Olec Accuprint AP30-5000 User manual

PP
AP30 - 5000 AP30 - 8000
High Resolution Printer
Service Manual
94MS36 Rev. F2 S/W Ver 2.06 O

94MS36 Rev. F2 S/W Ver 2.06
This manual is designed for technical personnel
and should only be used by authorized Dealer
service personnel.
This manual is written to provide an
understanding of the equipment, as well as a plan
for troubleshooting.

94MS36 Rev. F2 S/W Ver 2.06 0-1
0. Contents
1. Specifications
Crated dimensions .......................................................................1-1
Shipping weight...........................................................................1-1
Actual dimensions .......................................................................1-1
Effective exposure frame area ..................................................... 1-1
Optional reflectors .......................................................................1-2
Intensity .......................................................................................1-2
Cooling ........................................................................................1-2
Exhaust ........................................................................................1-2
Room Air Supply.........................................................................1-2
Water Drain .................................................................................1-2
Electrical specifications and connections ....................................1-3
Connecting power........................................................................1-4
2. Integrator Functions and Features
Integrator .....................................................................................2-1
Feature Quick Reference ............................................................. 2-3
Operator Control Panel ................................................................2-4
Table Showing the 12 Calibration Positions ............................... 2-4
Calibration Procedures ................................................................ 2-4
Changing the Calibration Number............................................... 2-6
Matching Exposure Surfaces .......................................................2-7
Splitting Steps.............................................................................. 2-8
Matching with a meter................................................................. 2-8
3. Integrator Program Set Up
To Enter the Select Mode ............................................................3-1
Lock Level Feature ......................................................................3-1
Lock Level Description and Operation .......................................3-2
Setting or Changing your Lock Code feature ..............................3-3
To Clear Lamp Statistics .............................................................3-3
To Clear Memory and Exposure Statistics .................................. 3-3
Two Value Exposure Mode.........................................................3-4
Split Exposure Mode ...................................................................3-4
Single Surface Mode ................................................................... 3-5
Board Count Display Mode.........................................................3-5
Frame Control Interface Mode ....................................................3-6
Automatic Vacuum Mode ...........................................................3-6
Auto Step Mode...........................................................................3-7
Set Default Vacuum Delay..........................................................3-7
Tray Mode ...................................................................................3-8
Type Mode................................................................................... 3-8
Exposure Statistics (Elapsed Hours)............................................3-9
Exposure Statistics (Total Exposures).........................................3-9

0-2 94MS36 Rev. F2 S/W Ver 2.06
Selecting a Memory Location....................................................3-10
Quick Keypad ............................................................................3-10
Entering an Exposure Time .......................................................3-10
Setting the Light Intensity ......................................................... 3-11
Making an exposure...................................................................3-11
Blank frame cycle...................................................................... 3-11
Error Handling System .............................................................. 3-12
4. Diagnostics
Output Diagnostics ......................................................................4-1
Output Functions Check ..............................................................4-1
Functions Table ...........................................................................4-2
Input Diagnostics......................................................................... 4-3
Typical values that you will see when all switches are good. .....4-3
Typical values that you will see when a fault occurs. .................4-4
5. Lamp Changing Instructions
Lamp Changing Instructions .......................................................5-1
6. Preventive Maintenance
Preventive Maintenance Daily.....................................................6-1
Preventive Maintenance Monthly................................................ 6-1
Preventive Maintenance Semi-Annually.....................................6-1
7. Vacuum System
Vacuum Pumps............................................................................7-1
Flushing the Pump.......................................................................7-1
Pump Disassembly ......................................................................7-2
Pump Checkout ...........................................................................7-2
Pump Replacement ......................................................................7-3
Tubing/Fitting Replacement ........................................................7-3
Vacuum Gauge Replacement ......................................................7-3
Vacuum Seal Replacement..........................................................7-4
Glass Photo Tool (Optional)........................................................7-6
8. Nose Assembly
Removing the Nose .....................................................................8-1
Replacing the Display and Keypad P.C.Board............................8-1
Replacing the Emergency kz Button ...........................................8-1
Replacing the Sand GButtons ..........................................8-2
Replacing the Glass Tool Vacuum Buttons.................................8-2
Replacing the Vacuum Gauges....................................................8-2
Nose Section Autoformer ............................................................8-2
Work Lights................................................................................. 8-3
Nose Fans ....................................................................................8-3
Cleaning or Replacing Nose Filters.............................................8-3
Nose Assembly Drawings ........................................................... 8-4

94MS36 Rev. F2 S/W Ver 2.06 0-3
9. Exposure Trays
Mylar® Replacement ..................................................................9-1
If Mylar® Pulls Out of the Frame ...............................................9-1
Outer Frame Replacement ...........................................................9-1
Tray Assembly Drawing..............................................................9-3
Mylar Frame Assembly ...............................................................9-5
Gas Strut Removal.......................................................................9-7
Replacing the linear bearings ......................................................9-7
Frame Glass Replacement ...........................................................9-8
Gas Strut Replacement ................................................................9-8
10. Center/Drive Assembly
Center/Drive Assembly Diagram ..............................................10-1
Frame Transport System............................................................10-3
Frame Drive Motor Replacement ..............................................10-3
Frame Drive Clutch Adjustment................................................ 10-3
Frame Speed Adjustment........................................................... 10-4
Adjust the 'FAST' pot on the control box. .................................10-5
Light Block Assembly...............................................................10-6
Replacing Lower Light Block Springs ...................................... 10-7
11. Air Conditioning System
Compressor................................................................................ 11-1
Inlet Filter ..................................................................................11-1
12. Diagrams
Control Box Front View ............................................................12-1
Control Box Wiring Diagram (Standard with 5kW) .................12-3
Control Box Wiring Diagram (Standard with 8kW) .................12-4
Control Box Wiring Diagram (480V all) ..................................12-5
Control Box Wiring Diagram (CE all) ......................................12-6
Unit Cabling Diagram (old nose) ..............................................12-7
Unit Cabling Diagram (new nose).............................................12-8
Unit Wiring and Tubing Diagram .............................................12-9
Base Assembly Diagram ......................................................... 12-10
13. Light Source
Component Layout ....................................................................13-1
Ballast/Tap Switch Wiring ........................................................ 13-5
Interlock System ........................................................................13-8
Lamp Voltage ............................................................................13-9
Lamp Power Path....................................................................... 13-9
Trigger Board .......................................................................... 13-10
Capacitors and Level Switching ..............................................13-11
Opening the Lamp Head..........................................................13-15
Shutter......................................................................................13-16
Shutter Switch .........................................................................13-16
Shutter Brake ...........................................................................13-16

0-4 94MS36 Rev. F2 S/W Ver 2.06
Shutter Motor...........................................................................13-17
Installing the Motor .................................................................13-17
Shutter Removal ......................................................................13-18
LT1 Shutter Assembly Drawing..............................................13-19
LT8 Shutter Assembly Drawing..............................................13-21
Idle Setting...............................................................................13-22
Lamp Head Blowers ................................................................13-23
Blown Fuse on PC Board ........................................................ 13-23
Lamp Head Signals.................................................................. 13-24
Light Function States...............................................................13-25
Printed Circuit Board Layout ..................................................13-27
Signal Description ................................................................... 13-28
Circuit Diagram (64MV407 60Hz) ........................................13-30
Lamphead for all Lights .......................................................... 13-31
AL 54 Power Supply 60Hz....................................................13-32
AL 54-480 Power Supply 60Hz ............................................13-33
AL 64 Power Supply 50Hz....................................................13-34
AL 84 Power Supply 60Hz....................................................13-35
AL 84-480 Power Supply 60Hz ............................................13-36
AL 94 Power Supply 50Hz....................................................13-37
Interconnect Cable................................................................... 13-38
14. Printing Light Check List
Check List for Printing Light Troubleshooting and Service .....14-1
15. Fault Trees
No Strike Fault Tree ..................................................................15-1
Shutter Rotation Fault Tree .......................................................15-2
16. Parts List
Parts List .................................................................................... 16-1
17. Warranty
Limited Warranty ......................................................................17-1
Lamp Warranty..........................................................................17-1

94MS36 Rev. F2 S/W Ver 2.06 1-1
1. Specifications
45"
38"
48.5"
45.5"
35"
89" with A/C
81"
72"
Crated dimensions
Length Width Height
95" 60" 80"
241 cm 152 cm 203 cm
Shipping weight
Crated 1600 lbs. 727 kg.
Uncrated 1375 lbs. 625 kg.
Actual dimensions
Cabinet welded heavy gauge steel construction with access doors on both
sides.
Length Width Height
89" 48.5" 81"
226cm 123cm 206cm
Note: The AP 30 - 5000 cannot be disassembled to pass through any
doorways or hallways. Please make sure there is adequate room
for its passage.
Effective exposure frame area
Width 30" 76 cm
Depth: 25" 64 cm

1-2 94MS36 Rev. F2 S/W Ver 2.06
Optional reflectors
Width 24" 61 cm
Depth: 18" 46 cm
Intensity
Low Medium High
AP 30-5000 1kW 2.5kW 5kW
AP 30-8000 2kW 4kW 8kW
Cooling
A self-contained air conditioning system is integrated into the rear of the
AP 30-5000 / AP 30-8000.
Exhaust
Two exhaust ducts, diameter 8 in.(203 mm)
To minimize the impact on the working environment, the exhaust must
be vented to the outside, a heat exchanger or up through a dropped ceiling.
A/C Filter
Rear
Front
36"
Power
36" 36"
Top View
Room Air Supply
The exposure lamp cooling air is drawn from the exposure room. The
ventilation system must be sized to maintain positive pressure in the
exposure room for cleanliness and to avoid drawing chemical fumes into
the printer.
Water Drain
A water drain or sump pump is necessary for the air conditioner
condensation.

94MS36 Rev. F2 S/W Ver 2.06 1-3
Electrical specifications and connections
Earth
Ground
L1 L2
L1 L2 L3
Figure A
380 / 415V~ 50Hz Connection
Wye: 3 Wires + Neutral + Ground
Terminal Block
N
380 / 415V~
OLITE
Power Supply
Blowers
Vacuum
Pumps
Electronics
Drives
Etc.
L3
N
Earth
Ground
L1 L2
L1 L2 L3
Figure B
208/240V~ 50Hz Connection
DELTA: 3 Wires + Ground
Terminal Block
N
208V~
OLITE
Power Supply #1
Blowers
Vacuum
Pumps
Electronics
Drives
Etc.
L3
208V~
OLITE
Power
Supply #1
Earth
Ground
L1 L2
L1 L2 L3
Figure C
480V~ 60Hz Connection
DELTA: 3 Wires + Ground
Terminal Block
480V~
OLITE
Power Supply #1
Blowers
Vacuum Pumps
Electronics
Drives, Etc.
L3
X1 X2 X3
480V~
OLITE
Power
Supply #2
X1
X2
X3
X4 H1 H2
H3
H4
L1 L2 L3
Blowers
Vacuum Pumps
Electronics
Drives, Etc.
X1 X2 X3
X1
X2X3
X4
H1 H2 H3 H4
480V~ OLITE
Power Supply #1
Earth
Ground
L1 L2
Figure D
480V~ 60Hz Connection
Single Phase: 2 Wires + Ground
Terminal Block
480V~ OLITE
Power Supply #2

1-4 94MS36 Rev. F2 S/W Ver 2.06
AP 30 - 5000 printer input
3 phase (Delta) See Figure C 3 wires + ground 480V~ 60 Hz, 18 amp.
3 phase (Delta) See Figure B 3 wires + ground 208/240V~ 60 Hz, 44 amp.
3 phase (Wye) See Figure A 3 wires + neutral + ground 380/415V~ 50 Hz, 24 amp.
Single phase See Figure D 2 wires + ground 480V~ 60Hz, 35 amp.
AP 30 - 8000 printer input
3 phase (Delta) See Figure B 3 wires + ground 208/240V~ 60 Hz, 65 amp.
3 phase (Wye) See Figure A 3 wires + neutral + ground 380/415V~ 50 Hz, 34 amp.
Connecting power
•Remove the lower rear panel of the printer by unscrewing the 5/32" Allen
head screws that attach it. Remove the two screws from the rear that
secure the sliding side doors. Slide both doors to the front.
•Run the main power cord through the round retaining plate on the lower
rear center of the printer.
•Connect the main leads to the 4-position terminal block and connect the
ground lead to the single ground terminal.
•Energize the main power circuit. You should hear the lamp head and
power supply cooling fans go into a cool-down cycle. Ensure that the
voltage select switch on the hinged control panel is switched to the lit
LED.
•Reinstall the lower rear panel. Make sure the air conditioner drain hose
is uncoiled and connected to a drain or allowed to drain into a suitable
container.
•Reinstall the side door securing screw.
•Installthe lower front and rear black trim pieces over the forklift channels,
using a 5/32" Allen wrench.
•Connect two 8" exhaust hoses to the outlets on the top rear of the printer.
This will remove the expended heat from the working environment.
!Cl PLEASE BE SURE THE DUCT HOSE IS VENTED TO AN OPEN CHAMBER, AS BACK PRESSURE WILL
GREATLY REDUCE THE COOLING CAPABILITIES OF
THE PRINTER.