REV: 000 Lumitron/ Luminator
Table Of Contents Introduction 3 Standard Operating Guide 3 Features & Specs 3 External Layout 4-8 Internal Layout 9-10 Wiring Diagrams 11 F.A.Q. 12-14 Ballast to Lamp Relationship 15 Timer Setting and Programming 16 Comprehensive Parts List 17 2
Introduction: The Lumitron is a high end exposure system in a small package. This unit has high output UV fluorescent bulbs that offer balanced light distribution throughout. Using the same powerful vacuum as our larger units, the Lumitron gives you perfect contact between your film positive and screen. The Luminator is an expandable exposure unit specially designed for the startup shop on a budget. This unit has high output UV fluorescent bulbs that offer balanced light distribution throughout. This system is compatible with direct emulsion or capillary films that allow versatility in your stencil systems. It comes standard with a 16 x 20" pressure pad to ensure even contact between your film positive and your screen. Standard Operating Guide: Plug in the unit, make sure it is plugged into a 3-wire grounded circuit (115 or 220 volt) depending on which machine you have. If you are unsure of the power requirements please call Workhorse Products 1-800-778-8779 DO NOT ALTER OR MODIFY THE PLUG IN ANY WAY! Turn on main power rocker switch until it lights up. Release the single latch and open the vacuum frame and place the coated, dry screen, print side down in the center of the glass with the film or vellum underneath, either taped to the glass or taped to the print side of the screen. (For optimum performance, place your screens in the center of the unit above the light source) Place one end of the rope next to the vacuum nipple located toward the rear and in the center of the vacuum frame, drape the other end of the rope across the inside (squeegee side) of the frame. This will allow all of the air to be evacuated out of the inside of the screen and provide necessary contact between your film or vellum and the emulsion. (Do not place the rope directly under the vacuum nipple as this will reduce the vacuum speed and could negatively affect your blanket to screen contact) Close the vacuum frame and lock it into position with the single latch, then turn on the unit, the vacuum will automatically come on. Wait until the blanket has drawn down around the screen completely before you start your exposure. The vacuum motor will change sound slightly as it goes into idle mode. Once the exposure timer has beeped indicating its finish, turn off the vacuum rocker switch and release the latches. Open the vacuum frame and remove your screen. NOTE: Open the frame slowly as screens can get stuck to the vacuum blanket due to tape, ink residue or wet emulsion( Keep your screens as clean as possible and inspect your frames periodically for sharp edges and splinters. This will aid in keeping your vacuum blanket and glass clean, and prevent wear on the vacuum blanket). Features/ Specs: Power Options: Construction: 115V, Single Phase, 60hz, 620 watts, 6 amps 230v (Euro), Single Phase, 50hz, 620 watts, 3 amps All steel construction. Features: UV Fluorescent Light system Dimensions: Digital time control, auto-shutoff and auto-repeat functions. Dimensions (LxWxD): 41" (104cm) x 43" (109cm) x 8" (20cm) 3
Front View Control Panel Main Power Switch Timer 115V Part A Part B Timer 220V (EURO Only) Part C 4
Lid Clamp Lid Clamp Part D Clamp Hook Hardware Included With Clamp Hardware Included With Clamp Hardware Included With Clamp 5
Gas Spring Gas Spring Part E Ball Stud Ball Stud Part F 6
Hinge Lock Washer Part G Pan Head Screw Part H Hinge Part I Pan Head Screw Part W Vacuum Assy. Mounted Blanket Part J Vacuum Pump 220V (EURO Only) Part K Vacuum Pump 115V Part L Vacuum Hose (2ft) Part M Modified Stem Part N Fender Washer Part O 7
Rear Mounted Receptacle Receptacle 115V, 15A Part P Receptacle 250V, 15A (EURO Only) Part Q 8
WARNING! RISK OF ELECTRICAL SHOCK! Turn ALL power to unit OFF before service. All service should be done by or under the supervision of a trained technician Control Panel, Internal Timer 115V Part B Timer 220V (EURO Only) Part C Main Power Switch Lamp Bank Part A Black Light Part R Black Light Part R Lamp Socket Part S 9
Left Ballasts, Mounted Ballast 115V Ballast 115V Ballast 115V Part T Part T Part T Ballast 220V Ballast 220V Ballast 220V (EURO Only) Part U (EURO Only) Part U (EURO Only) Part U Right Ballasts, Mounted Ballast 115V Ballast 115V Ballast 115V Part T Part T Part T Ballast 220V Ballast 220V Ballast 220V (EURO Only) Part U (EURO Only) Part U (EURO Only) Part U 10
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WARNING! RISK OF ELECTRICAL SHOCK! Turn ALL power to unit OFF before service. All service should be done by or under the supervision of a trained technician FAQ: 1. The vacuum is taking along time to remove all of the air. This can be caused by incorrect placement of the nylon cord. The nylon cord is used to create paths for the air to escape from the center of the screen. Place one end of the rope next to the vacuum nipple located toward the rear and in the center of the vacuum frame, drape the other end of the rope across the inside (squeegee side) of the frame. This will allow all of the air to escape out of the inside of the screen and provide necessary contact between your film or vellum and the emulsion. Do not place the rope directly under the vacuum nipple as this will reduce the vacuum speed and could negatively affect your blanket to screen contact If the nylon cord is properly placed, check the adjustment of the vacuum frame clamps, if out of adjustment tighten the nylon lock nuts an equal amount of turns on each one and try closing the frame. If it takes an excessive amount of force to lock them down back the nuts off and try again. They should be firm but no excessive to ensure a tight seal is formed. Also check the clear vacuum line running from the vacuum pump to the modified stem (Image 1) Check for kinks or disconnected lines, if necessary un-kink or replace vacuum lines. Image 1 2. The bulbs in my exposure unit are flickering (When I touch them they stop) This is caused by improper grounding. Make sure the receptacle that the unit is plugged into is properly grounded. Also have an electrician check the building ground. Another Symptom of a bad ground is when the timer is activated only some of the lights come on. 3. One of my bulbs is not coming on. This may be cause by a bad ballast. To test the bulb/ ballast with power to the unit off, remove the non-functioning bulb and swap it with a known working bulb. Turn the unit off, if the if the position of the non functioning bulb has not changed the ballast controlling that bulb is bad. If the position of the non functioning bulb does change, the bulb will need to be replaced. 12
3. (Continued) To replace the ballast, first remove the glass. Next, Identify which bulb is not working (See page 14, Ballast to Lamp Relationship) Image 2 Lamp #1 Lamp #2 Lamp #3 Lamp #4 Lamp #5 Lamp #6 Next locate the ballast covers located on the left and right sides. The position of the non functioning light will determine which cover to remove. If the non functioning lamps are 1, 2, or 3 the left cover will need to be removed. If the non functioning lamps are 4, 5, or 6 the right cover will need to be removed (Image 3 and 4) Image 3, Left Ballast Bank, Lamps 1-3 Image 4 Right Ballast Bank, Lamps 4-6 With the correct cover now removed, using the guide one page 15 to locate the faulty ballast. Once identified take notes of how the original ballast is wired, then, with the unit unplugged remove the ballast and place the new ballast in the same location. Connect the new ballast the same way the original was, if the correct plugs are not present on the new ballast use wire nuts to secure the wires together. Replace the covers and glass, then plug the unit back in. With the new ballast installed the unit is now ready for use. 13
4. The timer starts to countdown but no lights come on. This may be caused by a faulty timer. To test the timer remove the glass, located at the front of the unit the timer will now be exposed (Image 5) (Image 5) (Image 6) Locate the terminals marked #3 and #4, with power to the unit off, using a blade style fuse (Image 6) most commonly found it automotive applications, jumper the two wires together. Now turn the unit on, if the lights come on the timer will need to be replaced. 5. The vacuum pump is not running. With power to the unit off, unplug the vacuum from the rear of the unit. Next plug the unit into a receptacle in the building. If the vacuum still will not run the vacuum will need to be replaced. If the vacuum begins to run, with power to the unit on, using a digital Volt/Ohm meter in the ACV (200 750) setting, place one probe in one side of the receptacle and the other probe in the other (Image 7) the meter should read 115v-120v AC. If not turn the unit off and check the receptacles for loose connections. (Image 5) 14
Ballast to Lamp Relationship: Image 3 Lamp #6 Lamp #5 Lamp #4 Lamp #3 Lamp #2 Lamp #1 Ballast #4 Ballast #3 Ballast #5 Ballast #2 Ballast #6 Ballast #1 Note: The colors in this representation do not reflect the wire colors or harnesses in any way, simply to differentiate the ballast to lamp relationship. 15
Timer settings and programming: Setting Interval Timer: In modes 1 3, the device functions as a simple countdown timer. When you set the value, press the Start/ Resume button. When the value reaches 0, the relay is turned OFF and the beeper beeps 6 sets of 2 (250ms) beeps. To enter one of the 3 countdown modes, press and hold the Mode button for 1 second. Holding down this button the mode will switch every 2 seconds. Each time the mode switches, the appropriate LED of mode LEDs will be turned ON and the value displayed will change to the modes default value. An audible ¼ beep will also be heard. Mode 1: 0 99 second: DEFAULT DISPLAY =.01 Mode 2: 0 99 minute: DEFAULT DISPLAY = 00.00 Mode 3: 0 99 hour: DEFAULT DISPLAY = 00.00 Once the countdown value has been set, you can now start the timer by pressing the Start/ Resume button, the relay is turned ON. While the timer is counting down the user can stop the event by pressing the Stop button. The current countdown value will remain on the display. If you want to resume the session you just need to press the start button again. Counting will proceed from the point where stopped. During this operation, the run LED blinks once a second. Once the timer has counted down to 0 and stopped, you can execute the same session (time value) by pressing the [START/RESUME] button again. This will recall the timer value and display it. At this point, you have two options. The first being the ability to change the value by using the Increase or Decrease buttons and the second being the ability to use the same value and starting the event again by pressing the Start/ Resume button. Repeat Feature: the timer will remember the last time set. To change the setting from the original setting, press start switch to recall previous setting then input new setting. Before using exposure unit for the first time obtain an exposure calculator from your supplier. 16
Comprehensive Parts List. Description P/N Description P/N A. "Main Power" Switch 30-3100-2 B. Timer, 115V 30-76049-1R C. Timer, 220V (EURO Only) 30-76057-1 D. Lid Clamp 40-94462 E. Gas Spring 40-75021 F. Ball Stud 40-75015 G. Lock Washer 43-LOK-250-30 H. Pan Head Screw 41-PHMS-250-60 I. Hinge 47-75011 J. Blanket 20502R K. Vacuum Pump 220V (EURO Only) 31-76056 L. Vacuum Pump 115V 31-76051 M. Vacuum Hose (2 Feet) 52-74014 N. Modified Stem 75009 O. Fender Washer 43-FND-375-30 P. Receptacle 115V 15A 39-76212 Q. Receptacle 250V 15A (EURO Only) 39-2150 R. Black Light 34-1050 S. Lamp Socket 34-1005 T. Ballast 115V 34-2010 U. Ballast 220V (EURO Only) 34-2040-1 V. Weight Plate (Luminator) 11584 W. Sems Pan Head Phillips Screw 41-SEMS-10-20 17