 84-480, 85, 56, 56-480, 53, 54, 54-480,
55, 55-480, 50, 35, 25, 25-2, 23...................................................7-1
Lamphead for AL 100 ................................................................ 7-2
AL 83 Power Supply ..................................................................7-3
AL 84,85 Power Supply .............................................................7-4
AL 84-480 Power Supply ........................................................... 7-5
AL 56 Power Supply ..................................................................7-6
AL 56-480 Power Supply ........................................................... 7-7
AL 54,55 Power Supply .............................................................7-8
AL 54-480,55-480 Power Supply...............................................7-9
AL 53 Power Supply .................................................................7-10
AL 50 Power Supply ................................................................7-11
AL 35 Power Supply 60Hz......................................................7-12
AL 25-2 Power Supply ............................................................. 7-13
AL 25 Power Supply ................................................................7-14
AL 23 Power Supply ................................................................7-15
AL 20 Power Supply ................................................................7-16
AL 19 Power Supply ................................................................7-17
ALI 15 Power Supply...............................................................7-18
AL 15 Power Supply ................................................................7-19
Interconnect Cable for AL23, AL25, AL25-2, AL35, AL50, AL53,
AL83.......................................................................................... 7-20
Interconnect Cable for AL85, AL84, AL84-480, AL56, AL56-480,
AL55, AL55-480, AL54, AL54-480 .........................................7-21
8Fault Trees
No Strike Fault Tree ....................................................................8-1
Shutter Rotation Fault Tree ......................................................... 8-2
9AL 13 / AL 9
AL 13 Component Layout...........................................................9-1
AL 13 Control Board (64MV427C2) ..........................................9-2
AL 13 (120V~) Wiring Diagram ................................................. 9-3
AL 13 (220V~) Wiring Diagram ................................................. 9-4
AL 9, AL 9-PLUS Component Layout .......................................9-5
64MV427-Plus Board Layout for AL 9-Plus ..............................9-6
AL 9-Plus Wiring Diagram .........................................................9-7
64MV247 Board Layout for AL 9...............................................9-8
AL 9 Wiring Diagram..................................................................9-9
AL 9, AL 13 Cover Removal ....................................................9-10
Path of Power to the P.C.Board.................................................9-10
Interlock Systems ......................................................................9-10
Lamp Voltage ............................................................................9-11
Path Of Power To The Lamp..................................................... 9-11
Capacitors and Level Switching ................................................ 9-11

0-4 94MS20 Rev. B4
AL 9, AL 9 Plus Capacitor Wiring............................................9-12
AL 13 Capacitor Wiring ............................................................9-12
Shutter........................................................................................9-13
Shutter Switch ...........................................................................9-13
Shutter Motor.............................................................................9-13
Changing Shutter Motor Brushes ..............................................9-13
Steps to change shutter motor brushes. ..................................... 9-14
Idle Setting................................................................................. 9-17
Blower .......................................................................................9-18
Blown Fuse................................................................................9-18
Photocell ....................................................................................9-18
Photocell Rod Removal (AL9 Only) .........................................9-19
Shrouding The Lamp .................................................................9-19
10 Parts Lists
Parts Lists ..................................................................................10-1
11 Warranty
Limited Warranty ......................................................................11-1
Lamp Warranty.......................................................................... 11-1

94MS20 Rev. B4 1-1
1. Introduction
This manual is designed for technical personnel and is written to provide
an understanding of the equipment, as well as a plan for troubleshooting.
All OLEC lights respond to existing conditions. There are no fixed
cycles or timers. This allows the unit to respond correctly to conditions
that are not normal to operation, such as power failure or surges. Learning
what conditions cause the various responses will guide you to the
solutions.
This manual was written in several sections, each to provide information
in a different manner or specialized locations. Here is a quick guide to
the sections.
Features: A comparison between our lights and conventional light
sources, with an explanation of each feature, is provided to demonstrate
why we chose to design a light source so different from other sources.
Component Layout: Where to look for components referred to in the
manual.
Note: The AL9 and AL13 units are very similar. The AL15, ALI15,
AL19, AL20, AL23 (power supply only for the AL23) units are
very similar but some have fewer parts. The AL23 (lamphead
only for the AL23) AL25, AL25-2, AL35, AL50, AL53, AL54,
AL54-480, AL55, AL55-480, AL56, AL56-480, AL83, AL84,
AL84-480, AL85 and AL100 (power supply only for the AL100)
units are very similar but some have fewer parts. The AL100
lamphead shares some of the same internal components with the
other lampheads but the arrangement is quite different.
Troubleshooting: An outline of where to look for various symptoms.
This guide refers to the more detailed information in the general
information section that follows.
General: Contains specific information about the components in the
light and the path of the signals and power. It can be used for information,
or used with the troubleshooting guide.
Lamp Head Signals: Provides information about all the conductors to
the lamp head, their functions, and the voltages present.
Light Function States: A chart of the different functions the board
directs and the conditions that cause these functions. There is also a
description of the states.
Printed Circuit Board Pins: Provides the pin-outs from the printed
circuit board and an explanation of each.
Schematics: Full-unit schematics are provided. They are for the AL 9,
AL 13, AL 15, ALI 15, AL19, AL20, AL23, AL35, AL50, AL53, AL54,
AL54-480, AL55, AL55-480, AL56, AL56-480, AL83, AL84, AL84-
480, AL85, AL100.

1-2 94MS20 Rev. B4

94MS20 Rev. B4 2-1
2. Safety
Questions have been raised regarding the possible danger of exposure to
UV for equipment operators using high power lights. We address this
issue in terms of overall safety of such lights. OLEC lights are UL
approved and meet the strictest US electrical and safety standards,
including all OSHA requirements. Users and dealers should insist on
U.S. safety approval. It is required by law.
The Nature of UV
UV rays have been divided into three categories: UV“A” from 400-
315nm, UV“B” from 315-280nm, UV“C” for the shorter waves. UV
extends to about 10nm but air will filter out most rays shorter than 200
nm. To put this into perspective, the “near UV” or UV“A” is immediately
adjoining the visible spectrum extending from the color violet. Violet
extends to about 380 nm; red is at the opposite end of the visible spectrum
at 700 nm (see Illustration: Electromagnetic Spectrum). Most light
sources, including light bulbs, emit a certain amount of UV.
UV, Source of Health
Before one becomes unduly concerned with the harm UV can cause, it is
important to understand the many beneficial effects connected with
working outside and in bright areas with a certain amount of the “right”
UV. The germicidal effect, for instance, can rid the air of bacteria and is
used for that purpose extensively in hospitals. Exposure of the skin to
UV produces Vitamin D, necessary for the formation of bones and teeth.
Exposure to UV“A” is essential to life itself. Most life, human, animal
and plant, depends on it for growth and health.
Bad UV
One must avoid UV“B” and UV“C” even in small doses. UV“A” is
harmful only through overexposure. Never confuse the effects of UV
with the great harm that can be caused by microwave and X-ray radiation,
much of such damage being irreversible.
UV in Nature
Sunlight contains an abundance of UV, UV“A”, “B” and “C”, and the
negative effects of overexposure to sunshine have become well known.
These are primarily sunburn, sore eyes, headaches. Cataracts and skin
cancer are caused by prolonged exposure. Very damaging is the
erythematic energy, UV“B”, that penetrates the natural filter of ozone in
the upper layers of the atmosphere.

2-2 94MS20 Rev. B4
Ozone, UV“B” and UV“C”
No UV“C” is generated by OLEC lamps. OLEC lights and lamps use
“Ozone Free Quartz” for safety reasons to filter out most of the potentially
harmfulrays in theUV“B” region. Somemanufacturers do notuse “ozone
free quartz.” Such lamps require greatly enhanced protection through
safety glass, curtains, light tight housings, and special exhaust systems
to rid the air of ozone. If you smell ozone in your workplace, speak to
your supervisor or employer. DO NOT work under those conditions!
Safety Glass
Carefully selected safety glass is used on all OLITE UV lights under
the reflector. It filters out nearly all the remaining UV“B” so effectively
that any transmission is almost impossible to measure. This safety glass
is equipped with an important electrical interlock to prevent use of the
light if the glass is missing or installed improperly. Never use a light that
does not have a protective safety glass.
Light Leaks
Light heads that leak light around the safety glass during idling periods
should be avoided. Light above the safety glass always contains a certain
amount of UV“B”, particularly when NON-ozone free lamps” are used.
Poorly constructed light housings, with even small parts of the lighted
area of the lamp or the reflector visible during standby, can be dangerous.
Such lights are best used within an enclosure that is shut completely at
all times, especially during extended idling time. According to NIOSH,
UV“B” is quite different in its effect from UV“A.” It is cumulative and
between 600 to 1000 times as destructive.
Being exposed to constant UV leakage during idling time can quickly
exceed the daily maximum safe limit and eventually cause serious
personal damage. Never use or have anyone else use a light with leaks
past the safety glass (where you can see lamp or reflector from any
direction)!
Overexposure to UV
What constitutes overexposure to UV“A” should be considered in terms
of safe limits and the trade-off between documented health-promoting
effects of UV and danger of overexposure. For the UV“A” region, the
UV effecting exposure on film and plates, it is recommended that the
total radiant incidence on unprotected skin and eyes should not exceed
1.0 mW per cm2for periods longer than 1000 seconds (16 minutes). This
is the Standard, documented and recommended by the National Institute
for Occupational Safety and Health, NIOSH, a basis for OSHA.
For UV intensity under 1.0 mW per cm2there is no time limit. With
higher intensity the time should be reduced so that the total dose does
not exceed 1000 mW-sec/cm2(1 mW/sec = 1 mJoule).

94MS20 Rev. B4 3-1
3. Component Layout
Lamphead for AL 83, 84, 84-480, 85, 56, 56-480
31MOT06
Shutter Motor
39BLO14
Blower
64MV414
Trigger Board
55SW02
Shutter Position Switch
L1280, L1281 or L1282
Replacement Lamp
55SW03
Safety Interlock SwitchBlower
63D0142B03
Lamp Support Assembly
90RF83-C
45KOB05
Knob
Interconnect Cable To
Power Supply
62SA83-B
Shutter Assembly
PA91
Photocell 39BLO14 Reflector
Power Supply for AL 83
Terminal Strip
18 1
Power
Input
Power
Output
120 VAC
Coil Voltage
32TRC03
Autoformer 33RLY18 Power Relay
33RLY04
Mercury Relay
56FUS15
3Amp 250V 3AG
Slow Blow Fuse
52FUH04
Fuse Holder 32BAL01 Ballast
39BLO03
Blower
64MV407V04
Control Board 62D127-83 Capacitors
CL 83 Interconnect Cable
To Lamphead
53JKP01
Saftey
Interlock
Jack
55SW01
Rocker
Switches
62D331
Voltage
Selection
Switch
16D0334A18
Interconnect Cable
64MV422-83
Resistor
Board

3-2 94MS20 Rev. B4
Power Supply for AL 84
L1
T1 T2
L2
Power
Output
Power
Input
120 VAC
Coil Voltage
33RLY04
Sealed Relays 33RLY02
Power Relay
32TRC08
Autoformer
32BAL01
Ballast
52FUH04
Fuse Holder
39BLO03
Blower
64MV407-83
Control Board
53JKP01
Safety
Interlock
62D2652A00
Capacitor
Assembly
56FUS15
3Amp 250V 3AG
Slow Blow Fuse
18 Terminal Strip 1
CL 84
Power Supply for AL 84-480
L1
T1 T2
L2
Power
Power
120 VAC
33RLY04 33RLY02
32BAL01 52FUH04
39BLO03
64MV407-83
53JKP01
62D3533A00
56FUS15
18 Terminal Strip 1
Output
Input
Coil Voltage
3Amp 250V 3AG
Slow Blow Fuse
Sealed Relays Power Relay
Capacitor
Assembly
Safety
Interlock
Control Board Blower Fuse Holder Ballast
CL 84-480

94MS20 Rev. B4 3-3
Power Supply for AL 85
L1
T1 T2
L2
Power
Power
120 VAC
33RLY04 33RLY18
32TRC08
32BAL01
52FUH04
39BLO03
64MV407V04
53JKP01
62D1046-85
56FUS15
62D1047 Voltage
18 Terminal Strip 1
Output
Input
Coil Voltage
Sealed Relays Power Relay
3Amp 250V 3AG
Slow Blow Fuse
Autoformer
Capacitor
Assembly
Safety
Interlock
Control Board Blower Fuse Holder Ballast
Selection Switch
CL 85
Power Supply for AL 56
L1
T1 T2
L2
Power
Power
120 VAC
33RLY04 33RLY02
32TRC08
32BAL01
52FUH04
39BLO03
64MV407V04
53JKP01
62D2726A00
56FUS15
62D1047 Voltage
18 Terminal Strip 1
Output
Input
Coil Voltage
Sealed Relays Power Relay
3Amp 250V 3AG
Slow Blow Fuse
Autoformer
Capacitor
Assembly
Safety
Interlock
Control Board Blower Fuse Holder Ballast
Selection Switch
CL 56

3-4 94MS20 Rev. B4
Power Supply for AL 56-480
Power
Output
Power
Input
120 VAC
Coil Voltage
32TRC08
Autoformer
32BAL01
Ballast
52FUH04
Fuse Holder
39BLO03
Blower
64MV407V02
Control Board
53JKP01
Safety
Interlock
Jack
62D2723B00
Capacitor
Assembly
56FUS23
3Amp 250V 3AG
Slow Blow Fuse
L1
T1 T2
L2
33RLY04
Sealed Relays 33RLY02
Power Relay
18 Terminal Strip 1
2 1
CL 56-480
Lamphead for AL 53, 54, 54-480, 55, 55-480, 35, 25, 25-2, 23
64TR408
Trigger Board 62SASE-SW
Shutter Assembly L1250, L1252, L1261
Replacement Lamp 62D142
Lamp Support Assembly
39BLO03
Blower
31MOT06
Shutter Motor
90RF53-SW
Reflector
45KOB05
Knob
55SW03
Safety Interlock Switch
39BLO03
Blower
PA91
Photocell
55SW02
Shutter
Position
Switch

94MS20 Rev. B4 3-5
Power Supply for AL 53, AL 50
32TRC01
Autoformer
56FUS15
3Amp 250V 3AG
Slow Blow Fuse
52FUH04
Fuse Holder 32BAL01 Ballast
39BLO03
Blower
64MV407V03
Control Board 62D127 Capacitors
CL 53
CL 50
Interconnect Cable
To Lamphead
53JKP01
Saftey
Interlock
Jack
55SW01
Rocker
Switches
62D331
Voltage
Selection
Switch
16D0334A18
Interconnect Cable
64MV422V00
Resistor
Board
62D331
Voltage
Selection
Switch
on older
units
L1
T1 T2
L2
33RLY18
Power Relay
Terminal Strip
18 1
Power
Input
Power
Output
120 VAC
Coil Voltage
33RLY04*
Sealed Relay
* Older AL50 units
used just one of
these relays
Power Supply for AL 54, 55
L1
T1 T2
L2
Power
Power
120 VAC
33RLY04 33RLY02
32TRC01
32BAL01
52FUH04
39BLO03
64MV407
53JKP01
62D104
56FUS15
62D1047 Voltage
18 Terminal Strip 1
Output
Input
Coil Voltage
Sealed Relays Power Relay
3Amp 250V 3AG
Slow Blow Fuse
Autoformer
Capacitor
Assembly
Safety
Interlock
Control Board Blower Fuse Holder Selection Switch Ballast

3-6 94MS20 Rev. B4
Power Supply for AL 54-480, 55-480
L1
T1 T2
L2
Power
Power
120 VAC
33RLY04 33RLY02
32BAL01
52FUH04
39BLO03
64MV407
53JKP01
62D3654A00
56FUS15
18 Terminal Strip 1
Output
Input
Coil Voltage
Sealed Relays Power Relay
3Amp 250V 3AG
Slow Blow Fuse
Assembly
Capacitor
Safety
Interlock
Control Board Blower Fuse Holder Ballast
Power Supply for AL 35
32TRC01
Autoformer
56FUS15
3Amp 250V 3AG
Slow Blow Fuse
52FUH04
Fuse Holder 32BAL01 Ballast
39BLO03
Blower
64MV407V03
Control Board 62D127-35 Capacitors
CL 35
Interconnect Cable
To Lamphead
53JKP01
Saftey
Interlock
Jack
55SW01
Rocker
Switches
62D331
Voltage
Selection
Switch
16D0334A18
Interconnect Cable
64MV422V00
Resistor
Board
L1
T1 T2
L2
33RLY18
Power Relay
Terminal Strip
18 1
Power
Input
Power
Output
120 VAC
Coil Voltage
33RLY04
Sealed Relay

94MS20 Rev. B4 3-7
Power Supply for AL 25-2, AL 25
32TRC01
Autoformer
on AL 25-2
units ONLY
32BAL01
Ballast
39BLO03
Blower
64MV407V03
Control Board 62D126 Capacitors
CL 25-2
CL 25
Interconnect Cable
To Lamphead
53JKP01
Saftey
Interlock
Jack
55SW01
Rocker
Switches
16D0334A18
Interconnect Cable
64MV422-25
Resistor
Board
62D331
Voltage
Selection
Switch
on AL 25-2
units ONLY
L1
T1 T2
L2
33RLY18
Power Relay
Terminal Strip
18 1
Power
Input
Power
Output
120 VAC
Coil Voltage
33RLY04
Sealed Relay
Power Supply for AL 23
16D0334A18
Interconnect
Cable
54PWR04
Power Cord
64MV407V03
Control
Board
62D2753A00
Capacitor Assembly 33RLY08
Power Relay
Medium Relay
High Relay
32BAL01
Ballast
53JKP01-1
Safety
Interlock Jack
55SW01
Rocker
Switches
62BLO15
Power Supply Fan
32TRC01
Autoformer
CL 23

3-8 94MS20 Rev. B4
Lamphead for AL 15, 19, 20
16D271
Interconnect Cable
PA85
PA91
Photocell
31MOT06
Shutter
Motor
55SW02
Shutter
Position
Switch
55SW04
Safety
Interlock Switch
64TR408-T
Trigger
Board
63D0142B00
Lamp Support Assembly
45KOB05
Knob
62RA Reflector Assembly
For AL15 ONLY
62RA-1 Reflector Assembly
For AL19 / AL 20 ONLY
39BLO03-15
Blower
L1150A or L1250E Lamp for AL15 ONLY
L1250E Lamp for AL19 /AL 20 ONLY
Power Supply for AL 19, 20
16D0334A18
Interconnect
Cable
64MV407V03
Control
Board
62D139-3A
Capacitor Assembly 33RLY08
Power Relay
Medium Relay
High Relay
32BAL01
Ballast
53JKP01-1
Safety
Interlock Jack
55SW01
Rocker
Switches
62BLO15
Power Supply Fan
32TRC01
Autoformer
AL 20 units
ONLY
CL 19 / 20

94MS20 Rev. B4 3-9
Power Supply for AL 15
16D0334A18
Interconnect
Cable
64MV407V03
Control
Board
62D139
Capacitor Assembly 33RLY08
Power Relay
Medium Relay
High Relay
32BAL01
Ballast
53JKP01-1
Safety
Interlock Jack
55SW01
Rocker
Switches
62BLO15
Power Supply Fan
CL 15
Lamphead for AL 100
Note: AL100 uses two AL53 power supplies
45KOB05
Knob 64MV414 Trigger Board
64MV414
Trigger Board
55SW02
Shutter Position Switch
31MOT06
Shutter
Motor
39BLO03
Blower
16D334
Interconnect
Cables
55SW04
Safety Interlock
Switches (Qty. 2)
L1250, L1252 or L1261
Replacement Lamps
62D142
Lamp Support Assembly
11D599
Rear Reflector
11D1442
End Reflector
39BLO03
Blower
PA89
Photocell
39BLO03
Blower
63D1437
Shutter Assembly
64TR468
Safety Interlock
Interconnect
Board

3-10 94MS20 Rev. B4