ov 45hd image management system operation manual94mu25 rev. c1 sw ver. 2.06 2-1 2. introduction...

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OV 45HDImage Management SystemOperation Manual

94MU25 Rev. C1 S/W Ver. 2.06 O

94MU25 Rev. C1 SW Ver. 2.06

Note:This Operation Manual must be read and clearly

understood by all operators, supervisors andmaintenance personnel. It must be stored with theunit for reference at any time. All new operators

and personnel should be trained and be madefamiliar with its safe use.

Important:Report any malfunction or irregularity inoperation to your supervisor immediately!

94MU25 Rev. C1 SW Ver. 2.06 0-1

0. Contents1. Safety

Declaration of Conformity........................................................... 1-1Warning Explanation ................................................................... 1-1General Guidelines ...................................................................... 1-1Electrical Power ........................................................................... 1-1Ultra Violet Light ........................................................................ 1-2Maintenance and Service ............................................................. 1-2Environmental Information ......................................................... 1-2

2. IntroductionProduct Overview ........................................................................ 2-1Product Features .......................................................................... 2-1Options and Accessories .............................................................. 2-2Operating Safely .......................................................................... 2-2The Nature of Light ..................................................................... 2-3Spectramatch Lamps.................................................................... 2-3

3. Product SpecificationsGeneral Specifications ................................................................. 2-160 Hz Model Specifications ........................................................ 2-150 Hz Model Specifications ........................................................ 2-2Physical Dimensions ................................................................... 2-2Space Requirements .................................................................... 2-3

4. InstallationSelecting a Location .................................................................... 4-1Unpacking Instructions ................................................................ 4-1Removing the Unit from its Pallet ............................................... 4-1Disassembly Instructions ............................................................. 4-2Top Section Removal .................................................................. 4-2Nose Section Cover Removal ...................................................... 4-3Vacuum Frame Removal (Optional) ........................................... 4-3Center Section Removal .............................................................. 4-4Assembly Instructions ................................................................. 4-5Lower Section Installation ........................................................... 4-5Center Section Installation........................................................... 4-5Upper Section Installation ........................................................... 4-6Vacuum Frame Installation ......................................................... 4-6Nose Section Cover Installation .................................................. 4-6Electrical Connections ................................................................. 4-7

5. Integrator OverviewIntegrator Description .................................................................. 5-1Instant Memory Keypad .............................................................. 5-2Integrator Display Windows ........................................................ 5-2Feature Quick Reference ............................................................. 5-2

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6. Integrator SetupTurn on Power to the OV 45HD. ................................................. 6-1To Enter the Select Mode. ........................................................... 6-1Lock Level Feature. ..................................................................... 6-1Lock Level Description and Operation ....................................... 6-2Setting or Changing your Lock Code Feature. ............................ 6-2Vacuum Inspection Feature ......................................................... 6-3Motorized Filter Feature .............................................................. 6-3Split Filter Feature ....................................................................... 6-3Motorized Diffuser Feature ......................................................... 6-4Split Diffuser Feature .................................................................. 6-4Exposure Count Feature .............................................................. 6-5Frame Control Switch Feature ..................................................... 6-5Automatic Vacuum Feature ......................................................... 6-6Continuous Vacuum Feature ....................................................... 6-6Autostep Feature .......................................................................... 6-7Vacuum Delay Feature ................................................................ 6-7Tray Speed Feature ...................................................................... 6-8Filter Travel Time Feature ........................................................... 6-8Diffuser Travel Time Feature ...................................................... 6-9System Type Setting Feature ....................................................... 6-9To Clear the Lamp Statistics ..................................................... 6-10To Clear the Memory and Exposure Statistics .......................... 6-10Calibration Procedures .............................................................. 6-11Checking the Measure Numbers ................................................ 6-11

7. Integrator OperationSelecting a Memory Location. ..................................................... 7-1Entering an Exposure Time ......................................................... 7-1Entering a Filter into Memory ..................................................... 7-1Entering Filter Percentage into Memory ..................................... 7-1Entering a Diffuser into Memory ................................................ 7-2Entering a Split Diffuser Option Percentage ............................... 7-2Resetting the Exposure Count ..................................................... 7-2Entering a Vacuum Delay into Memory...................................... 7-2Starting a Blank Tray Cycle ........................................................ 7-3Operating in Vacuum Inspection Mode....................................... 7-3Program the Autostep Function ................................................... 7-3Making an exposure..................................................................... 7-4Obtaining Lamp Statistics ........................................................... 7-4Obtaining Exposure Statistics ...................................................... 7-5

8. MaintenanceLamp Changing Instructions ....................................................... 8-1Maintenance Schedule ................................................................. 8-2Maintenance Procedures .............................................................. 8-2Cabinet Dust Removal and Blower Maintenance........................ 8-2

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Drive Chain Lubrication and Adjustment ................................... 8-3Light Block Lubrication .............................................................. 8-3Vacuum Pump Maintenance ........................................................ 8-3

9. TroubleshootingError Messages ............................................................................ 9-1

10. WarrantyLimited Warranty ...................................................................... 10-1Lamp Warranty .......................................................................... 10-1

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94MU25 Rev. C1 SW Ver. 2.06 1-1

1. Safety

Declaration of Conformity

The OV 45HD conforms with the safety requirements of the EU. Relevantdata is inscribed on the ID plate near the power cable inlet.

Warning Explanation

This manual uses the following terms and symbols to indicate importantinformation regarding safety. Should you have difficulty understandinginformation preceded by these terms and symbols, please contact yourOLEC representative before proceding.

! Wb Risk of Injury and/or Property Damage

! Cl Risk of DamageNote: Special Information regarding the efficient use of the OV 45HD

General Guidelines

This Operation Manual must be read and clearly understood by alloperators, supervisors and maintenance personnel with special attentionto safe operation. It must be located near the unit for ready reference. Allnew operators and personnel should be trained and made familliar withits safe use. The manufacturer and supplier shall not be liable for anydamage arising out of improper or unauthorized use.

! W Report any malfunction or irregularity in operation toyour supervisor!Electrical Power

The OV 45HD is connected to the electrical power line. It must be installedin accordance with local safety codes and kept dry and clean at all times.It is equipped with interlocks and protective devices to assure operatorsafety.

! W Service must be performed by authorized servicepersonnel only!

! W Never disable or disconnect electrical interlock safetydevices!

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Ultra Violet Light

The OV 45HD uses a most effective energy saving light source that emitsUltra Violet Light or UV. Its enclosure is designed to protect the operatorfrom direct exposure to UV and is fitted with safety interlocks.

! W Service must be performed by authorized servicepersonnel only!

! W Never disable or disconnect the interlock safety devices!Maintenance and Service

Make sure to follow any instructions in this manual very closely whenattempting maintenance procedures.

! W If it becomes necessary to replace the lamp or any otherinternal component, the power line must first bedisconnected. Remove the power plug from the wall outletor from the back of the unit.

Environmental Information

The OV 45HD is manufactured with great care to protect the environment.The lamps are specifically designed to eliminate the emission of ozone.

! COnly original OLEC replacement lamps should be used!

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2. Introduction

Product Overview

The OV 45HD exposes films, plates, color and black and white proofing.The OV 45HD has two exposure frames, allowing the operator to exposein one frame, while loading the other frame. Metal halide lampsconcentrate all the effective energy into the precise spectral range requiredto obtain the highest resolution and sharpest image, keeping the operatorin mind through ease and safety of operation.

Separate vacuum pumps for each frame provide rapid drawdown times.Separate gauges on the control panel indicate the vacuum pressure foreach frame. The exposure unit can be operated in three light intensitymodes. The microprocessor controlled exposure integrator providesprecise and repeatable exposures. An optional "seconds" mode on theintegrator allows exposures by time.

A large dynamic intensity range of .9 kW up to a full 8000 W, is anotherreason for greatly improved yields. The low and medium intensity modesgive finer exposure control for materials requiring short exposure times.The high intensity mode gives rapid, accurate exposure for highproductivity. The lamps automatically switch to the low intensity modebetween exposures to conserve power and reduce heat buildup. Theprecise design of the lamp reflectors provides the highest resolution andthe sharpest image.

Exposure times are controlled by a microprocessor controlled integratorand a lamp head or frame mounted photocell. This system automaticallyregulates the exposure on each frame, to compensate for differences inlamp-to-frame distance. The operator selects a number of light units onthe integrator for the material to be exposed. When the operator pressesthe G button once, the vacuum will start. After sufficient vacuum,press the G button again. The motor-driven drawers will move intothe unit. The rotary shutter opens and the integrator will count the numberof programmed units.

Product Features

• Suitable for fast exposure of varying materials, plates, films and proofing

• Quick memory locations

• Built for high production

• User friendly -- One button control

• Low installation, operating, and maintenance costs

• Greatest ease of operation and maintenance

• Small footprint

• Selectable power 1K to 8K

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• Microprocessor controlled light integration

• Memory backup, in case of power failure

• Exposure programming and analysis

• Motor-driven, 35” x 45”, double drawers

• Modular design

• Adjustable lamp height

• Long lamp life design

• Excellent service and backup

• The system is competitively priced

• Manufactured in the U.S.A.

• Components are UL and TUV approved

Options and Accessories

• Any OLEC light from the 1K to 8K metal halide

• Motorized filter

• Motorized diffuser

Operating Safely

Ultra Violet Rays (UV)

Before operating the exposure unit, please become familiar with thecharacteristics of UV exposure lights. The unit is enclosed in order toeliminate any exposure to UV. However, never look directly into a UVlight source and avoid overexposures to the direct rays coming from thelamp and reflector.

Power Switching

By pressing the power button on the Integrator, the OV 45HD will gointo warm-up. When it is turned off, the unit will go into a cool-downcycle. In the event of momentary power loss or accidental switch off, theinformation stored in the integrator memory will be retained. It may beturned on again immediately, without any damage. However, it will gothrough the short, forced cool-off cycle before the lamps restrike.

Safety Features

The OV 45HD is designed with operator protection in mind. The operatoris protected from any direct light and UV coming from the exposurelamp by the cabinet and frame design. You can remove the side doors onthe unit to access all electrical components, the exposure lamp, powersupply, and the vacuum pumps. The exposure unit side doors haveelectrical interlock switches, which will suspend operation if a door isopened while the unit is in operation.

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94MU25 Rev. C1 SW Ver. 2.06 2-3

The Nature of Light

Electromagnetic Spectrum

Visible light and Ultra Violet (UV) are electromagnetic waves whichexist in a continuous spectrum of energy. They only differ in wavelengths.Visible energy or light is that part of the spectrum between 700 nanometers(red) through 400 nanometers (violet). UV energy ranges between 400nm to 10 nm. For maximum safety the lights filter out wavelengths ofUV energy below 320 nm.

OV 45HD Lamps

The OV 45HD use the unique L1250, L1261/L1281, L1280 and L1252/L1282 metal halide lamps. The additives in the lamps are carefullyselected to generate spectral emissions that are matched for most materials.The lamps provide optimum energy for exposure of most films and plates.In addition, it is also suitable for diazo materials, sensitive in the 410 nmrange as well as photopolymer materials most sensitive in the 370 nmarea. The energy spectrograph below illustrates the wide coverage of theOV 45HD lamps. This efficient conversion of electrical energy intoeffective wavelengths, accounts for the exceptionally short exposures atgreat power savings

Spectramatch Lamps

Relative Intensity L1261, L1281

Wavelength in nano-meters

100

90

80

70

60

50

40

30

20

10

0340 360 380 400 420 440


Relative Intensity L900, L1250100

90

80

70

60

50

40

30

20

10

0340 360 380 400 420 440


100

90

80

70

60

50

40

30

20

10

0340 360 380 400 420 440

Relative Intensity L1280 Relative Intensity L902, L1252, L1282


100

90

80

70

60

50

40

30

20

10

0340 360 380 400 420 440

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3. Product Specifications

General Specifications

General Description - 35 x 45 inch double-drawer single-sided uprightexposure machine with light integration and drawer motor drive.

Cabinet - Welded heavy gauge steel construction with access doors on bothsides.

Lamp - Metal halide, air cooled, ozone-free. The lamp height may be adjustedfrom 25" - 40" glass-to-glass, in 2-l/2" increments.

Drawer - Steel frames with a long life rubber blanket.

Contact System - Two oil-less rotary vane vacuum pumps work with theOLEC Accuvac system to provide quick, repeatable, and accurate vacuum.

Exposure area- 35 x 45 inches.

Drawer Drive - Reversing 1/8 hp PMDC gearmotor with SCR control.Dynamic acceleration and deceleration.

Controls - Electronic light integrator with LED display, comes with 40memories (battery backup), and single button control.

Motorized Filter - A dual motorized filter can be incorporated into the OV45HD.

Motorized Diffuser- A motorized diffuser can be incorporated into the OV45HD.

Modular - Unit can be disassembled into three sections.

60 Hz Model Specifications

Electrical - 208/240 volt 60 Hz, 1-phase, see chart below for amperage.

Model OV45HD-23 OV45HD-35 OV45HD-53 OV45HD-83 UNITS

Light High 2300 3500 5000 8000 Watts

Output Medium 1300 2000 2500 3500 Watts

Low 600 1000 1000 2000 Watts

Maximum Current 13 24 38 50 Amps

Shipping Weight 2250 2250 2260 2270 Pounds

Shipping Size 69x69x108 69x69x108 69x69x108 69x69x108 Inches

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50 Hz Model Specifications

Electrical - 220 Volt 50 Hz, 1-phase or 380 Volt 50 Hz, 3-phase, see chartbelow for amperage.

Model OV45HD-24 OV45HD-36 OV45HD-63 OV45HD-95 OV45HD-96 UNITS

LightOutput

High 2300 3500 5000 8000 8000 Watts

Medium 1300 2000 2500 3500 3500 Watts

Low 600 1000 1000 2000 2000 Watts

Input Voltage 220 220 220 380 220 V~ 50Hz

Maximum Current 13 24 38 50 22 Amps

Shipping Weight 660 670 680 725 725 Kilograms

Shipping Size 147x241x200 147x241x200 147x241x200 147x241x200 147x241x200 Centimeters

Physical Dimensions

51"95"

79"

36"

61"58"

34"

OV 45HD V

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Space Requirements

Front

24"24"

Rear 24"

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4. Installation

Selecting a Location

It is recommended to have the main power circuit breaker within easyreach of the operator. The selected location should have an electricaloutlet that will meet the power requirements. In addition, the selectedlocation must have enough area to allow adequate space around the unit.

Unpacking Instructions

The exposure unit weighs approximately 2000 lbs. (907 kg) unpacked. Itis recommended, for your safety and to prevent damaging the equipment,that you have an authorized person or professional riggers unpack theunit and remove it from the shipping pallet. Check clearances andobstructions along the route to the installation site.

! C Remove inside packing and strapping material beforeoperating exposure unit.

Caution: Remove Shipping Bolts

ProtectiveMaterial

Removing the Unit from its Pallet

• Remove the four (4) 1/2" bolts under the top layer of the pallet that securethe exposure unit to the pallet.

• Using a fork lift from the rear of the exposure unit, raise it off the pallet.

• Position the exposure unit in place and level it using the adjustable feet.

• Allow at least 1-1/2" (38 mm) of clearance from the floor to the bottomof the exposure unit.

Note: Position the exposure unit so as to leave 36 inches (914 mm) tothe nearest wall on both sides and to the rear.

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Disassembly Instructions

Due to the physical dimensions of the OV 45HD, it was designed to beseparated into three main sections for installation. These are the step bystep instructions to disassemble this unit for installation.

Tools required:

5/32" Allen key7/16" wrench7/16" socket, 3/8" drive3/8" drive ratchet3/8" drive 10" extension#2 Phillips screw driver, longSmall wire cutters to cut tie-wraps

Note: The vacuum hose connections are disconnected by depressingthe dark gray collar around the connector inlet and pulling thehose out. To reconnect, simply push the hose into the connectoruntil it stops.

Top Section Removal

• Remove all 4 side doors. The upper doors are removed by pulling out onthe lower section approximately 4-6 inches and lifting the door up andoff its retainers. The lower doors are removed by pulling out on the uppersection approximately 4-6 inches and lifting the door up and off itsretainers.

Note: Upper and lower doors are not interchangeable.

• Completely remove a motorized filter assembly at this time, if one isinstalled in the unit. Also, remove an HF1 exhaust system, if one isinstalled on the lamp head.

• Remove both black plastic dust shields from the lamp support assembly.

Note: If a motorized filter assembly was installed, there will only beone dust shield on the right hand side.

• Remove the 4 large black plastic thumbscrews from under the lamp headsupport assembly that are attached to the lamp head mounting plate.

• Disconnect the large black interconnect cable from the lamp head andfeed it back to the power supply. Also remove the lamp head photocellcable, if a lamp head mounted photocell is used. Feed this cable back tothe front of the center section and coil it up near the right hand noseassembly.

• Slide the lamp head towards the right side of the support assembly andlift it up and out of the unit.

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• Disconnect the vacuum hose and the two-pin connector at the right rearof the upper vacuum frame. Feed the hose and wire back to the top section.

• Remove the (10) 1/4-20, 7/16" bolts that hold the top and center sectionstogether. There are 5 in the front and 5 in the rear.

• Ensure that all cables and hoses between the upper and the center sectionare disconnected and clear.

• Using the lamp head support frame, lift the upper section off the lowerand center sections.

Nose Section Cover Removal

• From below the nose on the right side nose cover, where it meets themain unit, disconnect the (2) 12-pin connectors, the (1) 8-pin connectorand the (2) vacuum hoses.

Note: Mark one hose and one 12-pin connector with tape or a tie wrapfor identification on reassembly.

• Each nose/rail cover is held onto the rail weldment by (5) 1/4-20, 7/16"bolts, which may now be removed. There is one bolt on the inner front,two bolts can be accessed from inside the unit’s front bulkhead and twocan be removed from the inner rail.

• With all connections and bolts removed, carefully lift out and off on thecover, to remove them from the rail weldment. Be especially carefulwith the right cover, since it houses the integrator assembly.

Vacuum Frame Removal (Optional)

Note: If the frames remain mounted in the unit, They must be securelyfastened down in a mid position.

• Disconnect the 8-pin connector on the control box labeled “Motor LimitSwitches.”

• Manually position each frame, so the Allen screw that connects it to thechain is accessible through the holes in the left rail.

• Loosen the 5/32" Allen screw to free each frame from the chain.

• Disconnect the vacuum hose and the two-conductor wire from the rightrear of each frame. On the upper frame, pass the hose and the cable intothe top section. On the lower frame, pass the hose and the cable into thelower section.

• Very carefully, slide each frame out through the nose. Use at least twopeople as the frame assemblies are very heavy.

Note: Do not tip the frames on their sides or ends. The gas shocks willopen the glass lid and damage may result.

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Center Section Removal

Note: If the vacuum frames are in the unit, they must be securely fasteneddown with strapping and blocks to avoid any movement, shouldthis section need to be put on its side or end.

• Disconnect the 8-pin connector on the control box labeled “Motor LimitSwitches”.

• Manually position each frame to a mid position, one frame directly overthe other.

• Disconnect the vacuum hose and the two-conductor wire from the rightrear of the lower vacuum frame. Pass the hose and the cable back into thelower section.

• Disconnect the 3-pin drive motor connector and the 8-pin frame limitswitch connector located in the inner rear left corner by the frame drivemotor. Position the wires and connections to allow for section separation.

• Disconnect both center section door switch cables and pass the cablesdown into the lower section.

• Disconnect the top vacuum hose from the “T” connection at the innertop front right of the lower section. Push the hose up into the centersection.

• Remove the (3) 1/4-20, 7/16" bolts from under the nose that hold thecenter and lower sections together.

• Remove the (4) 1/4-20, 7/16" bolts from the rear section shelf that holdthe center and lower sections together.

• Remove the 1/4-20, flat head screw on the right rear section shelf. Along #2 phillips screwdriver can be used through the rail access holes.

• Remove the 1/4-20, 7/16" bolt on the left front where the two sectionsare held together.

• Remove the 1/4-20, flat head screw on the right front where the twosections are held together. A long #2 phillips screwdriver can be usedthrough the rail access holes.

• Remove the front rail from piece using a #2 phillips screwdriver.

• Ensure that all fasteners, cables and hoses between the center and lowersections are disconnected and clear.

• Carefully, lift the center section off of the lower section.

Note: Lift only from under the rail/side assembly. The metalwork couldbe damaged if lifted between the front rails. For moving andhandling the lower section, it may be easier to remove the powersupply. The lower section can be turned on its side to pass throughdoors, but not on its end. It should never be shipped on its side orend.

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Assembly Instructions

Tools and Materials Required:

5/32" Allen key7/16" wrench7/16" socket, 3/8" drive3/8" drive ratchet3/8" drive 10" extension#2 Phillips screwdriver, longTwenty (20) 6" UV tie wraps

Lower Section Installation

• Make sure that the four leveling legs are installed and place the lowersection into position and level the section. Leave at least 36" on bothsides and to the rear for access during assembly and use.

• If the light source power supply has been removed, it can now bereinstalled.

Center Section Installation

• Make sure that all fasteners, cables, and hoses, between the lower andcenter sections are clear.

• Carefully lift the center section onto the lower section.

Note: There is a cross brace below the rail assembly, where it meets thelower section top front. The center section should be positionedto align the three bolt holes in the brace and the lower section.

• Install the front rail trim piece. Do not tighten the screws fully at thistime.

• Install the three center front and rear 1/4-20, 7/16" bolts, washers, andnuts. Do not tighten them at this time.

• Install the two rear outer 1/4-20 fasteners. Do not tighten them at thistime.

• Install the two front outer 1/4-20 fasteners. Tighten all ten (10) 1/4-20fasteners at this time.

• Route the vacuum hose in the inner right front of the center section backdown to the “T” connector on the top inner right of the lower section.

• Route the center section door switch cables up through the access holesand connect them to “COM” and “NC” on the switch.

• Connect the 3-pin drive motor connector and the 8-pin frame switchconnector at the inner rear left corner next to the frame motor.

• Connect the vacuum hose and the 2-conductor wire to the right rear ofthe lower vacuum frame.

• Connect the 8-pin connector on the control box labeled “MOTOR LIMITSWITCHES.”

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Upper Section Installation

• Make sure that all fasteners, cables, and hoses, between the center andupper sections mating surfaces are clear.

• Using the lamp head support frame, lift the upper section onto the lowerand center sections.

Note: Be careful not to scratch the top edge of the front panel.

• Install and tighten the ten (10) 1/4-20, 7/16" bolts that hold the upper andcenter sections together. There are five in the front and five in the rear.

• Route the vacuum hose and the 2-pin connector down from the right rearof the upper section and connect it to the right rear of the upper vacuumframe.

• If the lamp head assembly was removed, reinstall it at this time, from theright side of the unit. Install the 4 black thumbscrews from under thesupport into the lamp head mounting plate. Also reconnect theinterconnect cable from the power supply and the photocell cable.

• If a motorized filter assembly was removed, reinstall it at this time. Alsoreinstall the black plastic dust shields.

Vacuum Frame Installation

• Very carefully, slide each frame into the nose assembly. Make sure thatthe frame guide rails mate up with the linear bearings without using anyforce.

• Connect the vacuum hose and the 2-conductor wire to the right rear ofeach frame. The upper frame hose and cable will come down from theupper section and the lower frame hose and cable will come up from thelower section.

• Manually position each frame so the Allen screw that connects it to thechain is accessible through the holes in the left rail and attach it.

Note: Remember, do not position the frames one directly over the other.One frame must be over the nose, while the other is in the unit.

• Connect the 8-pin connector on the control box labeled “Motor LimitSwitches” if it has not been done yet.

Nose Section Cover Installation

• Position the left side nose cover onto the rail.

• Install the five (5) 1/4-20, 7/16" securing bolts into the cover. There aretwo in the rail assembly, two from inside the left front upright and oneon the inner front. Secure them at this time.

• Position the right side nose cover onto the rail, but leave approximately6" at the bulkhead. Use caution not to damage the integrator or cables.

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• Connect the two vacuum hoses on the unit’s right front bulkhead, makingsure to connect the upper and lower gauges to the proper hose.

• Connect the two 12-pin connectors and the 8-pin connector at this time.

• Fully seat the right rail cover into position and secure with the five (5) 1/4-20, 7/16" bolts.

• Position the front rail trim strip to align with the front edges of the railcovers and tighten the #2 phillips screws that attach it.

• Make sure that all fasteners, hoses, and connections on the OV 45HD arecomplete and tight.

Electrical Connections

Connecting Power to the Exposure Unit.

Note: The exposure unit operates on 220 or 380 - 420 Volt, single phasepower. We recommend installing a circuit breaker box withineasy reach of the operator.

• Remove the rear access panel of the exposure unit by unscrewing thefour screws that attach it.

• Remove all side panels by gently pulling out on the panel and lifting thedoor off its retainers.

• Remove all internal shipping/packing material.

• Run the power cord through the access hole on the lower rear right of theexposure unit.

Access Panel forPower Connection

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• Connect the ground lead to the single ground terminal and the powerleads to the terminal block.

• Energize the circuit breaker. You will hear blowers going into a briefcool-down cycle. Ensure the two voltage selection switches are positionedtowards the lit LED. The power supply has a selection switch, as doesthe hinged control panel.

• Reinstall the rear access panel of the exposure unit, using the four screws.

• Reinstall the side panels onto the OV 45HD.

• Install the lower front and rear black trim pieces over the forklift channels,using the 5/32" Allen wrench supplied.

• You may now push the gray power key on the integrator to power up theunit.

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5. Integrator Overview

Integrator Description

! CMake sure that once power is applied to the OV45HD thatyou press the RESET button on the right rear of the unit justabove the electrical access panel to insure proper operation.

P PowerPress the power button on the integrator to turn the OV 45HD on or off.When the unit is off, the light system blowers will run for about twominutes to cool the lamp.

Y MemoryPressing the memory key will advance the memory location. The displaywill show which memory is selected.

V VacuumPress the vacuum key and use the numerical keypad to enter a vacuumdelay time. The window shows the delay in seconds.

e ExposurePress the exposure key and use the numerical keypad to enter an exposure.The window shows the exposure units selected. This key can also beused to move forward through the selectable features in the setup mode.

02468

97531

P

[0000]e[0000]V[00]Y

TIUDmF

147

258

369

0

I IntensityPress this key to select Low, Middle or High power. LEDs lit will indicatethe level selected.

D DiffuserPress this key to select the motorized diffuser option.

F FilterPress this key to select the motorized filter option.T SecondsPress this key to expose by time, not integrated light units. This key alsocan be used to move backward through selectable features in the setupmode.

U MenuThis key is used as the autostep indicator and for the continuous vacuumfeature.

m MeasureThis key is used to check the lamp intensity.

0 Numerical KeypadThese keys are used to enter the vacuum time, exposure units, and toaccess a particular memory location.

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Instant Memory KeypadThe OV 45HD has 40 independent memory locations, the first ten ofwhich are on the lower section of the integrator for instant access. Thereis a space provided to write down the application of these memories.Simply press the lower 0 through 9 key that corresponds to the mostcommonly used applications.

Integrator Display Windows

The OV 45HD has three display windows which provide importantfeedback during setup and operation. These three windows are located atthe top of the integrator next to the power button. This manual shows theinformation contained in the display windows during setup and operation.You should always check display information to verify proper operation.

[88] Memory Window

[8888] Delay Window

[8888] Exposure WindowFeature Quick Reference

The following feature descriptions appear in the Exposure Window whilesetting each feature. In order to select or setup the following features youmust first be in the setup mode.

[LocK] Lock Level Feature

[codE] Lock Code Feature

[HoLd] Vacuum Inspection Feature

[Fmtr] Motorized Filter Feature

[SFmt] Split Filter Feature

[diFF] Motorized Diffuser Feature

[SdiF] Split Diffuser Feature

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[bcnt] Exposure Count Feature

[FrCl] Frame Control Switch Feature

[AUAC] Automatic Vacuum Feature

[CAUC] Continuous Vacuum Feature

[AStP] Auto Step Feature

[dUAC] Vacuum Delay Feature

[trAY] Tray Speed Feature

[Fmtt] Filter Travel Time Feature

[diFt] Diffuser Travel Time Feature

[tYPE] System Type Setting Feature

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94MU25 Rev. C1 SW Ver. 2.06 6-1

6. Integrator Setup

Turn on Power to the OV 45HD.

• Press the P button on the nose of the OV 45HD to turn the unit on.

[OU45] The display will cycle through its power on sequence and momentarilydisplay [OU45] in the Delay Window and [_Hd_] in the Exposure Window.• Once it cycles through it will go to its normal displays.

To Enter the Select [SEL_] Mode.

Note: This step must be followed in several of the program set ups.

• Press the P key to turn the unit on.

[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_].Lock Level [LocK] Feature.

The lock levels are provided to keep operators from accessing any featuresand functions that should be left alone. There are five different lock levelsavailable. Lock levels 1 - 3 can be selected for each individual memorylocation, while lock levels 0 and 4 apply to all of the memory locations.

• Level 0

No locks. Most of the features and functions can be accessed by anyoperator.

• Level 1

Locks functions for seconds, enter, vacuum and intensity, for eachmemory location.

• Level 2 & 3

Locks functions for seconds, enter, vacuum and intensity, for eachmemory location and also the Integrator Program Set Up Features.

• Level 4

Locks all functions. A code is required to change any operatingparameters.

Note: You must ensure the lock level is set to 0 before continuing withthe Integrator Program Set Up Features.


[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_].[LocK] Press the Y key once the exposure window will read [LocK].• Press the V key once.

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• If the Lock Level is set at 0 or 1 the Memory and Exposure windows willdim.

[codE] If the Lock Level is set for 2,3 or 4 the bottom display will read [codE].Enter your 3 digit code and the press the V key. The Memory andExposure windows will dim. Then press the 0 key, then press the Vkey.

Note: If you want a higher Lock Level after you have completed theIntegrator Program Set Up and/or made any changes return toLock Level to set the desired lock level. (described below)

Lock Level Description and Operation

• Lock Level 0 The Vacuum window will read [0000].

• Lock Level 1 The Vacuum window will read [0001]. Locks functionsfor seconds, enter, vacuum and intensity, for each memory location. Oncethis mode is turned on and the set up programing has been completed,enter all needed information into a memory location. Then press the Ukey the memory window will read [Ac] and the exposure window willread [LocK], press the V key to turn the lock for this memory on or off,then press the U key. When the lock is turned on a decimal point will bedisplayed after each of the two digits in the memory window.

• Lock Level 2, 3 The Vacuum window will read [0002]. or [0003].Locks functions for seconds, enter, vacuum and intensity, for eachmemory location and Integrator Program Set Up Features. Once this modeis turned on, enter all needed information into a memory location. Thenpress the U key the memory window will read [Ac] and the exposurewindow will read [LocK], press the V key to turn the lock for this memoryon. When the lock is turned on a decimal point will be displayed aftereach of the two digits in the memory window. Once this level is turnedon and the set up programing is completed, you will not be able to unlockthe features described above without the Lock Code.

• Lock Level 4 The Vacuum window will read [0004]. Locks all functions.When the lock is turned on a decimal point will be displayed after eachof the two digits in the memory window. Once this level is turned on andthe set up programing has been completed, to change any programedfeatures or exposure statistics you must use the Lock Code to set theLock Level to 0.

Setting or Changing your Lock Code [codE] Feature.


[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_].[Su] Press the Y key. The Memory window will read [Su]. This places you inset up mode.

94MU25 Rev. C1 SW Ver. 2.06 6-3

[codE] Press the e key until [codE] appears in the Exposure window.• Press the V key the Memory and Exposure windows will dim. Enteryour new 3 digit code, then press the V key to set entry.

• Press the 0 key twice to exit this mode.

Vacuum Inspection [HoLd] Feature



[Hold] Press the e key until [Hold] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].

• Press the e key to go directly to the next step or 0,0 to exit the setup mode.

Note: If this feature is turned on the center display will show [----].

Motorized Filter [Fmtr] Feature

Note: If your unit is not equipped with a motorized filter, set this optionto be [oFF_].



[Fmtr] Press the e key until [Fmtr] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


Split Filter [SFmt] Feature

Note: The split filter option will work only if the filter option is turned[_on_].

The OV 45HD enables you to select the percentage of an exposure thefilter will be used. Some proofing materials require only partial filter

6-4 94MU25 Rev. C1 SW Ver. 2.06

exposure. For instance on a 30-unit exposure, with a 50% filter, the framewill draw vacuum and move in as normal. After 15 units, the shutter willclose, vacuum will be retained and the filter will retreat. When the filteris fully retracted, the remaining 15 units will be completed. To activatethis feature:



[SFmt] Press the e key until [SFmt] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


Motorized Diffuser [diFF] Feature

Note: If your unit is not equipped with a motorized diffuser, turn thisfeature [oFF_].



[diFF] Press the e key until [diFF] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


Split Diffuser [SdiF] Feature

Note: The split diffuser feature will work only if the motorized diffuserfeature is turned [_on_].

The OV 45HD enables you to select the percentage of an exposure thediffuser will be used. This could be very helpful when making shrinks orspreads. For instance, on a 30-unit exposure with a 50% diffuser, theframe will draw vacuum and move in as normal. After 15 units, the shutterwill close, vacuum will be retained and the diffuser will extend. Whenthe diffuser is fully extended, the remaining 15 units will be completed.


94MU25 Rev. C1 SW Ver. 2.06 6-5


[SdiF] Press the e key until [SdiF] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


Exposure Count [bcnt] Feature

Note: Another feature of the OV 45HD is its ability to display the numberof exposures that have taken place over a specific period of time.

To activate this option:



[bcnt] Press the e key until [bcnt] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


Note: When activated, the Delay window will show how manyexposures have taken place since last resetting the count. As moreexposures are made, the OV 45HD will keep track of them andshow them in the Delay window. The Delay window will nolonger display the vacuum count down.

Frame Control Switch [FrCl] Feature

! C OLEC recommends leaving this feature turned [_on_] so thatframe movement will not be possible with the frame glass inthe up position.


[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_].

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[Su] Press the Y key. The Memory window will read [Su]. This places you inset up mode.[FrCl] Press the e key until [FrCl] appears in the Exposure window.

• Press the V key to turn function [_on_] or [oFF_].


Automatic Vacuum [AUAC] Feature

Note: The automatic vacuum feature will work only if the frame controlfeature is turned [_on_].



[AUAC] Press the e key until [AUAC] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


Note: With this feature turned on, vacuum will start automatically uponframe closure. Then the operator may press the G button onceto send the frame into the OV 45HD to start the exposure. PressingG once without opening the upper or lower frame will start ablank cycle without vacuum or exposure. If a vacuum delay isused, the exposure will not begin until the vacuum delay timehas counted down.

Continuous Vacuum [CUAC] Feature



[CUAC] Press the e key until [CUAC] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


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Note: This feature must be enabled in combinatiuon with the autostep[AStP] feature. Failure to enable autostep [AStP] disables thecontinuous vacuum [CUAC] feature. This feature may be set foreach individual memory location. Setting this feature for onelocation does not enable it for all locations.

[AStP] Press the Y key until [AStP] appears in the Exposure window.• Press the V key to turn this function [_on_] or [oFF_].• Press the e key until [CUAC] appears in the Exposure window.

• Press the V key to turn this function [_on_] or [oFF_].


Autostep [AStP] Feature

Note: This feature allows you to run a series of exposures.



[AStP] Press the e key until [AStP] appears in the Exposure window.• Press the V key to turn function [_on_] or [oFF_].


Note: If Autostep is selected, the LED over the key U will indicate thefeature is in [_on_] or [oFF_] mode. If [_on_], press V key toturn Autostep [oFF_].

Vacuum Delay [dUAC] Feature

Note: This feature sets memory locations to the vacuum delay specifiedby the operator, but does not override any previously set values.To set all memory locations, you must first clear existing values.

This feature can ensure sufficient vacuum time is provided in the frameprior to exposure. The time begins when the G button is pressed, orwhen the frame is closed in [AUAC] mode. The frame can move into positionand wait before automatically starting the exposure. To activate thisfeature:


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[dUAC] Press the e key until [dUAC] appears in the Exposure window.• Press the V key. The Memory and Exposure windows will dim.

[0030] Enter the desired time you wish to have the vacuum delayed before makingthe exposure. For example, to select 30 seconds, press 3,0 on thenumerical keypad, then press the V key again.


Tray Speed [trAY] Feature

Note: The default tray speed is set at the factory to 5 seconds. OLECdoes not recommend changing this setting without consulting theOV 45HD service manual. Damage to the transport can occur.



[trAY] Press the e key until [trAY] appears in the Exposure window.• Press the V key. The Memory and Exposure windows will dim.

[004.0] Enter the desired time you wish the tray speed set. For example, to select4 seconds, press the 4,0 keys on the numerical keypad, then press theV key again.


Filter Travel Time [Fmtt] Feature

Note: This feature is factory preset to 4 seconds and should not bechanged. The Lock Level must be set to 0 before you can programthis feature and reset when finished.



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[Su] Press the Y key. The Memory window will read [Su]. This places you inset up mode.[Fmtt] Press the e key until [Fmtt] appears in the Exposure window.

• Press the V key. The Memory and Exposure windows will dim.

[004.0] Enter the desired time you wish to delayed before making the exposurein order to allow the filter to move into place. For example, to select 4seconds, press the 4,0 keys on the numerical keypad, then press theV key again.


Diffuser Travel Time [diFt] Feature

Note: This feature is factory preset to 6 seconds and should not bechanged. The Lock Level must be set to 0 before you can programthis feature and reset when finished.



[diFt] Press the e key until [diFt] appears in the Exposure window.• Press the V key. The Memory and Exposure windows will dim.

[006.0] Enter the desired time you wish to delayed before making the exposurein order to allow the diffuser to move into place. For example, to select 6seconds, press the 6,0 key on the numerical keypad, then press theV key again.


System Type Setting [tYPE] Feature

Note: This setting is factory preset and should not be changed, exceptafter updating the firmware.



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[Su] Press the Y key. The Memory window will read [Su]. This places you inset up mode.[tYPE] Press the e key until [tYPE] appears in the Exposure window.

[codE] Press the V key. The [codE] message appears in the Exposure window.• Press 0,0,0 or enter the code you programmed.

[OU45] Press V key until [OU45] appears in the Exposure window.• Press 0,0 to return to normal operation.

To Clear the Lamp Statistics

Note: This step clears all lamp statistics.


[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_].[St04] Press the 7 key 5 times; the Delay window will read [St04] and countdown to [St01]; the Exposure window will read [ClrL], upon pressing

the 7 key the fifth time the Delay window will revert to [SEL_].

Note: You can abort clearing the lamp statistics by pressing the 0 keybefore pressing the 7 key 5 times and you will not clear any ofthe current lamp statistics.

• Press 0,0 to exit this mode.

To Clear the Memory and Exposure Statistics

! C This step clears all programmed memories and resets them to0.• Press the P key to turn the unit on.

[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_].[Pr04] Press the 9 key 5 times; the Delay window will read [Pr04] and countdown to [Pr01]; the Exposure window will read [ClrE], upon pressing

the 9 key the fifth time the Delay window will revert to [SEL_].

Note: You can abort clearing the exposure and lamp statistics by pressingthe 0 key before pressing the 9 key 5 times and you will notclear any of the current exposure and lamp statistics.

• Press 0,0 to exit this mode.

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Calibration Procedures

Note: THE OV 45HD HAS BEEN CALIBRATED AT THEFACTORY. Allow the exposure unit a 2 minute warm-up periodbefore any calibration procedures. This will allow for completeand accurate light level stabilization. The upper tray should beinside while calibrating the unit.

• Press the P key on the integrator to power up the light, the front remoteswitches, and the exposure unit's computer system.

• The exposure unit's calibration has been set at the factory. You may,however, have to adjust calibration for your particular lamp type. One ofthe many convenience features of your OV 45HD is its ability to calibrateitself. To operate this feature, perform the following procedure:

[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_].• Press the m key once and the light level will change to low power.

• Press the m key 5 times. The shutter will open and calibration starts.

• After approximately 20 seconds, press the I key once to advance tomiddle power.

• After approximately 20 seconds, press the I key once to advance tohigh power.

• Press 0,0,0 to exit.

Note: It is not necessary to calibrate both frames. The OV 45 will knowwhich frame was calibrated and will automatically compensatefor the lamp head to frame distance of the other frame. Whencalibrating check the number that is displayed in the Vacuumwindow at low, the number must be between [0005] and [0015] ifit is not, then adjust the photocell to get the display to read between[0005] and [0015]. At the high light level value should be lessthan [0090].

Checking the Measure Numbers

• Press the m key. The Memory window will read [Ut] and the Exposurewindows will read for example [100.0]. This is the "Upper Tray" calibrationnumber.

• Press the Y key. The Memory window will read [Lt] and the Exposurewindows will read for example [_80.0]. This is the "Lower Tray" calibrationnumber.

Note: You may wish to record calibration levels below.

Low Medium High

[Ut]

[Lt]

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94MU25 Rev. C1 SW Ver. 2.06 7-1

7. Integrator Operation

Selecting a Memory Location.

• You may advance to any of the memories you choose. Enter the memorynumber on the numerical keypad, for example 3,0, then press the Ykey.

• You may also cycle up through all the memory locations by pressing theY key repeatedly.

• The first 10 memories on the lower portion of the integrator control panelcan be labeled for quick identification and access.

Entering an Exposure Time

• Press the e key once. The memory and Vacuum windows will dim toindicate the exposure window has been selected.

• Enter exposure time by using the numerical key pad.

Note: There is a decimal point, so you can also select tenths. Forexample, press 1,2,3,0.

• Press the e key again to confirm your entry into the memory.

• You may now select any other options for your exposure, such as a filter,the desired light level and the diffuser. A lit LED over these keys willindicate that feature as being selected.

Entering a Filter into Memory

• While programming, press the F key to select a filter. The first LEDwill indicate the top or Kokomo Filter has been selected and will moveinto place before the exposure begins

• Press the F key again and the second LED will be on to indicate thelower or clearing filter has been selected.

• Press the F key a third time and the right LED will be on to indicateboth filters will be moved into place before the exposure begins.

• Press the F key a fourth time. No LED will be lit, indicating no filterwill be used.

Entering Filter Percentage into Memory

Note: Motorized filter option must be turned [_on_] and Split filter optionmust be turned [_on_] to allow this feature to work.

• Press the F key. The top display will read [F0] and the lower displaywill read [P000].

• Press and release the Y key to cycle through the filter options.

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Example: [F1] is the upper filter, [F2] is the lower filter, [F3] is bothfilters, and [F0] will not use any filter.

• Use the numerical keypad to select what percentage of the total exposurethe filter is needed.

Note: Pressing 5,0 will make the lower display read [P050]. Thismeans that 50% of the exposure will be with the filter and 50%without it. By pressing 7,5 the lower display will read [P075].This means that 75% of the exposure, the first 75%, will use theselected filter. A [P100] reading will use the filter for 100% ofthe exposure.

• Select the desired filter percentage. Press the F key once to return tonormal operation and to begin the exposure.

Entering a Diffuser into Memory

• While programming the memory, press the D key. A lit LED over thekey will indicate that the diffuser will be used for that memory.

Entering a Split Diffuser Option Percentage

Note: The motorized filter option must be turned [_on_] and Split filteroption must be turned [oFF_] to allow this feature to work.

• Press the D key. The center display will read [FACt] (factor) and thelower display will read the percentage of diffusion time.

• Press on the numerical key pad to enter the percentage you want.

Note: Pressing 5,0 will make the lower display read [P050]. Thismeans that 50% of the exposure will be with the diffuser and50% without it. By pressing 7,5 the lower display will read[P075]. This means that 75% of the exposure, the second 75%,will use the diffuser. A [P100] reading will use the diffuser for100% of the exposure.

• Press the D key to return to normal operation.

Resetting the Exposure Count

• After an exposure, press the V key once. The other displays will dim.

• Press the 0 key once to reset the count to zero.

• Press the V key again to return all 3 display windows to normal operation.

Entering a Vacuum Delay into Memory

• Press the V key. The center display will read vacuum delay time currentlyprogramed into the memory selected.

94MU25 Rev. C1 SW Ver. 2.06 7-3

• Press on the numerical key pad to enter the delay you want.

Note: Pressing 3,0 will make the center display read [0030]. Thisgives you a 30 second delay before the exposure can start if thetray is in position. The exposure cannot start if the tray is not inposition. If this time is set to [0000] the integrator will revert tothe default vacuum delay.

Starting a Blank Tray Cycle

This allows you to change frame positions without activating a vacuumor exposure.

• Press and hold the S button.

• Press the green G button.

• Release both buttons when the trays start moving.

Operating in Vacuum Inspection Mode

Note: Vacuum inspection mode must be turned [_on_].

• Place job in upper tray, activate vacuum, and then press the G button.Upper tray will move in exposure unit and no exposure will start.

• Place second job in lower tray, activate vacuum, and then press the Gbutton.. Lower tray will move in and no exposure will start.

• Inspect upper tray, press the G button. Trays will move and exposurewill start.

• Inspect lower tray, press the G button. Trays will move and exposurewill start.

Program the Autostep Function

Note: The Autostep option must be turned on to allow this feature towork.

• Select memory location 0 and program in the first exposure time in theseries and turn the Autostep for that memory on by pressing the Y key.LED above the key is illuminated.

• Select Memory location 1 and program in the second exposure time inthe series.

Note: At all times, the memory window will indicate the memory to beused for the tray which is in the loading position. If the decimalpoints are in the window, this indicates that the memory for thetray in loading position is different than the one being used forthe current exposure. The bottom window will indicate the unitsremaining for the current exposure.

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Making an exposure

• Place your work material into the frame and close the frame lid.

• Press the G button once to start the vacuum pump. The vacuum gaugewill indicate vacuum.

• Press the G button a second time to move the frame into the OV 45HDand start the exposure.

Note: To stop the frame after it has started moving, press the S buttononce. To retrieve it, press the S button again. To stop the frame,examine your work, and continue, press the S button once,then press the G button to continue.

Obtaining Lamp Statistics

Note: This feature allows you to determine how many hours are on thelamp.

Note: To clear Exposure Statistics refer to Section To Clear the LampStatistics.


[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_]. This places you in select mode. You now have the ability toadvance through various exposure statistics.

• Press the 1 key once. The exposure window will display the exposuretime of the last exposure, regardless of the memory or intensity.

• Press the 1 key again. The elapsed time in hours the unit has been onwill be displayed.

Note: This hour count includes all lit lamp time, regardless of whetheror not the unit was exposing.

• Press the 1 key again. The total time in hours the lamp has been used inmedium or center power will be displayed.

Note: This is medium power exposing time.

• Press the 1 key again. The total time in hours the lamp has been used inlow power will be displayed.

Note: This is low power exposing time.

• Press the 1 key again. The total time in hours the lamp has been used inhigh power will be displayed.

Note: This is high power exposing time.

• Press the 0 key once to exit this mode.

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Obtaining Exposure Statistics

Note: This feature allows you to determine how many exposures at allintensity levels your unit has taken on the current lamp.

Note: To clear Exposure Statistics refer to Section To Clear the LampStatistics.


[SEL_] Press the keys 1,2,3t4 in sequence. The Vacuum window willread [SEL_]. This places you in select mode. You now have the ability toadvance through various exposure statistics.

• Press the 2 key once. The integrator exposure window will display thenumber of exposures that have been done at high power.

• Press the 2 key again. The integrator exposure window will display thenumber of exposures that have been done at low power.

• Press the 2 key again. The integrator exposure window will display thenumber of exposures that have been done at medium power.

• Press the 0 key once. That will then take you out of select mode andreturn you to normal operating mode.

Note: The exposure statistics should be reset when the lamp is changed.

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94MU25 Rev. C1 SW Ver. 2.06 8-1

8. MaintenanceLamp Changing Instructions

! W The lamps and safety glass may be very hot and can causeburns.• Turn the unit off. The internal light source blowers will run for

approximately 2 minutes to cool the lamp.

• Turn off the power to the unit and lock it out.

• Remove the right top side cabinet door to gain access to the lamp head.Lift out and up to remove the door from its retainers.

• From above the lamp head support, remove the black plastic dust shield.

• From below the lamphead support, remove the four black thumbscrewsthat go into the lamp head plate.

• Slide the lamphead to the operator's right side.

• Support the safety glass on the lamp head and loosen the two thumbscrewsto release the glass and carefully slide the holding brackets up or down.The safety glass will slide out on either side.

• Loosen the thumbscrews for both lamp leads.

• Carefully lift each end of the lamp to disconnect it from the holders andremove it.

• Clean the reflector with a mild solvent, such as rubbing alcohol, and aclean soft cloth. Use glass cleaner to clean the safety glass. Dirty reflectorsand glass can substantially reduce light output.

! C Wear lightweight fabric gloves and unpack the new lamp. DoNOT touch the lamp with your hands; oils and acids fromyour skin will contaminate the quartz tube and shorten its lifeconsiderably. Clean the lamp with the alcohol wipes that aresupplied with the lamp.

• Install the lamp ceramic ends into the lamp support assemblies. Be sureto center the lamp

• Insert the lamp wire spade lugs under both thumbscrews and tighten.Make certain that the wires are positioned such that they do not touch thelamp body or reflector and cooling tube.

• Reinstall the safety glass and tighten the thumbscrews. Make sure thesafety interlock lever is pressed towards the lamp by the safety glass.Also make sure the safety glass is loose enough to allow for heat expansionduring an exposure.

• Slide the lamphead back to its original position and reinstall the fourblack thumbscrews and the plastic dust shield.

• Reinstall the side cabinet door.

• Turn on the power to the unit and press the P key on the integrator toignite the lamp.

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Maintenance Schedule

Monthly Maintenance (Approximately 1 Hour)

• Clean all external filters

• Check blanket seals for cuts or tears

• Lightly oil both tray tracks

Semi-Annual Maintenance (Approximately 2 Hours)

! W Be sure incoming power has been turned off before attemptingthis procedure.• Perform monthly maintenance.

• Replace lamp, or as needed.

• Vacuum dust from unit and power supply.

• Clean reflector and safety glass on lamp head.

• Lightly lubricate and check frame drive chain tension.

• Lightly oil upper and lower light blocks.

• Clean both filters on each vacuum pump.

• Lightly lubricate all eight (8) gas spring mounts.

Maintenance Procedures

• Cleaning External Filters

The OV 45HD has a filter in the lower rear center of the unit. This filtershould be inspected and cleaned on at least a monthly basis.

• Inspecting the Blanket Seal

The blanket seal should be checked every month or periodically for cracks,cuts and tears. A faulty seal will greatly increase vacuum time. If a sealis found to be faulty, the blanket should be renewed as soon as possible.

• Lubricating the Tray Tracks

! C Do NOT use an Aerosol Teflon or Silicone spray in theOV45HD.• Both the upper and lower tray tracks should be lightly oiled every month.

Soak a small piece of cloth or paper towel in a lightweight machine oiland rub it on the tray track bearing surface. Keeping the linear bearingsoiled will ensure smooth and quiet operation of the motorized tray system.

Cabinet Dust Removal and Blower Maintenance

• On a semiannual interval the inner cabinet and power supply should becleaned to prevent dust buildup.

• Turn the OV 45HD off and allow the internal blowers to run throughtheir cool-down cycle.

• Disconnect power and remove both lower side cabinet doors.

• Lift out and up on the door to remove it from its retainers. Remove thepower supply cover.

94MU25 Rev. C1 SW Ver. 2.06 8-3

• By using a vacuum or compressed air, remove all accumulated dust anddebris from the cabinet and the power supply.

! C Do NOT use an Aerosol Teflon or Silicone spray in theOV45HD.• If the lamp head has an external blower: There is an oil access hole on

the motor housing which allows the application of a few drops of lightmachine oil to the motor bearings. The lower cabinet blower also has anoil access hole for light machine oil.

Drive Chain Lubrication and Adjustment

! C Do NOT use an Aerosol Teflon or Silicone spray in theOV45HD.• While performing the semiannual maintenance, the frame drive chain

should be lightly oiled. Rubbing an oil soaked rag along the chain willsufficiently lube it. Do not apply so much oil that it will run or drip.

• The chain's adjustment is along the inner left hand side of the nose section.The adjustment should be to allow no more than a 1" chain flex betweenthe drive motor and the adjuster wheel.

• Turning the adjuster nut clockwise will tighten the chain tension andcounterclockwise will loosen it.

Light Block Lubrication

! C Do NOT use an Aerosol Teflon or Silicone spray in theOV45HD.• During the semiannual procedures, the hinge on the upper and lower

light blocks should be lightly oiled. A coat of light machine oil can beapplied to the piano-style hinge on the light blocks. Be sure not to usetoo much oil or the excess could drip on the trays during operation.

Vacuum Pump Maintenance

! C Never lubricate this oilless air pump.• The end plate, body, rotor and mounting bracket are all cast iron.Consequently any moisture that accumulates in the pump will tend tocorrode the interior, especially if it stands idle. The muffler box, on thefront of the unit, is made of aluminum. The vanes are made of hard carbonand are precision ground. They should last many thousands of hours,depending upon the degree of vacuum or pressure at which the pump isrun.

• The carbon vanes and grease packed motor bearings require no oil. If themotor fails to start or slows down when under load, shut the unit off andunplug. Check that the supply voltage agrees with the motor post terminalsand the motor data name plate. If anything appears to be wrong with themotor, return the complete pump to an OLEC servicing dealer.

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94MU25 Rev. C1 SW Ver. 2.06 9-1

9. Troubleshooting

Error Messages

Note: If an error occurs, the machine displays an error code to aid introubleshooting. The message [Err_] will appear in the middledisplay, and a number in the lower display. Look up the numberbelow for a description of the condition.

[0001] Frames did not reach intended position after the maximum amount oftime. Solution: Determine why. Were the frames moving at all? Did theyget close? Is something obstructing their movement? See I/O test modefor instructions on how to test motors and switches.

[0002] Not used.

[0003] Internal error. Please call your service rep. Solution: Cycle the powerswitch. Please note the circumstances under which this error occurred;was the machine exposing? Calibrating? Idle? Were new exposure valuesbeing entered? What was the last button pressed? How long ago?

[0004] Frames not in position at start of exposure. Solution: Put the frames inposition by cycling the power switch. If the frames don't move, checkthe wiring to the frame motor and the frame position sensing switches. Ifeverything is OK, and this error still occurs, call your servicerepresentative. See also the I/O test mode description.

[0005] Switch error. The machine thinks both frames are at the exposure position.Possible causes are: Bad cable between master board and memory board,switches have failed, bad or no connection to switches.

[0006] Communication error. Remote board is not communicating with themaster board. Possible causes are: no power to remote board, bad ordisconnected communication cable.

[0007] Remote board has reset or temporarily lost power. After clearing theerror, normal function should continue.

[0008] At least one lamp intensity/frame/surface has not been calibrated.Solution: Ensure the unit has been completely calibrated.

9-2 94MU25 Rev. C1 SW Ver. 2.06

94MU25 Rev. C1 S/W Ver. 2.06 10-1

10. Warranty

OLEC

Limited WarrantyOLEC equipment is warranted against defects in material for ONE (1) Year from dateof purchase. Faulty parts will be repaired, replaced, or purchase price refunded at OLEC'soption, for the original Buyer, provided the parts have been replaced by authorizedpersonnel and are returned prepaid to the OLEC factory in Irvine, CA. Shipment mustbe accompanied by proof of purchase and the Dealer/Distributor name.

This Warranty applies only to equipment which was installed and used according toinstructions and in the way it was intended to be used by the manufacturer. Unauthorizedrepairs, use of non-OLEC parts and lamps, modification, or Serial Numbers that havebeen removed or defaced, void this Warranty. Glass parts are not included in thisWarranty. Lamps are covered according to the Warranty below.

The OLEC Corporation and/or the Seller shall not be liable for any loss, damage orinjury arising out of the improper use of, the failure of, or the inability to use theequipment. It is the Buyer's responsibility to ascertain the suitability of the equipmentfor the application. The Buyer assumes all risk and responsibility for the properinstallation, for reading the Instruction Manual and retaining it with the equipment forthe safe use of the OLEC product. All operators must be made familiar with the properuse and safe operation upon installation and periodically thereafter.

No one is authorized to assume any obligation, either on behalf of the OLEC Corporationor the Seller, which is not in accordance with the above.

Lamp WarrantyShould any original OLITE Lamp fail prematurely when used in OLEC lights, itshould be returned promptly to OLEC, prepaid. It should be accompanied by proof ofpurchase, explanation of the type of failure incurred, and the approximate useful life ofthe lamp prior to failure. If it is determined by OLEC that the failure or shortened lifehas been caused by faulty material or workmanship, full or partial replacement will beextended to the Buyer.

IMPORTANT: The use of any lamp, other than those purchased or approved by OLECwill void this Warranty.

All Warranty Service should be handled through the Distributor

through whom the equipment was purchased.

O

Corporation1800 E. St. Andrew Pl, Santa Ana Ca U.S.A. 92705

U.S.A. (714) 258-5600 Fax (714) 258-5601

ov 45hd image management system operation manual94mu25 rev. c1 sw ver. 2.06 2-1 2. introduction...

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