Martin MAC 2000 Wash XB Bedienungsanleitung

MAC 2000 Wash

service manual

MAC 2000 Wash Service Manual

PROCEDURES

Head procedures

CMYC belts and flags, replace . . . . 12

CMYC module, install . . . . . . . . . . . . 5

CMYC module, remove . . . . . . . . . . . 5

CMYC module, separate . . . . . . . . . 11

CMYC motors, replace . . . . . . . . . . 13

Color wheel 1 belt, replace . . . . . . . . 6

Color wheel 1 motor, replace . . . . . . . 6

Color wheel 2 belt, replace . . . . . . . . 6

Color wheel 2 motor, replace . . . . . . . 6

Color wheel module, install . . . . . . . . 7

Color wheel module, remove . . . . . . . 5

Color wheels, adjust . . . . . . . . . . . . . 7

Dimmer blades, replace & adjust . . . 10

Dimmer motor, replace . . . . . . . . . . 11

Effect fans, replace . . . . . . . . . . . . . . 7

Head side covers, remove and install 7

Heat filter assembly, remove & install 8

Heat filter, replace . . . . . . . . . . . . . . . 9

Left lamp fan, replace . . . . . . . . . . . . 7

Reflector, replace . . . . . . . . . . . . . . . . 9

Right lamp fan, replace . . . . . . . . . . . 8

Starter, replace . . . . . . . . . . . . . . . . . 9

Zoom belt, replace . . . . . . . . . . . . . . . 4

Zoom lens assembly, replace . . . . . . 5

Zoom module, install . . . . . . . . . . . . . 3

Zoom module, remove . . . . . . . . . . . . 3

Zoom motor, replace . . . . . . . . . . . . . 4

Zoom rail, replace . . . . . . . . . . . . . . . 5

Yoke procedures

Tilt belt, left, replace . . . . . . . . . . . . .14

Tilt belt, right, replace . . . . . . . . . . . .15

Tilt motors, replace . . . . . . . . . . . . . .16

Tilt motors, synchronize . . . . . . . . . .16

Yoke covers, remove . . . . . . . . . . . .14

Base procedures

Ballast fan, replace . . . . . . . . . . . . . 19

Base fans, replace . . . . . . . . . . . . . . 19

Electronic ballast, replace . . . . . . . . 19

Left pan motor, replace . . . . . . . . . . 20

Main PCB, replace . . . . . . . . . . . . . 18

Pan belt, replace . . . . . . . . . . . . . . . 17

Pan motors, synchronize . . . . . . . . . 21

Power supply, replace . . . . . . . . . . . 18

Right pan motor, replace . . . . . . . . . 20

INTRODUCTION

Risk of electrical shock

Removal of any cover exposes connectors

that carry lethal electric currents. While

working on a fixture under power:

• Make sure the fixture is electrically

grounded.

• Use a supply with ground-fault-inter-

rupt protection.

• Never touch any connector that carries

voltage.

• Be careful with tools that conduct elec-

tricity.

Risk of UV radiation and

lamp explosion

Discharge lamps emit harmful ultraviolet

(UV) light that can cause eye and skin burns

through direct exposure. They also work

under high pressure that occasionally causes

them to explode. To eliminate the risk of

injury from the discharge lamp,

• Never operate the lamp with covers or

lenses removed.

• Do not look directly into the light.

Electrostatic discharge

Printed circuit boards (PCBs), individual

ICs, and Hall sensors can be damaged by

electrostatic discharge (ESD). To avoid

damaging these ESD sensitive parts:

• Ensure that you and your tools have the

same potential (ground) as the fixture

before and when handling any of the

above components.

• Store PCBs in antistatic (electrically

conducting) bags and store ICs in anti-

static foam.

• Power off the fixture and allow capaci-

tors do discharge before removing or

inserting components on the PCB.

Inductive loads

Power off the MAC 2000 Wash before

connecting or disconnecting step motors.

Failure to do so can damage the motor

drivers.

Threadlock

Threadlock is highly recommended on all

machine screws except self-tapping

(Taptite) screws to prevent loosening.

Threadlock should be reapplied if the

screws are removed.

Two types of threadlock are available from

Martin. For set screws, use Loctite 290, P/N

37020002. For all other screws, use Loctite

243, P/N 37021002. Both come in 10 ml

tubes.

Be careful to avoid getting any material on

shafts or axles. A needle and syringe makes

an idea application tool.

Long set screws: Start the screw and turn it

until it contacts the shaft. Back the screw 2

turns, apply a small drop or 2 of Loctite 290

to the threads, and then tighten the screw as

you normally would.

Short set screws: Back the set screw out of

the adaptor until 2 threads stick out of the

shaft. Apply a small drop or 2 of Loctite 290

to the threads, and then tighten the screw

within 60 minutes.

Other metric screws: Apply a drop of

Loctite 243 (blue) to 3 or 4 threads, or

spread a thin stripe with a syringe, before

starting the screw.

Self-tapping screws

The reuse of self-tapping “Taptite” screws

is not recommended as these screws are

designed to cut threads and can strip

existing threads when reinserted. Change to

metric hardware of the same size when

reinstalling parts originally held with

Taptites.

If installing a new part without threads, use

new self-tapping screws. Do not use old

taptites to cut new threads!

Lubrication

Silicone grease, P/N 37302002, “Silicon

grease, clear, 100g”, is used, for example, to

lubricate brass bushings inside of pulleys

and between moving metal plates such as

the motor bracket for color wheel 1 on the

MAC 2000 Wash.

Slides are generally lubricated with the high

viscosity silicone oil, P/N 37302005, “High

viscosity silicone oil, 200 ml, in applicator

bottle.”

Bearings are lubricated with P/N 37302004,

“Silicone oil, 200 ml, in applicator bottle”.

Comments

Your feedback is appreciated. Please send

your comments and suggestions for

improvements to:

Martin Professional

Olof Palmes Allé 18

DK 8200 Aarhus N, Denmark

Attn: Service

E-mail: servic[email protected].

Always disconnect the fixture

from AC power before and while

servicing.

HEAD PROCEDURES

Zoom module, remove

1Remove the top and bottom head

covers and the front lens. Fully back out

the thumbscrew for the lens retaining

wire.

2Unplug cables from the outside row

of the left-side zoom module junction

print. Unplug the unlabeled 2-pin con-

nector from socket 38.

3Unplug the wires from the outside

row of the right-side zoom module junc-

tion print. Unplug connectors 42, 23,

and the unlabeled 2-pin fan plug from

the inside row.

4Unplug the wires from the back row

of the CMYC module junction print and

the thermo-sensor, which is in front of

the junction print.

5Unplug connector 16 from the dim-

mer junction print.

6Remove the 4 zoom module fasten-

ing screws.

7Pull the zoom module (and attached

color wheel module) up, out of the

head.

Zoom module, install

1Lock the head in the horizontal, top

up position.

2Place the ends of the wire bundles

outside of the head, forward of the

yoke.

3Lower the module into the chassis,

working it past each “sticking point” in

turn. Fasten.

4Reconnect the wires to the left and

right junction prints.

5Plug connector 16 into the dimmer

junction print. (Fig. 4)

6Insert the CMYC wire bundle into

the slot in the zoom module. Connect

The color wheel module remains

attached to the zoom module in

this procedure.

Fig. 1 Unplug left junction print

Fig. 2 Unplug right junction print

Fig. 3 CMYC thermo-sensor PCB

Fig. 4 Dimmer junction PCB

Fig. 5 Zoom module screws

Fig. 6 Place wires forward of yoke

Fig. 7 “Sticking points”

Fig. 8 Right junction connections

MAC 2000 Wash Service Manual

the wires to the junction print. Secure

the bundle under the flexible tie.

Zoom belt, replace

1Remove the zoom module. (p. 3)

2Remove the belt clamp screws.

3Loosen the set screws and remove

the belt clamp from the belt.

4Flip the module over and loosen the

zoom motor screws. Push the motor in

to loosen and remove the old belt.

5Pull the belt tension pulley forward

and loop the new belt over it as shown

in Fig. 12.

6Lead the belt to the motor and loop

it over the gear. Loop the other end of

the belt over the front pulley.

7Tighten the belt by moving the zoom

motor back until the tension pulley

starts to move. Tighten the motor

screws.

8Place the belt clamp on the belt with

the set screws inside the loop and the

small bar between the belt and the

screws. Tighten the set screws.

9Fasten the belt clamp to the lens

car.

10 Install the zoom module. (p. 3)

Zoom motor, replace

1Remove the zoom module. (p. 3)

2Unplug the motor wires and remove

the motor screws. Loosen the bracket

enough to remove the motor.

3Transfer the gear to the new motor

with 0.6 mm (0.025 in.) clearance

between the motor and the gear.

Tighten the set screw.

4Position the motor in the bracket

with the socket facing out. Tighten the

bracket screws. Start the motor screws

but do not tighten.

5Place the belt over the gear. Push

the motor out to tighten the belt until the

tension pulley just begins to move.

Tighten the motor screws.

6Plug in the motor wires.

7Install the zoom module. (p. 3)

Fig. 9 CMYC wire bundle path

Fig. 10 Belt clamp screws

Fig. 11 Loosen the belt

Fig. 12 Loop belt over tensioner

Fig. 13 Zoom belt

Fig. 14 Belt clamp

Fig. 15 Loosen bracket to remove motor

Fig. 16 0.6 mm (0.025 in.)

MAC 2000 Wash Service Manual

Zoom lens assembly, replace

1Remove the zoom module. (p. 3)

2Remove the belt clamp screws.

(Fig. 10)

3Remove the 4 screws that fasten

the zoom car to the zoom slide. Do not

remove the slide from the rail.

4Fasten the replacement zoom lens

assembly to the slide.

5Fasten the belt clamp.

6Install the zoom module. (p. 3)

Zoom rail, replace

1Remove the zoom lens assembly.

(p. 5)

2Separate the color wheel module

from the zoom module. (p. 5)

3Remove the white plastic plate at

the back of the module.

4Unscrew and remove the zoom rail.

5Starting with the third hole from the

front, fasten the new zoom rail to the

zoom module with 5 M3x6 panhead

Torx screws, P/N 08050702.

6Place the stand-off on the M3x12

panhead Torx screw and insert the

screw through the first hole in the rail.

Fasten with an M3 nut.

7Install the zoom lens car stop. (Fig.

18)

8Install the color wheel module. (p. 7)

9Install the zoom lens assembly. (p.

10 Install the zoom module. (p. 3)

CMYC module, remove

1Remove the zoom module. (p. 3)

2Remove the module fastening

screws: there are two on the top and

two on the bottom.

3Slide the module forward as far as it

will go, then lift it out of the top of the

head.

CMYC module, install

1Lock the head in the horizontal, top

up position.

2Move the wire bundles forward and

out of the way.

3Orient the module with the junction

print up and to the right. Lower the

module into the chassis at an angle.

Square the module with the flaps over

the chassis and slide it back as far as it

will go. Align the screw holes and fasten

at the top and bottom.

4Install the zoom module. (p. 3)

Color wheel module, remove

1Remove the top head shell.

2Disconnect plugs 28/29, 9, and 10

from the inside row of the left-side zoom

module junction print. (Fig. 1)

When removing the zoom car, do

not remove the slide from the rail.

Fig. 17 Do not remove slide from rail

Fig. 18 Zoom lens car stop

Fig. 19 Zoom slide stop

Fig. 20 1 of 4 CMYC module screws

Fig. 21 Insert module at an angle

Fig. 22 Color wheels 1 & 2

MAC 2000 Wash Service Manual

3Remove the color module attach-

ment screws and separate the color

wheel module from the zoom module.

Color wheel 1 belt, replace

1Remove the top head shell.

2Press the motor down to release

belt tension. Remove the old belt and

install a new one.

Color wheel 1 motor, replace

1Remove the color wheel module. (p.

2Release belt tension and slip the

belt off the motor gear. (Fig. 24)

3Remove the sensor print to access

the screw underneath. Remove the

screws that fasten the motor bracket to

the module plate.

4Unhook the spring from the motor

bracket. (Fig. 28)

5Transfer the gear (or install a new

one) to the shaft of the replacement

motor with 10 mm clearance between

the bottom of the gear and the face of

the motor. Tighten the set-screw. (No

further adjustment is required.)

6Transfer the mounting bracket to the

new motor. Do not open the new motor!

7Apply a drop or two of silicone

grease (P/N 37302002) to the motor

bracket. Attach the bracket to the plate

with metric screws and bushings.

8Hook the tension spring onto the

motor bracket and connect the motor

wires.

9Reinstall and connect the Hall sen-

sor circuit board.

10 Reinstall the drive belt.

11 Install the color wheel module. (p. 7)

Color wheel 2 belt, replace

1Remove the color wheel module. (p.

2Unscrew and remove the wheel.

3Remove the old belt. Place the new

belt over the motor gear and the axle.

4Reinstall the color wheel and loop

the belt onto the color wheel gear.

5Place the open position over the

tension pulley, pull the pulley in, and

loop the belt over the pulley.

6Install the color wheel module.

Color wheel 2 motor, replace

1Remove the color wheel module.

2Remove the belt from the tension

pulley and motor gear.

3Unscrew and unplug the old motor.

4Transfer the standoffs to the

replacement motor. Do not open the

new motor!

5Transfer the gear (or install a new

one) to the shaft of the replacement

motor with 1.1 mm clearance between

the bottom of the gear and the face of

the motor and tighten the set-screw.

(No further adjustment is required.)

6Place the motor on the plate with

the socket towards the other motor.

Fig. 23 Color module screws

Fig. 24 Release belt tension

Fig. 25 Motor bracket screws

Fig. 26 10 mm clearance

Fig. 27 Motor and bracket

Fig. 28 Color wheel 1 motor

Fig. 29 Color wheel 2 belt

MAC 2000 Wash Service Manual

Fasten with 4 M3x6 mm countersunk

screws. Plug in the wires.

7Loop the belt over the motor gear

and tension pulley. Verify that the wheel

turns smoothly without binding.

8Install the color wheel module. (p. 7)

Color wheels, adjust

The color wheels are magnetically indexed

using a routine that does not require

mechanical adjustment.

If the wheels are not centered in the optical

path, the Hall sensor IC is probably bent out

of position. The problem can be solved by

entering a position offset in the calibration

menu. In extreme cases it may be necessary

to move the sensor IC.

Color wheel module, install

1Insert the module in the head, mak-

ing sure that the bottom flaps straddle

the chassis plate. Fasten.

2Connect plugs 28/29, 9, and 10 to

the inside row of the left-side zoom

module junction print. (Fig. 1)

Head side covers, remove

and install

1Remove the screws that fasten the

cover: each cover has two screws.

2Pull front covers straight out to

remove. The rear covers must be pulled

out 1 cm at the back before pulling

back.

3When reinstalling the front covers,

verify that the air filter lies flat.

4When reinstalling the rear covers, it

helps to tilt the head down.

Effect fans, replace

1Remove the zoom module. (p. 3)

2Unplug, unscrew, and remove the

defective fan.

3Install the replacement fan with the

air-flow arrow pointing in. To avoid strip-

ping the threads, use M4x30 metric

screws (P/N 008070410) instead of the

original taptites.

4If replacing the left fan, connect the

plug to the front 2 pins of socket 38.

(Fig. 1)

5If replacing the right fan, connect

the plug to the rear 2 pins of socket 37.

(Fig. 8)

6Install the zoom module. (p. 3)

Left lamp fan, replace

1Remove the zoom module (p. 3)

and CMYC module (p. 5). Remove the

left-rear side cover. (p. 7)

2Cut the cable tie if required to

access the lower fan screw. Remove

the fan attachment screws.

3Work the fan assembly free of the

reflector housing.

4Remove the metal heat shield and

the ceramic insulation from the old fan.

5Cut cable ties as required and free

the fan cable. Remove the fan.

6Prepare the new fan. Cut a piece of

foil backing (P/N 33002002) to fit and

apply it to the back of the fan. Place a

40 cm (16 in.) length of sleeve over the

leads, cut the leads to length, and

install a 2-pole plug.

7Install the insulation and heat shield

on the foil-backed side of the prepared

fan.

8Work the fan assembly back into

place and fasten.

9Lead the fan cable forward, through

the holes in the side chassis. Slide the

cable insulation fully back to the fan and

then retie the bundle above the starter.

10 Replace the cable tie at the bottom

fan screw.Keep the wires and thermo-

Fig. 30 Color wheel motors

Fig. 31 Bottom flaps straddle plate

Fig. 32 Apply foil to fan

Fig. 33 Fan heat shield and insulation

Fig. 34 Cable path

MAC 2000 Wash Service Manual

switch clear of the fan to maintain maxi-

mum airflow.

Right lamp fan, replace

1Remove the zoom module (p. 3)

and CMYC module (p. 5). Remove the

front and rear covers from the right side

of the head. (p. 7)

2Remove the fan attachment screws.

3Work the fan assembly free of the

reflector housing. Though the fit is tight,

it should not be necessary to loosen or

remove the reflector housing.

4Unplug the thermo-switch.

5Cut cable ties as required and

remove the old fan cable. Remove the

fan assembly from the head.

6Prepare the new fan. Cut a piece of

foil backing (P/N 33002002) to fit and

apply it to the back of the fan. (Fig. 32)

Place a 40 cm (16 in.) length of sleeve

over the leads, cut the leads to length,

and install a 2-pole plug.

7Remove the old fan from the heat

shield and install the new fan.

8Lead the fan cable out through hole

1, in through hole 2, under the wire bun-

dle, and out through hole 3 as shown in

Fig. 38.

9Connect the thermo-switch leads.

10 Work the fan assembly into position,

align the screw holes, and fasten.

11 Pull slack in the fan cable towards

the front. Gather the fan cable together

with the cables labeled ‘42’ and ‘23’ and

tie at point 4 in Fig. 38 Wrap the black

wires around the fan cable a few times

to hold them together. Replace any

other cable ties that you removed.

12 Verify that the openings in the plate

around the fan are sealed with high-

temperature polyester electrical tape.

13 Reassemble the head.

Heat filter assembly, remove

& install

1Remove the zoom module (p. 3)

and CMYC module (p. 5).

2Bend open the cable retention tabs

and move the cables out of the way.

3Remove the four heat filter module

screws and remove the module.

4Installation is the reverse.

Fig. 35 Tie bundle at bottom screw

Fig. 36 Thermo-switch connections

Fig. 37 Right lamp fan assembly

Fig. 38 Right fan cable path

Fig. 39 Move wires out of way

Fig. 40 Module attachment screws

MAC 2000 Wash Service Manual

Heat filter, replace

1Remove the heat filter assembly. (p.

2Remove the damaged filter(s).

Clean and degrease the metal plates

with an alcohol cleaner.

3Apply a dab of red, high tempera-

ture silicone adhesive about the size of

a 1 mm ball on each corner of the heat

filter holder. Place the middle frame on

the holder and align the screw holes.

4Place the heat filter glass inside the

middle frame with the coated side down

(towards the lamp) and with the long

edge parallel to the bent sides of the fil-

ter holder. (To find the coated side, hold

the filter up to a source of light. When

the coated side is up, the edges of the

glass have a reddish tint. When the

coated side is down, the edges have a

more gray or black appearance.

5Place the top frame over the glass

and fasten with four screws (4.2x13

self-tap, Torx, black).

6Remove any excess glue that

extends beyond the metal corners and

clean the glass.

7Reinstall the heat filter assembly.

Allow the glue to harden for at least 12

hours before use.

Reflector, replace

1Remove the heat filter assembly. (p.

2Remove the outer screws from the

reflector spring clips, loosen the inner

screws, and turn the clips away from

the rim.

3Remove the reflector and install the

the replacement, carefully aligning the

opening with the lamp.

4Secure the reflector with the spring

clips. Tighten all 8 screws and verify

that the reflector cannot turn.

5Reassemble.

Starter, replace

1Remove the zoom module (p. 3),

CMYC module (p. 5), and the front and

rear left-side head covers (p. 7).

2Remove the lamp.

3Turn the lamp in/out adjustment

screw fully counterclockwise.

4Pry the lamp socket assembly off

the lamp access plate.

5Remove the starter wires from the

lamp socket terminals.

6Loosen the wire clamp at the base

of the lamp access plate by removing

one of the push-on fasteners.

7Pull the wires back to the starter,

cutting cable ties as you go.

Fig. 41 Apply adhesive

Fig. 42 Insert glass filters

Fig. 43 Install top frame

Fig. 44 Turn clips to free reflector

Fig. 45 Turn fully CCW

Fig. 46 Pry out the adjustment plate

Fig. 47 Loosen the cable clamp

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