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AutoCure 6000 AC6-4238 Manual
- AutoCure 6000 AC6-4238 Manual [ English ]
Assembly and Operating Manual
AC6-4238 – TABLE OF CONTENTS
1. WARNINGS AND DANGER ........................................................................................ 4
• WARNING, CAUTION & NOTE .................................................................................. 5
2. EQUIPMENT SAFETY GUIDELINES
• CAUTION! ....................................................................................................................... 6
• Lamps, Pyrometer Positioning Beam, Environment ......................................................... 7
3. OPERATING INSTRUCTIONS
• Temperature Controllers Single or Double Ramp Operation ............................................ 8
• Temperature Controller Displays ..................................................................................... 8
• Cycle Start Button, Heater Position ................................................................................. 8
• Setting the Temperature Controller Parameters .............................................................. 9
4. LAMP INSTALLATION AND REPLACEMENT INSTRUCTIONS
• DANGER!! Precautions for Handling Quartz Infrared Lamps ......................................... 10
• CAUTION!! Lamp Instruction/Replacement Procedure .................................................. 10
5. HEATER POSITION INSTRUCTIONS
• General Instructions (Read All) ...................................................................................... 11
• Heat Masking ................................................................................................................ 12
• Positioning/Set-up of Heater Head Instructions ........................................................ 12-13
• Yellow Pendent (for overhead arm movement) .............................................................. 14
6. MAINTENANCE
• Actuator & Pivot Points .................................................................................................. 15
• Lamps, Reflectors and Heat Sensor (Pyrometer) Lens .................................................. 15
7. TROUBLESHOOTING GUIDE
• Heater Power Problems ................................................................................................ 16
• Temperature Controller Problems .................................................................................. 17
• Temperature Problems .................................................................................................. 18
8. TEMPERATURE CONTROLLER ERROR CODES ......................................................... 19
9. PYROMETER ASSEMBLY (DRAWING# AC-61231 – 4 pgs) ...................................... 20-23
10. SERVICE INSTRUCTIONS FOR PYROMETER ........................................................... 24
• Old and New Raytek Units (2 pgs) ............................................................................ 25-26
• Replacement of New Pyrometer Sensor (2 pgs) ....................................................... 27-28
• Replacement of Pyrometer Controller (2 pgs) ........................................................... 28-29
• Verification / Calibration Procedure .......................................................................... 30
• Begin Verification / Calibration Cycle ...................................................................... 31
• Verify Lock Status of Raytek Comm Module .......................................................... 31
• Adjusting Raytek Calibration Procedure (3 pgs) .................................................. 32-34
• Begin Calibration Cycle ........................................................................................... 34
• Calibration Adjustment ............................................................................................. 35
• Lock Out the Comm Box ............................................................................................ 36
11. BACK PANEL/BILL OF MATERIAL
• Dual Head (2 pgs) ................................................................................................ 37-38
12. JUNCTION BOX ...................................................................................................................... 39
13. MECHANICAL DRAWINGS/PARTS LIST (3 pgs) ............................................................. 40-42
14. TABLES (4 pgs) ................................................................................................................. 43-46
15. AUTOCURE MODEL NUMBERS ............................................................................................. 47
• AC6-4238-240-PL ............................................................................................................... 48
• Electrical Schematic (2 pgs) ..................................................................................... 49-50
• Spray/Bake .................................................................................................................... 51
• Heater Heads (5 pgs) ............................................................................................... 52-56
• Recommended Spare Parts .......................................................................................... 57
• AC6-4238-380-PL ............................................................................................................... 58
• Electrical Schematic (2 pgs) ..................................................................................... 59-60
• Spray/Bake .................................................................................................................... 61
• Heater Heads (5 pgs) ............................................................................................... 62-66
• Recommended Spare Parts .......................................................................................... 67
• AC6-4238-480-PL ............................................................................................................... 68
• Electrical Schematic (2 pgs) ..................................................................................... 69-70
• Spray/Bake .................................................................................................................... 71
• Heater Heads (5 pgs) ............................................................................................... 72-76
• Recommended Spare Parts .......................................................................................... 77
• AC6-4238-480-SP ............................................................................................................... 78
• Electrical Schematic (2 pgs) ..................................................................................... 79-80
• Spray/Bake .................................................................................................................... 81
• Heater Heads (5 pgs) ............................................................................................... 82-86
• Recommended Spare Parts .......................................................................................... 87
• AC6-4238-575-PL ............................................................................................................... 88
• Electrical Schematic (2 pgs) ..................................................................................... 89-90
• Spray/Bake .................................................................................................................... 91
• Heater Heads (5 pgs) ............................................................................................... 92-96
• Recommended Spare Parts .......................................................................................... 97
• AC6-4238-575-SP ............................................................................................................... 98
• Electrical Schematic (2 pgs) ................................................................................... 99-100
• Spray/Bake .................................................................................................................. 101
• Heater Heads (5 pgs) ........................................................................................... 102-106
• Recommended Spare Parts ........................................................................................ 107
16. BGK-CARLISLE FLUID TECHNOLOGIES CUSTOM PRODUCTS WARRANTY .................. 108
1. Warnings and Danger
DANGEROUS VOLTAGES ARE
PRESENT IN THIS EQUIPMENT!
CONTACT WITH LIVE PARTS
COULD CAUSE
SERIOUS INJURY OR DEATH!
CONNECTION, INSTALLATION, MAINTENANCE,
ADJUSTMENT, SERVICING AND OPERATION TO BE
DONE BY QUALIFIED PERSONNEL ONLY.
ENSURE THAT EQUIPMENT IS COMPLETELY
AND PROPERLY GROUNDED BEFORE APPLYING
SUPPLY POWER AND BEFORE EQUIPMENT
OPERATION.
EN
www.carlisleft.com Manual AC6-4238
(Revised 03/2021)
In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:
Read the following warnings before using this equipment
! WARNING
! WARNING NOTE
or
in
! WARNING
or
in minor
! CAUTION
AUTOMATIC EQUIPMENT
Automatic equipment may start suddenly without warning.
INSPECT THE EQUIPMENT DAILY
Inspect the equipment for worn or broken parts on a daily basis. Do not
operate the equipment if you are uncertain about its condition.
NEVER MODIFY THE EQUIPMENT
Do not modify the equipment unless the manufacturer provides written
approval.
NOISE HAZARD
You may be injured by loud noise. Hearing protection may be required when
using this equipment.
READ THE MANUAL
read and all safety,
and maintenance in the
TRAINING
All must be before equipment.
EQUIPMENT HAZARD
can cause the to or start
and result in injury.
LOCK OUT / TAG-OUT
Failure to de-energize, disconnect, lock out and tag-out all power sources
before performing equipment maintenance could cause serious injury or
death.
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment instruction
manual.
KEEP EQUIPMENT GUARDS IN PLACE
Do not operate the equipment if the safety devices have been removed.
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE
OF AN EMERGENCY
WEAR SAFETY GLASSES
Failure to wear safety glasses with side shields could result in serious eye
injury or blindness.
PROJECTILE HAZARD
You may be injured by venting liquids or gases that are released under
pressure, or flying debris.
STATIC CHARGE
Fluid may develop a static charge that must be dissipated through proper
grounding of the equipment, objects to be sprayed and all other electrically
conductive objects in the dispensing area. Improper grounding or sparks can
cause a hazardous condition and result in fire, explosion or electric shock and
other serious injury.
PROP 65 WARNING
WARNING: This product contains chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
WEAR RESPIRATOR
Toxic fumes can cause serious injury or death if inhaled. Wear a respirator
as recommended by the fluid and solvent manufacturer’s Safety Data Sheet.
TOXIC FLUID & FUMES
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in
the eyes or on the skin, inhaled, injected or swallowed. LEARN and KNOW the
specific hazards or the fluids you are using.
FIRE AND EXPLOSION HAZARD
Improper equipment grounding, poor ventilation, open flame or sparks can
cause a hazardous condition and result in fire or explosion and serious injury.
MEDICAL ALERT
Any injury caused by high pressure liquid can be serious. If you are injured or
even suspect an injury:
Go to an emergency room immediately.
Tell the doctor you suspect an injection injury.
Show the doctor this medical information or the medical alert card
provided with your airless spray equipment.
Tell the doctor what kind of fluid you were spraying or dispensing.
GET IMMEDIATE MEDICAL ATTENTION
To prevent contact with the fluid, please note the following:
• Never point the gun/valve at anyone or any part of the body.
• Never put hand or fingers over the spray tip.
• Never attempt to stop or deflect fluid leaks with your hand, body, glove
or rag.
• Always have the tip guard on the spray gun before spraying.
• Always ensure that the gun trigger safety operates before spraying.
It is the of the to this to the of the
For see the
PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are basically any areas where
there are moving parts.
2. Equipment Safety Guidelines
(Read and understand this manual before operating equipment.)
CAUTION!!
1. Turn power off at source before servicing equipment or attempting any electrical or
mechanical maintenance, especially lamp replacement.
2. If the control panel main power switch is ON, voltage may exist at the lamps even
though the lamps are not emitting light. AN ELECTRICAL SHOCK COULD POSSIBLY
RESULT!
3. Heater head(s) contains high voltage. Do not insert metallic objects into cooling louver
openings.
4. Before applying supply power, make sure the AutoCure arm(s) are grounded properly
before equipment operation.
5. Before each operation of the AutoCure arm(s), inspect the repair arm(s) heater
lamp(s). If any lamps are broken or break at any time, shut the power off and
discontinue use. When the damaged or broken lamp(s) are replaced by the qualified
personnel, turn the power back on.
6. This is an automatic piece of equipment. Heater can very quickly come on to full
intensity without warning to unaware personnel.
7. Heater surfaces can become hot when used at high power for extended periods. Use
caution whenever handling heater head(s). The heater head(s) have black insulated
handles to use for moving or manipulating heater head(s).
8. Do not move heater when in operation because it will move the temperature sensor
viewing area and the heater head's distance to product. If the heater accidentally
moves, check temperature sensor viewing area with the Positioning Beam and
verify acceptable positioning of heater head.
9. Use care when manipulating or positioning heater head(s) and arms. Avoid possible
pinch points.
10. The positioning beam/pyrometer must be aimed at the surface target to be heated.
If it is not properly aimed at the surface target, (i.e. aimed into open air) the pyrometer
will read a lower temperature causing the unit to go to high lamp intensities for
abnormal time lengths. If used in this condition for extended period of time, it can
damage the unit.
11. When the unit is NOT in operation, the E-stop button MUST be pressed for safety
of personnel, unit, and other material/equipment in vicinity of the heater head(s).
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LAMPS
All lamp end covers and grills must be installed before operating and using the repair arms to avoid
electrical shock.
The lamps of the repair arms have similarities to a standard incandescent light bulb. During the
repair arm curing cycle, the repair arm lamps can sometimes emit bright light similar to a standard
incandescent light bulb. As you would with an incandescent light bulb, we high recommend you
DO NOT STARE DIRECTLY INTO THE BRIGHT LIGHT.
DO NOT HANDLE INFRARED LAMPS WITH BARE HANDS. Remove any contamination with
alcohol and a clean, soft cloth. Contamination on quartz tubes allows the quartz to overheat, which
leads to premature lamp failure.
PYROMETER POSITIONING BEAM
A class 2 laser emits in the visible region (635-870mN) at 1mW of power. The blink reflex of the
human eye (aversion response) will prevent eye damage, unless the person deliberately stares
into the beam for an extended period. DO NOT STARE INTO THE BEAM.
ENVIRONMENT
Heater head contains high voltage connections that are open to atmosphere. These units are not
air-purged. Ensure use of unit is acceptable in the area in which it will be used.
3. Operating Instructions
Temperature Controller Single or Double Ramp Operation (See Figure 1)
Single Ramp Operation: The temperature ramps in a predetermined amount of time from
ambient to a set point temperature and holds at that temperature for a required amount of
time.
Double Ramp Operation: The temperature ramps in a predetermined amount of time from
ambient to the first set point temperature and holds at that temperature for a required amount
of time, it then ramps in a predetermined amount of time to a second set point temperature and
holds at that temperature for a required amount of time.
Temperature Controller Displays
The upper display indicates the mode of the heating cycle and the process temperature. During
the Ramp mode the upper display will toggle between the process temperature and ramping.
Once the cure temperature (set point) has been reached the upper display will toggle between
the hold time remaining (in minutes) and the process temperature. When the hold time becomes
less than one minute the upper display will toggle between the hold time remaining (in seconds)
and the process temperature. The lower display indicates the cure temperature (set point).
Cycle Start Button
The product will heat to the set point temperature and remain there for the time selected. The
hold time will start when the temperature reaches 15°F before set point.
Heater Position
If the heater is too far from the product, the temperature will not be reached and the hold
timer will not be activated.
Setting the Temperature Controller Parameters (See Figure 2)
Single Ramp
1. Turn power on.
2. Turn positioning beam on and position heater.
3. Set controller parameters
4. Hold the button for 1-2 seconds
a. Set rp1 (ramp time) in minutes
Press
b. Set ct1 (cure temp) in degrees
Press
c. Set hd1 (hold time) in minutes
Press
d. Set rp2 = 0 (this disables 2nd ramp)
Press
5. Press the to exit setup menu
6. Set auxiliary heater off or on
7. Press the cycle start
Double Ramp
1. Turn power on.
2. Turn positioning beam on and position heater.
3. Set controller parameters
4. Hold the button for 1-2 seconds
a. Set rp1 (ramp time) in minutes
Press
b. Set ct1 (cure temp) in degrees
Press
c. Set hd1 (hold time) in minutes
Press
d. Set rp2 (2nd ramp time) in minutes
Press
e. Set ct2 (2nd cure temp) in degrees
Press
f. Set hd2 (2nd hold time) in minutes
Press
5. Press the to exit the setup menu
6. Set auxiliary heater off or on
7. Press cycle start
Figure 2
4. Lamp Installation a nd Replacement Instructions
Danger!!
Turn power off at source before removing end covers and servicing lamps. A fatal electrical shock
could possibly result.
Precautions for Handling Quartz Infrared Lamps
Do not handle infrared lamps with bare hands. Remove any contaminations with alcohol and a
clean, soft cloth. Contaminations on quartz tubes cause the quartz to overheat, which may lead to
premature lamp failure.
Caution!!
If lamps are replaced, with lamps having metal ends, metal ends must be removed to permit
proper assembly and prevent the possibility of arcing or shorting.
Lamp Installation / Replacement Procedure
1. Make sure main system circuit breaker is OFF.
2. Rotate heater so lamps are horizontal.
3. Remove end covers to gain access to lamp leads.
4. Disconnect wire from the ceramic terminal block and remove lamp that is being replaced.
5. Carefully slide the lamp through the lamp support.
6. Remove electrical insulation sleeves from the old lamp on both lamp leads and install them on the
new lamp leads. Push the sleeve to the ceramic end of the lamp (see drawing below).
7. Secure the lamp lead to the power wire coming into the heater at the ceramic terminal block.
8. Install end covers.
NOTE: If lamp leads are too tight, damage to lamp may result.
Make sure lamp sleeving
is pushed all the way into
ceramic end of lamp Lamp Support
(outer reflector)
End Cover
Ceramic terminal
in heater head
Ensure all bare wire is
contained up to terminal
(trim lead if necessary) Heater Power Co
5. Heater Position Instructions
Important: Precautions and Instructions
General Instructions (Read All)
1. The Positioning Beam (red dot) is an aid for proper placement of the heat sensor. The
heat sensor reads an area of 0.8 to 1.2 diameter depending on the heater's distance from
the surface. The sensor takes an average temperature reading of the
area and displays it on the temperature controller. Note: the red dot is not at the
exact center of the sensing area. As you face the control panel the dot is 3/4 to
the left of the heat sensor.
2. Make sure the heat sensing area is reading a painted surface. If the sensing area is
positioned incorrectly and is partially reading tape, masking, trim, plastic, rubber, a
window, or a wheel well, it will measure an average temperature much higher or
lower than the actual temperature of the painted surface. Thus, the heater will
possibly overheat the area and scorch the paint, or not heat the part enough and the paint
will not be cured.
3. The heater head distance from the product is important. If the heater head is too far
away, the product will not reach cure temperature and will run indefinitely trying to get to
temperature. If the heater head is to close striping may occur. The recommended
distance of the heater face to the product is 8 -12. The heater should be as parallel as
possible to the product surface, which helps maintain uniform heating over the heated
area.
4. Before heating a repair, determine if there are any types of reinforcements or extra
thicknesses of metal in the area to be cured. These areas will heat at different rates
and not achieve the same temperature as the single thickness metals without
reinforcements. Aim the heat sensor on, or near, the multiple thickness or reinforced
areas so they will be fully cured.
5. Once the cycle has started, do not move the unit. This will cause the temperature sensor
to see a different area, which may be cooler. If the temperature drops 18°F, it will reset
the timer and run another complete cycle. To help the unit's stability, be sure to lock the
casters on the base of the arm after positioning the heater to lock it in place.
6. Check the control panel 3 to 5 minutes into the cycle. See if the temperature has risen to
set point and if the timer has started. If it hasn't, determine the problem and correct it. If
there is a problem with the position or setup of the arm where it cannot achieve the set
point temperature, the timer will not turn on. The heater will run at full intensity indefinitely.
7. To achieve a full cure on a repair area, including overspray, the effective cure area of
the heater must be considered. The effective cure area of the rectangular shaped heater
heads is an oval shape that is just slightly smaller than the heater head. A general rule for
the effective cure area dimensions are 1 in from the sides and end covers of the
heater head, which creates the outer boundaries of the oval. When main and auxiliary
heater heads are used together, add the two areas together.
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Heat Masking
1. Any heat sensitive materials or surfaces (including plastic, rubber, trim, pin stripes,
decals, light lenses, mirrors, door handles, interior materials, etc.) in the heating area
must be masked or removed during the heating cycle. High temperature/reflective
masking material approved for this type of application is required.
2. When curing small areas, it is not recommended to use heat masking around the area
except to cover heat sensitive materials. The heat sensor sees an area
approximately 1 in diameter, a heating area that is 1.5 or smaller could result in a
false reading if the heat sensor is reading the masking.
Positioning / Set-Up of Heater Head Instructions
Positioning / Set-Up of an arm on flat surfaces (doors, hood, roofs, trunk lids, etc.)
1. Follow any of the instructions previously mentioned in the precautions and instructions
section.
2. Always position heaters parallel and 8 to 12 from the surface.
3. Aim the positioning beam on spot being repaired; make sure that the beam is not aimed
at heat sensitive materials.
4. Engage caster locks.
5. Recheck heat sensor aim with the positioning beam.
6. Set the temperature and time settings.
7. Start heat cycle.
8. Approximately 3-5 minutes after start, check that the temperature is at set point and the
timer has started.
9. When the timer and the heater lamps shut off, the cycle is complete and ready for the
next repair.
10. Press the E-stop button on unit when cycle has completed before moving unit to next
repair or in to storage position.
Positioning / Set-Up of a heater on a curved or contoured surfaces (fender, hood, roof, trunk corners)
1. Follow any of the instructions previously mentioned in the precautions and instructions
section.
2. Always position heaters parallel and 8 to 12 from the surface. Adjust the A and B heaters
to the contour of the curve, with the most direct heat radiation in the area of the repair.
3. Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at
heat sensitive materials.
4. Engage caster lock.
5. Recheck heat sensor aim with the positioning beam.
6. Set the temperature and time settings.
7. Start heat cycle.
8. Approximately 3-5 minutes after start, check that the temperature is at set point and the
timer has started.
9. When the timer and the heater lamps shut off, the cycle is complete and ready for the next
repair.
10. Press the E-stop button on unit when cycle has completed before moving unit to next
repair or in to storage position.
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Positioning/Set-Up of an arm on roof posts (heavy reinforcements/multiple metal thickness)
1. Follow any of the instructions previously mentioned in the precautions and instructions
section.
2. Position heaters parallel to the surface, the length of the heater along the length of the
roof post. Do not put the heater 90° to the post, unless the repair area is very small.
The heater should be about 8 from the surface for the heavy reinforcement in the
posts.
3. Aim the positioning beam on spot being repaired; make sure that the beam is not aimed
at heat sensitive materials. The post is very narrow, so carefully position the heat
sensor where it will see the post.
4. Engage caster lock.
5. Recheck heat sensor aim with the positioning beam.
6. Set the temperature and time settings.
7. Start heat cycle.
8. Approximately 3-5 minutes after start, check that the temperature is at set point and the
timer has started.
9. When the timer and the heater lamps shut off, the cycle is complete and ready for the
next repair.
10. Press the E-stop button on unit when cycle has completed before moving unit to next
repair or in to storage position.
Positioning/Set-Up of an arm on rocker panels (heavy reinforcements/multiple metal thickness)
1. Follow any of the instructions previously mentioned in the precautions and instructions
section.
2. Position heaters parallel to the surface, the length of the heater along the length of the
rocker panel. If there is an auxiliary heater head, use both heaters and bend them at
about a 135° angle to focus more direct heat around the curve of the rocker panel. The
heater should be spaced about 8 from the surface for the heavy reinforcement in the
rocker panel.
3. Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at
heat sensitive materials
4. Engage caster lock.
5. Recheck heat sensor aim with the positioning beam.
6. Set the temperature and time settings.
7. Start heat cycle.
8. Approximately 3-5 minutes after start, check that the temperature is at set point and the
timer has started.
9. When the timer and the heater lamps shut off, the cycle is complete and ready for the next
repair.
10. Press the E-stop button on unit when cycle has completed before moving unit to next
repair or in to storage position.
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1. While running a cycle without a second ramp set up in the controller, operator may
toggle the start button a second time resulting in bypassing the ramp feature.
2. While running a cycle with a second ramp set up in the controller, operator may toggle
the start button a second time resulting in bypassing both ramps and going directly to
second cure temperature without ramping feature.
3. Pushing the E-stop button will stop the current heating cycle.
NOTE: These are procedures that give reliable results for most repairs. Unusual or
complex repairs might need modified procedures. Contact BGK service for
assistance.
Yellow Pendent (for overhead arm movement)
The yellow pendant has a button labeled Beam On and Start. Toggling the Beam on
activates the position beam and toggling the start button will initiate the heating cycle. Refer
to Setting the Temperature Controller Parameters in the Operating Instructions for further
instructions.
The controller has the following programmed features which allow the operator some
flexibility on running heating cycles:
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6. Maintenance
The AutoCure™6000 will require some basic maintenance when used on a regular basis. Failure to
do so may degrade the performance of the unit.
Disconnect main power at the source before performing any maintenance procedures.
Actuator
1. Periodically check clevis ends for wear, cracks or distortion.
2. Periodically check the shoulder bolt/nut and 3/8 diameter rod for excessive wear.
3. Periodically apply a few drops of oil at these pivot points.
Pivot Points
1. Single head units have three (3) castle nut/spring combinations and two (2) shoulder bolts with
Nylock nuts. If pivot points become loose, heater positioning will not be maintained. Check
these points monthly.
2. Dual head units have seven (7) castle nut/spring combinations and two (2) shoulder bolts with
Nylock nuts. If pivot points become loose, heater positioning will not be maintained. Check
these points monthly.
3. To adjust spring tension; remove cotter pin, tighten castle nut (usually one or two notches) and
replace cotter pin through bolt.
Lamps, Reflectors and Heat Sensor (Pyrometer) Lens
1. Clean with soft cloth and alcohol monthly. Heat sensor accuracy is dependent on a clean lens.
Tension Spring/
Castle Nut
Nylock Nut Tension Spring/
Castle Nut (4)
(under heater skin)
Tension Spring/
Castle Nut (2)
Tension Spring/
Castle Nut (2)
Single Head Dual Head
Pyrometer
7. Troubleshooting Guide
Heater Power Problems
Problem
Heater lamps come on immediately when disconnect is closed.
Possible Cause and Corrective Action
• With power OFF, measure the resistance from the lamp wires to ground. The
measurement should be more than 100 K ohms. If it is less than 100 K, check the lamp wiring
and heater head for shorts to ground. Check for a bad firing circuit board or a shorted SCR
by: exchanging the firing circuit board with one from a known good control. Does the problem
follow the firing circuit board or does it stay with the SCR – replace the defective component.
• Contactor held closed – failed ON. Replace the contactor.
Problem
Heater lamps do not come on.
Possible Cause and Corrective Action
• Is the Power On/Off button illuminated, is the temperature controller on? - Check that
incoming line power is present; transformer fuses, primary and secondary are good.
• Do the contactors energize when the Cycle Start button is pressed? – Check for loose wires
associated with the contactors,change the temperature controller.
• Check that the set point (bottom display) is higher than the process temperature (top
display).
• Are the line fuses in front of the contactors good – check voltage on the load side of the
fuses or remove the fuses and check with an ohmmeter.
• Is the green LED on the firing circuit lit? – Check that the firing circuit has 24 vac, with an
ammeter check that the 4-20ma input signal is present from the temperature
controller. If the 4-20ma signal is not present, see the section No Output Signal
from Temperature Controller.
• Do any of the zones function? – If the above points have been checked, confirm that
there is a complete circuit through the lamps and all wiring is tight – change the
SCR.
• Are all zones dead? – Zone A should function regardless of the zone switch setting, there is
only one firing circuit for all zones - change the firing circuit
Temperature Controller Problems
Problem
Temperature controller has no display.
Possible Cause and Corrective Action
Check the supply voltage (24 VAC) to the unit at terminals 11 and 12. If voltage is
present, replace the controller. If voltage is not present, check source of power (fuses,
transformers, wiring, etc.)
Problem
No output signal from temperature controller.
Possible Cause and Corrective Action
• Check that the set point (bottom display) is higher than the process temperature
(top display).
• Check the 0-5v input to the temperature controller at pins 9 & 10. If the 0-5v
signal is not present, confirm that the Raytek pyrometer is functioning.
• Is the LCD display lit? If not, check that the Raytek input power (12 vdc) is
present, check that the power supply board is supplying 12 vdc (TB 4) – replace
the temperature controller, Raytek, or the power supply board.
Problem
Temperature controller output signal is present, but heater lamps do not come on.
Possible Cause and Corrective Action
Possible defective power controller firing circuit board and/or SCR. Check for a bad
firing circuit board or SCR by exchanging the firing circuit board with one from a
known good control. Does the problem follow the firing circuit board or does it stay
with the SCR – replace the defective component.
Problem
Positioning Beam does not work
Possible Cause and Corrective Action
Check that the power supply board is supplying approximately 3.25 vdc (TB 3). Check that
the wires are secure on the power supply board and on the push button. Open the cover on the
Heat sink assembly on the back of the heater and retest for the 3.25 v. If the power supply is
functioning and there is no voltage at the heat sink assembly, open the Raytek pyrometer
and test for the voltage (the 2 wire nuts) – replace the Positioning Beam.
• Check for loose connections on the heat sensor (pyrometer) wiring.
• While the heater is running at temperature, gently wiggle the pyrometer
cable and have someone watch for sudden temperature changes. If this
happens – replace the cable.
Problem
The temperature display jumps up or down many degrees within a second.
Possible Cause and Corrective Action
• Read the instructions in the manual on how to position and run the heater.
• Clean the temperature sensor lens as described in maintenance section.
• The optical pyrometer is not seeing the surface of the object being heated. The
pyrometer has about a 1-inch diameter field of view on the objects’ surface. Position the
heater head with the pyrometer so it sees the surface being heated. Make sure the
pyrometer is not seeing parts of a window, wheel well, tape, masking, etc.
Temperature Problems
Problem
The heater reaches set-point temperature, but the paint isn't cured properly or is darkened,
or the heater does not reach set-point temperature.
Possible Cause and Corrective Action
Display
Err.H
Err.L
LPbr
0100
0101
0202
0303
3865
36 Plus other
2 digit code
Problem
Open Sensor
Reversed Sensor
Loop Break
Checksum Error
RAM Error
Defaults Loaded
EEPROM Write Failure
Power Fail Resume
Feature Disabled
Unexpected or invalid
interrupt
Actions
Check sensor,wiring,
and input
Check Sensor
polarity
Correct problem and
Reset controller
Press Any Key to
perform a soft reset
and reinitialize
controller
No further resume
actions available
Reset Controller
Ramp/ Soak Errors
02= Recipe Empty (i.e. no non-zero ramp times)
05= Insufficient Setpoint - Process Value Deviation
8. Temperature Controller Error Codes
4
r=J
o7
-
D
�
-
0-U
C �
---j;,
B
ITEM QTY
l l
3 1
4 2 X 2
5
8 1
9 1
10 l
11 1
- 12 l
13 l
14 2
15 2
16 2
17 2
18 1
19 2
20 2
A 21 2
22 28
23 35
24 35
25 2
26 2
27 1
4
I 3 ,:I, 2 I 1
REVISION HISTORY
1 REV DESCRIPTION DCO DATE APPROVED
B UPDATEDBOM 18943 8/16/12 RAN
C ADDED NEW PYROMETER 19524 8/16/13 RAN
D CHANGED 6655-01 TO AC-200077, 6655-05 20079 1/21/15 RAN TO AC-200078
CHANGED QTY OF #18 FROM 2 TO 1 AND
0
0 0
E REMOVED REF QTYS ON PAGE 2 20168 3/13/15 RN
� ( n � MOVED NOTES 1-2,4-7. REVISED NOTE 8.
, ..
.o
b
REMOVED NOTES 2,9,10. ADDED 18
' b
F ASSEMBLY NOTES. RENUMBERED NOTES. 20425 8/31/2015 EAO
REMOVED FRONT AND BOTTOM VIEW
0
'
®
b FROM SHEET 1
'
®
b
F+ CORRECT REVISION 20482 10/20/2015 EAO
G WAS AC-200052-1 20832 5/26/16 EAO
0
' b ADDED NOTE FOR MOUNT FLUSH,
b RENUMBERED FOLLOWING NOTES, WAS
b H SEED CRIMPER, REVERSE DIRECTION OF 30856 1/11/2017 EAO CONNECTORS ON BLACK/ BROWN WIRE
Jo
I I..' SHEET 4, ADD LENGTH OF TAPE TO NOTE
0 TT�o
6
l_�B
�l,Z!�i!1
FL..U/0 TEC::HNCJLOGIES
BGK
A�l3t=IIUVO
NOTES:
TOP VIEW 1. OPEN HOUSING AND LOOSEN 4 TERMINALS TO REMOVE PYROMETER.
PARTS LIST
PART NUMBER DESCRIPTION
42936 PYROMETER SENSOR
AC-200026 PYROMETER WIRE CUP
TR-SSEM·283 SHRINK TUBING
AC-65427 LASER
AC-61229 PLATE INTERMEDIATE
AC-61228 INSULATOR PYROMETER
AC·61227 MOUNT INSULATOR
AC-61232 HOUSING PYROMETER
AC-61230 COVER PYROMETER
AC-200099-3 SCREW MACH FL HD SLOT 8-32
X2.750
AC-200032 STANDOFF HEX 8-32 X .750
AC-13938 WASHER LOCK EXTERNAL
AC-10142 SCREW MACH TRUSS PH 8-32 X
3/8
AC-200088 CAUTION LABEL
AC-200031 FEMALE CONNECTOR
AC-200030 MALE WIRE CONNECTOR
AC-200033 CABLE SLEEVE
AC-200052-4 (Gl MESH
AC-200077 BROWN WIRE
AC-200078 GREEN WIRE
72591-01 WHITE CABLE SLEEVE
AC-200034 WIRE NUTS
STRAIGHT-THROUGH STRAIN AC-200026 RELIEF
I
2. LOOSEN NUT AND REMOVE NUT, GROMMET, AND 3 WASHERS. DISCARD
ONE WASHER.
NOTES (CONTD): 6. WRAP 3.3 COPPER TAPE AROUND PYROMETER TO ENSURE RUNNING m
(USE AC-200198). WRAP 4.5 OF TAPE AROUND LASER {AC-65427) @
21. APPLY SHRINK TUBING ONTO MESH AFTER TRIMMING WIRES TO
7. APPLY THERMAL JOINT COMPOUND USING APPUCATOR AND SPREAD
ACROSS ENTIRE CIRCUMFERENCE (USE AC-200199),
8. CENTER PYROMETER AND LASER TO THROUGH HOLES WHILE ASSEMBUNG
PLATES.
9. INSTALL LASER FACE FLUSH WITH HEAT SINK @
10. STRIP BACK 5/16 MINIMUM.
11, ASSEMBLE WITH TOOL HEYCO NO. 29.
12. ASSEMBLE WITH WEIDEMUELLER 901250. @
13. ASSEMBLE WITH KUNE CRIMPER 1005.
14. STRIP BACK 1/4 MINIMUM.
15. USE TOOL TO INSTALL TERMINALS ONTO WIRES.
16, INSTALL FLEXIBLE CONDUIT AROUND WIRES.
17, INSTALL SHRINK WRAP.
18. INSTALL CABLE THROUGH PYROMETER HOUSING.
19. INSTALL GROMMET OVER SHRINK WRAP INTO PYROMETER HOUSING.
•-Clilll!J __ ,................. 1:30 I BDl-
/
2. �Ire ... ,_>., - Clilll!I
.. = t,.11:D.....,,. .. .,.
l!!IClilll!leJ . 3.��(l,dd-)•- Clilll!J ==�-Cl'rcrCII
�Q�.l,;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;,l,.....,.....,.,J. ______ 0�
0
·----------==•�-=------
' -
.,31,,__ 0r• BGK. �- ,.._,_
�DMD PROOIJCT 1- 1-- 1-r:;• ;t!
x;;-� REPAIR ARM 1-- 1-- l�/07119 i'
:;-�AL l£AO ARM l;;,;2' l�M-x:;-;;;ilJ1
1
1
2
2
3
3
4
4
A A
B B
2 PLACE: FRACT:
3 PLACE: ANGULAR:
TOLERANCESDRAWN:
SCALE:
DRAWN DATE:
MATERIAL:
FINISH: DRAWING NO: REV: SHEET:
OF
THIS MATERIAL IS THE PROPERTY OF BGK FINISHING SYSTEMS
IT MUST NOT BE COPIED OR IT'S CONTENTS DISCLOSED WITHOUT
AUTHORIZATION z 2012 BGK FINISHING SYSTEMS
1 1 B
C Lameyer
.03 1/32
.015 9/4/2012
JUNCTION BOX,STD,8X6X6,AC6
AC-200188DEBURR SHARP EDGES
SIZE:
JOB NO:
QTY AS SHOWN (-1): QTY OPPOSITE (-2):
PROJ MGR: REL DATE:
NEXT ASSY:
-
CTL
Parts List
DESCRIPTIONPART NUMBERTYPEQTYITEM
6 CUT DIN RAIL-P11
J-BOX,8X6X6A8066CHP12
INNER PANEL,8X6A8P6P13
AB IEC ONE CIRCUIT FEED THROUGHT BLOCKAC-200058P34
AB END ANCHORAC-200059P25
AB END BARRIERAC-200060P16
AB IEC ONE CURCUIT FEED THROUGH GND BLOCKAC-200061P17
ITEM 1
ITEM 5
ITEM 4
ITEM 6
ITEM 4
ITEM 4
ITEM 5
ITEM 7
ITEM 2
ITEM 3
PURCHASE COMPLETE FROM:
MCKINLEY HILL CORP.
651-717-1700
=m
12 � AC,3IOS
A m
®7,Z!l-i!=I
FL.LJIC TECHNCJLCJG/ES
Ir---�
I
�----+--
r
DETAIL D
0-VIEWOusEAC-3832NYll�!11r-crt:m�rnlJ7':���rcu;��-�1A
NEXTAlJB'f: PNUNO: DRAWINGNO:
BGK
A ®/;ltA-if=I BRAND
REYISION HISTORY
TABLE AAA HEAD CORD & UNE CORD PLUS MTG
HARDWARE
0-----VIEW C HANGE 0-QUANTTIYOWIGE I APP DATEI DCO IDESCI REV
Al
AC6 - BREAK DOWN TOTAL AMP LAMP WIRINCii USE SUB-ASSY HEATER HEAD
VOLTAGEOPllON DESCRIPllON DRAW DETAIL UNIT(AC6) PRINT
2116-380-SP
211�SP
2116-575-SP
2125-240-f>L
2125-480-f)L
◄125-240-f>L
◄138-240-PL
◄138-380-fl
◄138-48(),p_
2216-240-PL
i 2216-380-SP
221�SP
2216-575-SP
2225-240-SP
2225-JSO,SP
2225-57S-SP
e@ ◄225-240-PL
◄225-380-fl
◄225-480.f'I.
◄225-575-f'I...
◄225-57S-SP
NOTES:
2116-240I 1600 Watt
5/ngleHead
2ll6-380V1600Watt
Single Head
2ll6-480I 1600 Watt
5/ngleHead
2116-57SV 1600 Watt
Single Head
2125-240I 2500 Watt
Single Head
2125-480I 2500 Watt
Single Head
4125-240I 2500 Watt
5/ngleHead
4125-480I 2500 Watt
5/ngleHeod
4138-240I 3800 Watt
5/ngleHeod
4138-arallel AC-682<8 AQ-16-2116
M7 Series-flarallel AC-<82<8 AQ-16-2116
7.35 Series-hrallel AC-<82<8 AQ-16-2116
7.16 Parallel AC-68248 AQ-16-2125
10.◄2 Parallel AC-<82<8 AQ-16-2125
1◄.33 Parallel AC-<82<8 A0t&-0125
20.83 Parallel AC-68248 A0t&-0125
16.n Parallel AC-68248 A0t&-0138
21.◄2 Parallel AC-68248 A0t&-0138
24.3 Parallel AC-68248 A0t&-0138
26.67 Parallel AC-<82<8 AQ-16-2216
17.09 ffi]Series-hrallel AC-<82<8 AQ-16-2216
13�3 Series-hrallel AC-<82arallel AC-<82<8 AQ-16-2216
1◄.33 Series-Parallel AC-682<8 AOl&-2225
18.36 Series-hrallel AC-68248 AOl&-2225
20.83 Parallel AC-68248 AOl&-2225
7.90 Series-hrallel AC-68248 AOl&-2225
28.66 Parallel AC-<82<8 A0t&-0225
36.73 Parallel AC-<82<8 A0t&-0225
41.67 Parallel AC-68248 A0t&-0225
[!]20.83 Series-hrallel AC-<82<8 A0t&-0225
45.93 Parallel AC-<82 AC-14242- W/�IOX
AC-54945
AC-54945
AC-54945
AC-54945
AC-549COOD
PAIUNo.
AC-200081·7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
& AC-200081-7
AD
HEAD CORD+ LOCK NUT
HEATER HEAD
AC-200115-3,AC-200117·1
AC-200115-3,AC-200117·1
AC·20011S-3,AC·200117·1
AC·20011S-3,AC·200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-l
AC-200081-7 £:i_ AC·20011S-3,AC·200117-t
AC-200081-S AC·20011S-3,AC·200117-1
&AC-200081·7 £:i_ AC·20011S-3,AC·200117·1
AC-200081-Sfr., AC-200115-J,AC-200117·1
,q,,
I&.
AC-200081-<I AC-200115-8,AC-200117·1
AC-200081-7 & AC-200115-3,AC-200117-1
AC-200081-7 AC·20011S-3,AC·200117·1
AC·.54945 AC-200006 & AC-200081-7 AC-200115-3,AC-200117-1
AC·.54945
AC-54945
AC·.54945
AC-54945
AC·.54945
AC-200125-3
AC-200125-3
AC-200125-3
AC-200125-3
AC-200125-3
AC-200125-3
AC-200194-2 AC-200081-7
AC,200006
AC-200006
-02 AC-200006
A
-OZ AC-200194-2
A
-01 AC-200006
-01 AC-200006
-01 AC,200006
AC-200006
AC-200194-2
-01 AC-200194-2
AC-200081-S
AC-200081-S&
AC-200081-7
AC-200081-7
AC-200081-S
AC-200081-S
AC-200081-S
AC-200081-7
I& AC-200081_.&
AC-200081·7 £:i_
CONTINUED ON SHEET 2
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-8,AC-200117·1
AC-200115-3,AC-200117-l
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC·20011S-3,AC·200117·1
AC-20011�·200117-�
AC-200115-8,AC-200117·1
D-oESCRIPTION OIANGE (}--ASSEMBLY a-t.ANGE
t:,,�-PARTOIANGE
◊-A DDED
iY ACl IJNE�!. l!ll AG AH2
ADl coO:�� No.,==.,-.· UNe!fo.,,. Afl ��.,.•• AGlLOO<Nurll'l
15
15
IS
IS
15
IS
15
15
15
15
15
15(X2)(E
1S(X2)
1S(X2)
1S(X2)
1S(X2)
IS(X2)
1S(X2)
1S(X2)
1S(X2)
1S(X2)
lS(X2)
1S(X2)
1S(X2)
lS(X2)
AC-200081·7 AC-200115-4,AC-200117-2 l �
AC-200081-7 AC-200115-4:c-200117-2
AC-200081-7 AC·200115-4,AC·200117·2 1 �
AC-200081-7 AC·200115-4�·200117·2
AC-200081·7 AC-200115-4,AC-200117-2 l �
AC-200081-7 AC-200115-4,AC-200117-2 �
AC-200081-7 AC·200115-4,AC·200117·2 1
AC-200081·5 AC·200115-4,.tC·200117·2 t
AC-200081·7 AC·200115-4,AC·200117·2 1
AC-200081·5 AC-200115-4,AC-200117-2 1
AC-200039
AC-200042
AC-200042
AC-200042
AC-200042
.b.AC-200039
AC-200037
AC-200038
AC-200037
AC-200038
AC-200081-4 AC-200115-2,AC-200117·2 t & AC-200040
AC-200081-4 AC-200115-2�200117-2 2@ AC-200037
AC-200081-7 AC·200115-4,AC·200117-2 2
AC-200081-7 AC-200115-4�-200117·2 2
AC-200081-7 AC-200115-4,AC-200117-2 2
AC-200081-7
AC-200081·7
�
AC-200115-4,AC-200117-2 2
AC-200115-4,
AC-200117·2
AC-200081-S AC-2001151F·200117-2 2
,&AC-200042
AC-200042
AC-200042
:1 AC,2000<2
nt,AC-200039
AC-200039 �
AC-200081·7 AC·200115ifC·200117·2 2 & AC-200041 1!1
AC-200081-4 AC-200115-ftC-200117-2 2 ,&. AC-200037
AC-200081-3 AC-200114-f'C·200117-3 2 al, AC-200037
AC-200081-2 AC-200114-tdf·200117-3 2 AC-200038
AC-200081-7 AC·20011�·200117-2 2 bt.AC-200039
AC-200081-2 AC·200114-�-200117·3 2 AC-200038
AC-200081·7 AC·200115mf·200117·2 2 £AC·200039
•&
4. SP· REQUIRES WRITTEN DEVIATION BY ENGINEERING DOOJMENTARY SPECIAL
SET11NGS AND OR CABlE LENGTHS
7. MAX POWER SET11NG 75%
5. SOME UNITS REQUIRE ONE UNE CORD SEE TABLE A TO DETERMINE IF 1WO
2. BECAUSE OF THE QTY'S Of MATERIALS THICKINESS, THE VARIENCE Of TOLERANCES MAY REQUIRE A COMBINATION Of ITEMS 4 AND 5. ARE REQUIRED (J(2XX-XXX-XX VOLTAGE OP'TIONS REQUIRE 1WO CORDS)
8. ATTACH CAUTION TAG, AC-200105
TO UNE CORD USING AC-200013 TIE.
ENSURE A CORREoW0LTAGE LABEL IS
PLACED ONTO TAG
3. CONNECT CABlE TO PYROMETER FOLLOW COLOR CODING ON PYROMETER ASSY.
8 I 7 I
@-= l,l!l---l!=I
FLLJICJ TECHNCJLCJGIES
I
6. QTY VARIES
I
9. MAX POWER SETTlNG 60%
3 I
SEESHT.4
�
Al l!'l All
AC-200191-<I
AC-200191-3
al, AC-200191-1
AC-200191-<I
AC-200191-3
AC-200191-<I
AC-200191-l
AC·200191-<I
al, AC-200191·2
AC-200191-3
AC-200191-<I
al, AC-200191-2
AC-200191-l
£ AC-200191-1
AC-200191-<I
AC-200191-2
AC-200191·3
£ AC-200191-1
AC-200191-<I
AC-200191-2
AC-200191-3
AC-200191·3
Lfi AC-200191-1
£ AC-200191-1
°'''
AU10Cll!E6000
I
AC-200193-2
AC-200019
REF
AC-200193-3
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200193-3
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200193-3
AC-200019
REF
AC-200193-2
AC-200019
REF
AC-200019
REF
AC-200193-3
AC-200191-3
BGK
A ®/&!t-i!#I BRAND
AUTOCURE 6000 MODEL NUMBERS
AC6-4238-240-PL
AC6-4238-380-PL
AC6-4238-480-PL
AC6-4238-480-SP
AC6-4238-575-PL
AC6-4238-575-SP
lamiller
Cross-Out
AC6-4238-240-PL
100
-101
-102
-103
-104
-105
-106
-107
-108
-109
-110
-111
-112
-113
-114
-115
-116
-117
-118
-119
-120
-121
-122
-123
-124
-125
ru 1,1,t-1,=1
FLUID TEC::HNCJLCJGJES
BGK
A ®/flt.Li!=# BRAND
J-BOX 111D ON END
FES100N 00R) (SIZED FIii 1£A1ER LOAD) HEATER CONTROL
IJF�WAY CON 11D
/,,- L1 ----------------------·----1-•��l--,!.-'-!,,....��.!:L1!.+-------+- 108
CRDAClU 106
CYCI.E/E-SltlP
�'1� 0RG (15) ,..._
4 3 .,,., 1211
PB 108 -
I LINEN! AC1UA10R 1.-i 24VdcMOTilR
AC1UA10R UP LIIIT
+.
a:ti5
____;:4
2
7c:...1 -+++-'ll.ll'J/=BIU<,._,(.:;•41l'L...f CR
--:11,f�C...l&-,,.<'1,;;1-1111=T_. (:28,,,8,_l --<l--+I �f----11
8,
0
_, � REDJluc lrn A'I r � BU 113
� t
BU< (30)
-
;ie� 37
AC1UA10R �30 AC1UA10R
IP LIIIT Ill! �---------' t':.?�
he
ORG• 1311 �
l:: =
BAN 1321 =-
� ------- I I I
OOAD 104
§ § I I I
j FU 106 ' �u •-1D=---__.1 __________ _._1-'1D ____ ,=-_=ai_-
12 - � 1 ,.,. H1R I
�
10 IIJ(
11
240V
.� . )
CON111
I �CR1)<11 I 13 fl 11'-,.'0--'1-4---,
ISCR103 I 1
I
(+lo (-! 2a 6 SCR B -ail .Ill &1 T 1 250VA ...fR'h
'IJill. � iz. • � LT 1()81 ,.'llV, I
J� SCR FIING QRCUIT I
I,�, l+l ...
0 (+)I (-)1
15 18 17 4-20ma 18
...flUlllll.... -115506-!!r, 18 I
17
_,,,, ;:; 1111T 1181 18 I
18
I
�
- �1211 P�8
All 6
l....+-.....:i,:.... ..... -�+RED='=':...,1�11n-----+l---1�7+---<�--17Cl--o 5 4
-:::
(+)1
_ BUJ k:-' �
HEATER ARM
(F)
(-) (+)
9 10
<) 24 25
GND
(F)
AUXILIARY
HEATER
-f�:
M
22
SS 11B
_ 0RG 1211 21 fF22H)8 COi 0
r=--,.. - GAN• 1221 22 221
2J
�4-<@-----+-+---t---l-------t_-5==.......:::�X�tORG=:','::'
,.,
,.'-',.�
-.l
----t+--'2J=-f----+ll-----'RED 1221 =
'IEI. (?-,
0-!IY
- -
BU<_,, = ll.ll (241 -
(SPN<t./ ...,, X 1111Tl25l
24
25
P'IR 118 PYROIIElER • 1C
• 00T 1
enc,•rn:2 ef1C3 j4RELAY
.. RELAY
(SEE MECIWICAL BILL IJF IIAlEJIAI,)
MTD ON MAIN HEATER
(F)
LASTIUIBERUSED43
F1EID - (F)
I ALL WIRING/COMPONEN1S SHOWN Wl1H DASHED UNESIl_ ARE SUf!UED AND/OR INSl'AU..ED BY lHE INSrALLER;:!
l'::if ff8l �t� FUSI
*
1
1� 8.02D' 33.43! 18.72A LPCC 20
I
**THIS DOCUMENT APPLIES IF YOUR SYSTEM IS EQUIPPED WITH A
SPRAY/BAKE SWITCH
Small junction box to interlock controls during spraying.
Maximum Load: 40A FLA, 50A Resistive
Four configurations:
240V 1ø 480V 1ø
240V 3ø 480V 3ø
2 Modes of Operation
Local: There is a 2 position switch on the front of the box to switch from Spray to Bake.
The 2 terminals for the remote mode must be jumped.
Remote: There are 2 terminals to connect a remote dry contact from another control.
The switch must be in the bake position if the remote contacts are used.
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
RECOMMENDED SPARE PARTS
TO ORDER:
CONTACT: SPARE PARTS ORDER ENTRY
PHONE: 1-800-726-8097
E-MAIL: orderentry@CarlisleFT.com
AC6-4238-240-PL
Reference Number
Spares
Qty
Part Number Part Description
CON110, CON111 1 005898 CONTACTOR, 40A, 2-POLE, 24 COIL
FU105 4 E-178 FUSE,2A,600V,CLASS CC
FU109A, FU109B 4 AC-200046 FUSE,2A,250VAC,TIME DELAY
FU109C, FU109D 4 AC-200045 FUSE,10A,250VAC,TIME DELAY
FU101A, FU101B, FU104A,
FU104B
4 AC-200037 FUSE, LOW PEAK CLASS CC, 20A
INST116 1
AC-74816-240-F-
100
TEMP. CONTROLLER (Setup-100%, F deg, 240v)
PROX116 1 AC-200024 SWITCH, INDUCTIVE PROXIMITY
PWRSUP123 1 AC-46847 POWER SUPPLY,24VAC - 12VDC & 3.25VDC
SCR 103 FC 1 003317
Firing Circuit Board-PWR CTRLR,4-20MA,240V, 380V,
480V
SCR 103, SCR 104 1 002985 POWER CONTROLLER,SCR,40A, 240V, 380V, 480V
103 2 AC-200051 POWER CONTROLLER THERMSTRATE,H
CR110A, CR110B, CR116 1 062486 RELAY,1 PDT,24VDC/AC
1 AC-200064 LASER KIT (Targeting laser only)
PYR 118 1 AC-61231 PYROMETER ASSEMBLY KIT (Complete)
Bridge 110 1 062001 RECTIFIER,BRIDGE,25A,50V
1 AC-73709 ACTUATOR
SS114 1 064558 SELECTOR SW OP, 2 POS,MAINT
2 AC-39917 HANDLE, PLASTIC, TAPERED 3/8-16
1 AC-73841-8 PENDANT, 4-BUTTON, 8FT CABLE-Complete
15FT AC-62797 CABLE, SHIELD, 6 COND., RED
102 6 39328 LAMP, IR, 3800W/570V, CER, CLEAR
AC6-4238-380-PL
**THIS DOCUMENT APPLIES IF YOUR SYSTEM IS EQUIPPED WITH A
SPRAY/BAKE SWITCH
Small junction box to interlock controls during spraying.
Maximum Load: 40A FLA, 50A Resistive
Four configurations:
240V 1ø 480V 1ø
240V 3ø 480V 3ø
2 Modes of Operation
Local: There is a 2 position switch on the front of the box to switch from Spray to Bake.
The 2 terminals for the remote mode must be jumped.
Remote: There are 2 terminals to connect a remote dry contact from another control.
The switch must be in the bake position if the remote contacts are used.
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
RECOMMENDED SPARE PARTS
TO ORDER:
CONTACT: SPARE PARTS ORDER ENTRY
PHONE: 1-800-726-8097
E-MAIL: orderentry@CarlisleFT.com
AC6-4238-380-PL
Reference Number
Spares
Qty
Part Number Part Description
CON110, CON111 1 005898 CONTACTOR, 40A, 2-POLE, 24 COIL
FU105 4 E-178 FUSE,2A,600V,CLASS CC
FU109A, FU109B 4 AC-200046 FUSE,2A,250VAC,TIME DELAY
FU109C, FU109D 4 AC-200045 FUSE,10A,250VAC,TIME DELAY
FU101A, FU101B, FU104A,
FU104B
4
AC-200038
AC-200037
FUSE, LOW PEAK CLASS CC, 25A (For 100% Power)
FUSE, LOW PEAK CLASS CC, 20A (For 75% Power)
INST116 1
AC-74816-380-C-100
AC-74816-380-C-75
TEMP. CONTROLLER (Setup-100%, C deg, 380v)
TEMP. CONTROLLER (Setup-75%, C deg, 380v)
PROX116 1 AC-200024 SWITCH, INDUCTIVE PROXIMITY
PWRSUP123 1 AC-46847 POWER SUPPLY,24VAC - 12VDC & 3.25VDC
SCR 103 FC 1 003317 Firing Circuit Board-PWR CTRLR,4-20MA,240V, 380V, 480V
SCR 103, SCR 104 1 002985 POWER CONTROLLER,SCR,40A, 240V, 380V, 480V
103 2 AC-200051 POWER CONTROLLER THERMSTRATE,H
CR110A, CR110B, CR116 1 062486 RELAY,1 PDT,24VDC/AC
1 AC-200064 LASER KIT (Targeting laser only)
PYR 118 1 AC-61231 PYROMETER ASSEMBLY KIT (Complete)
Bridge 110 1 062001 RECTIFIER,BRIDGE,25A,50V
1 AC-73709 ACTUATOR
SS114 1 064558 SELECTOR SW OP, 2 POS,MAINT
2 AC-39917 HANDLE, PLASTIC, TAPERED 3/8-16
1 AC-73841-8 PENDANT, 4-BUTTON, 8FT CABLE-Complete
15FT AC-62797 CABLE, SHIELD, 6 COND., RED
102 6 39328 LAMP, IR, 3800W/570V, CER, CLEAR
AC6-4238-480-PL
**THIS DOCUMENT APPLIES IF YOUR SYSTEM IS EQUIPPED WITH A
SPRAY/BAKE SWITCH
Small junction box to interlock controls during spraying.
Maximum Load: 40A FLA, 50A Resistive
Four configurations:
240V 1ø 480V 1ø
240V 3ø 480V 3ø
2 Modes of Operation
Local: There is a 2 position switch on the front of the box to switch from Spray to Bake.
The 2 terminals for the remote mode must be jumped.
Remote: There are 2 terminals to connect a remote dry contact from another control.
The switch must be in the bake position if the remote contacts are used.
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
RECOMMENDED SPARE PARTS
TO ORDER:
CONTACT: SPARE PARTS ORDER ENTRY
PHONE: 1-800-726-8097
E-MAIL: orderentry@CarlisleFT.com
AC6-4238-480-PL
Reference Number
Spares
Qty
Part Number Part Description
CON110, CON111 1 005898 CONTACTOR, 40A, 2-POLE, 24 COIL
FU105 4 E-178 FUSE,2A,600V,CLASS CC
FU109A, FU109B 4 AC-200046 FUSE,2A,250VAC,TIME DELAY
FU109C, FU109D 4 AC-200045 FUSE,10A,250VAC,TIME DELAY
FU101A, FU101B, FU104A,
FU104B
4
AC-200040
AC-200038
FUSE, LOW PEAK CLASS CC, 30A (For 100% Power)
FUSE, LOW PEAK CLASS CC, 25A (For 75% Power)
INST116 1
AC-74816-480-F-
100 AC-
74816-480-F-75
TEMP. CONTROLLER (Setup-100%, F deg, 480v)
TEMP. CONTROLLER (Setup-75%, F deg, 480v)
PROX116 1 AC-200024 SWITCH, INDUCTIVE PROXIMITY
PWRSUP123 1 AC-46847 POWER SUPPLY,24VAC - 12VDC & 3.25VDC
SCR 103 FC 1 003317
Firing Circuit Board-PWR CTRLR,4-20MA,240V, 380V,
480V
SCR 103, SCR 104 1 002985 POWER CONTROLLER,SCR,40A, 240V, 380V, 480V
103 2 AC-200051 POWER CONTROLLER THERMSTRATE,H
CR110A, CR110B, CR116 1 062486 RELAY,1 PDT,24VDC/AC
1 AC-200064 LASER KIT (Targeting laser only)
PYR 118 1 AC-61231 PYROMETER ASSEMBLY KIT (Complete)
Bridge 110 1 062001 RECTIFIER,BRIDGE,25A,50V
1 AC-73709 ACTUATOR
SS114 1 064558 SELECTOR SW OP, 2 POS,MAINT
2 AC-39917 HANDLE, PLASTIC, TAPERED 3/8-16
1 AC-73841-8 PENDANT, 4-BUTTON, 8FT CABLE-Complete
15FT AC-62797 CABLE, SHIELD, 6 COND., RED
102 6 39328 LAMP, IR, 3800W/570V, CER, CLEAR
AC6-4238-480-SP
**THIS DOCUMENT APPLIES IF YOUR SYSTEM IS EQUIPPED WITH A
SPRAY/BAKE SWITCH
Small junction box to interlock controls during spraying.
Maximum Load: 40A FLA, 50A Resistive
Four configurations:
240V 1ø 480V 1ø
240V 3ø 480V 3ø
2 Modes of Operation
Local: There is a 2 position switch on the front of the box to switch from Spray to Bake.
The 2 terminals for the remote mode must be jumped.
Remote: There are 2 terminals to connect a remote dry contact from another control.
The switch must be in the bake position if the remote contacts are used.
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
RECOMMENDED SPARE PARTS
TO ORDER:
CONTACT: SPARE PARTS ORDER ENTRY
PHONE: 1-800-726-8097
E-MAIL: orderentry@CarlisleFT.com
AC6-4238-480-SP
Reference Number
Spares
Qty
Part Number Part Description
CON110, CON111 1 005898 CONTACTOR, 40A, 2-POLE, 24 COIL
FU105 4 E-178 FUSE,2A,600V,CLASS CC
FU109A, FU109B 4 AC-200046 FUSE,2A,250VAC,TIME DELAY
FU109C, FU109D 4 AC-200045 FUSE,10A,250VAC,TIME DELAY
FU101A, FU101B, FU104A,
FU104B
4 AC-200042 FUSE, LOW PEAK CLASS CC, 10A
INST116 1
AC-74816-480-F-
100
TEMP. CONTROLLER (Setup-100%, F deg, 480v)
PROX116 1 AC-200024 SWITCH, INDUCTIVE PROXIMITY
PWRSUP123 1 AC-46847 POWER SUPPLY,24VAC - 12VDC & 3.25VDC
SCR 103 FC 1 003317
Firing Circuit Board-PWR CTRLR,4-20MA,240V, 380V,
480V
SCR 103, SCR 104 1 002985 POWER CONTROLLER,SCR,40A, 240V, 380V, 480V
103 2 AC-200051 POWER CONTROLLER THERMSTRATE,H
CR110A, CR110B, CR116 1 062486 RELAY,1 PDT,24VDC/AC
1 AC-200064 LASER KIT (Targeting laser only)
PYR 118 1 AC-61231 PYROMETER ASSEMBLY KIT (Complete)
Bridge 110 1 062001 RECTIFIER,BRIDGE,25A,50V
1 AC-73709 ACTUATOR
SS114 1 064558 SELECTOR SW OP, 2 POS,MAINT
2 AC-39917 HANDLE, PLASTIC, TAPERED 3/8-16
1 AC-73841-8 PENDANT, 4-BUTTON, 8FT CABLE-Complete
15FT AC-62797 CABLE, SHIELD, 6 COND., RED
102 6 39328 LAMP, IR, 3800W/570V, CER, CLEAR
AC6-4238-575-PL
**THIS DOCUMENT APPLIES IF YOUR SYSTEM IS EQUIPPED WITH A
SPRAY/BAKE SWITCH
Small junction box to interlock controls during spraying.
Maximum Load: 40A FLA, 50A Resistive
Four configurations:
240V 1ø 480V 1ø
240V 3ø 480V 3ø
2 Modes of Operation
Local: There is a 2 position switch on the front of the box to switch from Spray to Bake.
The 2 terminals for the remote mode must be jumped.
Remote: There are 2 terminals to connect a remote dry contact from another control.
The switch must be in the bake position if the remote contacts are used.
A
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BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
RECOMMENDED SPARE PARTS
TO ORDER:
CONTACT: SPARE PARTS ORDER ENTRY
PHONE: 1-800-726-8097
E-MAIL: orderentry@CarlisleFT.com
AC6-4238-575-PL
Reference Number
Spares
Qty
Part Number Part Description
CON110, CON111 1 005898 CONTACTOR, 40A, 2-POLE, 24 COIL
FU105 4 E-178 FUSE,2A,600V,CLASS CC
FU109A, FU109B 4 AC-200046 FUSE,2A,250VAC,TIME DELAY
FU109C, FU109D 4 AC-200045 FUSE,10A,250VAC,TIME DELAY
FU101A, FU101B, FU104A,
FU104B
4 AC-200040 FUSE, LOW PEAK CLASS CC, 30A (For 100% Power)
INST116 1
AC-74816-575-C-
100
TEMP. CONTROLLER (Setup-100%, C deg, 575v)
PROX116 1 AC-200024 SWITCH, INDUCTIVE PROXIMITY
PWRSUP123 1 AC-46847 POWER SUPPLY,24VAC - 12VDC & 3.25VDC
SCR 103 FC 1 E-984
Firing Circuit Board-POWER CONTROLLER,575V,40A,4-
20MA
SCR 103, SCR 104 1 022759 POWER CONTROLLER,SCR,575V,40A
103 2 AC-200051 POWER CONTROLLER THERMSTRATE,H
CR110A, CR110B, CR116 1 062486 RELAY,1 PDT,24VDC/AC
1 AC-200064 LASER KIT (Targeting laser only)
PYR 118 1 AC-61231 PYROMETER ASSEMBLY KIT (Complete)
Bridge 110 1 062001 RECTIFIER,BRIDGE,25A,50V
1 AC-73709 ACTUATOR
SS114 1 064558 SELECTOR SW OP, 2 POS,MAINT
2 AC-39917 HANDLE, PLASTIC, TAPERED 3/8-16
1 AC-73841-8 PENDANT, 4-BUTTON, 8FT CABLE-Complete
15FT AC-62797 CABLE, SHIELD, 6 COND., RED
102 6 39328 LAMP, IR, 3800W/570V, CER, CLEAR
AC6-4238-575-SP
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'IE. (23)
**THIS DOCUMENT APPLIES IF YOUR SYSTEM IS EQUIPPED WITH A
SPRAY/BAKE SWITCH
Small junction box to interlock controls during spraying.
Maximum Load: 40A FLA, 50A Resistive
Four configurations:
240V 1ø 480V 1ø
240V 3ø 480V 3ø
2 Modes of Operation
Local: There is a 2 position switch on the front of the box to switch from Spray to Bake.
The 2 terminals for the remote mode must be jumped.
Remote: There are 2 terminals to connect a remote dry contact from another control.
The switch must be in the bake position if the remote contacts are used.
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
BGK
AeJilfEIIj/ .... ...,
RECOMMENDED SPARE PARTS
TO ORDER:
CONTACT: SPARE PARTS ORDER ENTRY
PHONE: 1-800-726-8097
E-MAIL: orderentry@CarlisleFT.com
AC6-4238-575-SP
Reference Number
Spares
Qty
Part Number Part Description
CON110, CON111 1 005898 CONTACTOR, 40A, 2-POLE, 24 COIL
FU105 4 E-178 FUSE,2A,600V,CLASS CC
FU109A, FU109B 4 AC-200046 FUSE,2A,250VAC,TIME DELAY
FU109C, FU109D 4 AC-200045 FUSE,10A,250VAC,TIME DELAY
FU101A, FU101B, FU104A,
FU104B
4 AC-200039 FUSE, LOW PEAK CLASS CC, 15A (For 100% Power)
INST116 1
AC-74816-575-C-
100
TEMP. CONTROLLER (Setup-100%, C deg, 575v)
PROX116 1 AC-200024 SWITCH, INDUCTIVE PROXIMITY
PWRSUP123 1 AC-46847 POWER SUPPLY,24VAC - 12VDC & 3.25VDC
SCR 103 FC 1 E-984 Firing Circuit Board-POWER CONTROLLER,575V,40A,4-20MA
SCR 103, SCR 104 1 022759 POWER CONTROLLER,SCR,575V,40A
103 2 AC-200051 POWER CONTROLLER THERMSTRATE,H
CR110A, CR110B, CR116 1 062486 RELAY,1 PDT,24VDC/AC
1 AC-200064 LASER KIT (Targeting laser only)
PYR 118 1 AC-61231 PYROMETER ASSEMBLY KIT (Complete)
Bridge 110 1 062001 RECTIFIER,BRIDGE,25A,50V
1 AC-73709 ACTUATOR
SS114 1 064558 SELECTOR SW OP, 2 POS,MAINT
2 AC-39917 HANDLE, PLASTIC, TAPERED 3/8-16
1 AC-73841-8 PENDANT, 4-BUTTON, 8FT CABLE-Complete
15FT AC-62797 CABLE, SHIELD, 6 COND., RED
102 6 39328 LAMP, IR, 3800W/570V, CER, CLEAR
www.carlisleft.com Manual AC6-4238
(Revised 03/2021)
WARRANTY POLICY
This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited
warranty. The use of any parts or accessories, from a source other than Carlisle Fluid
Technologies, will void all warranties. Failure to reasonably follow any maintenance
guidance provided, may invalidate any warranty.
For specific warranty information please contact Carlisle Fluid Technologies.
For technical assistance or to locate an authorized distributor, contact one of our international sales
and customer support locations.
For the latest information about our products, visit www.carlisleft.com
Region Industrial / Automotive Automotive Refinishing
Americas
Europe, Africa
Middle East, India
China
Japan
Australia
Carlisle Fluid Technologies is a global leader in innovative finishing technologies.
Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.
BGK™, Binks®, DeVilbiss®, Hosco®, MS®, and Ransburg®
are all registered trademarks of Carlisle Fluid Technologies, Inc.
©2020 Carlisle Fluid Technologies, Inc.
All rights reserved.
AC6-4238 OVERHEAD HEATER ASSEMBLY AND OPERATING MANUAL
TABLE OF CONTENTS (2 pgs)
1. WARNINGS AND DANGER
WARNING, CAUTION & NOTE
2. EQUIPMENT SAFETY GUIDELINES
CAUTION!!
Lamps, Prometer Positioning Beam/Environment
3. OPERATING INSTRUCTIONS
Temperature Controller Single or Double Ramp Operation
Temperature Controller Displays
Cycle Start Button, Heater Position
Setting the Temperature Controller Parameters
4. LAMP INSTALLATION AND REPLACEMENT INSTRUCTIONS
DANGER!! Precautions for Handling Quartz Infrared Lamps
CAUTION!! Lamp Installation/Replacement Procedure
5. HEATER POSITION INSTRUCTIONS
General Instructions (Read All)
Heat Masking
Positioning/Set-Up of Heater Head Instructions (2 pgs)
Yellow Pendant (for overhead arm movement)
6. MAINTENANCE
Actuator & Pivot Points
Lamps, Reflectors and Heat Sensor (Pyrometer) Lens
7. TROUBLESHOOTING GUIDE
Heater Power Problems
Temperature Controller Problems
Temperature Problems
8. TEMPERATURE CONTROLLER ERROR CODES
9. PYROMETER ASSEMBLY (DRAWING# AC-61231 - 4 pgs)
10. SERVICE INSTRUCTIONS FOR PYROMETER ASSEMBLY
Old and New Raytek Units (2 pgs)
Replacement of New Pyrometer Sensor (2 pgs)
Replacement of Pyrometer Controller (2 pgs)
Verification / Calibration Procedure
Begin Verification / Calibration Procedure
Verify Lock Status of Raytek Comm Module
Adjusting Raytek Calibration Procedure (3 pgs)
Begin Calibration Cycle
Calibration Adjustment
Lock out the Comm Box
11. DUAL HEAD BACK PANEL / COMPONENTS (2 pgs)
12. JUNCTION BOX
13. MECHANICAL DRAWINGS (3 pgs)
14. TABLES (4 pgs)
15. AUTOCURE MODEL NUMBERS
AC6-4238-240-PL
Electrical Schematic (2 pgs)
Spray/Bake
Heater Heads (5 pgs)
Recommended Spare Parts
AC6-4238-380-PL
Electrical Schematic (2 pgs)
Spray/Bake
Heater Heads (5 pgs)
Recommended Spare Parts
AC6-4238-480-PL
Electrical Schematic (2 pgs)
Spray/Bake
Heater Heads (5 pgs)
Recommended Spare Parts
AC6-4238-480-SP
Electrical Schematic (2 pgs)
Spray/Bake
Heater Heads (5 pgs)
Recommended Spare Parts
AC6-4238-575-PL
Electrical Schematic (2 pgs)
Spray/Bake
Heater Heads (5 pgs)
Recommended Spare Parts
AC6-4238-575-SP
Electrical Schematic (2 pgs)
Spray/Bake
Heater Heads (5 pgs)
Recommended Spare Parts
16. BGK-CARLISLE FLUID TECHNOLOGIES CUSTOM PRODUCTS WARRANTY
