MAC 2000 Wash
Contents
1. Fig 21 Insert module at an angle 4 Install the zoom module p 2 2002 Martin Professional A S Denmark Updated November 12 2002 Color wheel module remove Fig 22 Color wheels 1 amp 2 1 Remove the top head shell 2 Disconnect plugs 28 29 9 and 10 from the inside row of the left side zoom module junction print Fig 1 3 Remove the color module attach ment screws and separate the color wheel module from the zoom module Fig 23 Color module screws Color wheel 1 belt replace 1 Remove the top head shell 2 Press the motor down to release belt tension Remove the old belt and install a new one Fig 24 Release belt tension Color wheel 1 motor replace 1 Remove the color wheel module p 4 2 Release belt tension and slip the belt off the motor gear Fig 24 3 Remove the sensor print to access the screw underneath Remove the screws that fasten the motor bracket to the module plate 4 7 p W w K i Fig 25 Motor bracket screws 4 Unhook the spring from the motor bracket Fig 28 5 Transfer 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 Fig 26 10 mm clearance 6 Transfer the mounting bracket to the new motor Do not open the new motor Fig 27 Motor and bracket MAC 2000 Wash Service M2. 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 2002 Martin Professional A S Denmark Updated November 12 2002 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
3. fan 16 Adjust the wires for a neat lead at the lamp socket 17 Place the cable clamp over both screws and secure with a push on fas tener Fig 47 18 Reassemble the fixture and install the lamp 19 Adjust the lamp as described in the user manual MAC 2000 Wash Service Manual Dimmer blades replace amp adjust 1 Remove the CMYC module p 4 2 Remove the heat shield on the back lamp side of the module Fig 53 Heat shield 3 Remove the V shaped plate over the top dimmer The top of the module is the side with the junction print Fig 54 V plate over top dimmer 4 Loosen the shaft adaptor set screws and remove the dimmer blades 5 Remove any nicks or burrs from the motor shaft with fine sandpaper Fig 55 Remove burrs 6 Install a replacement dimmer blade on the top motor with a gap of 1 5 mm between the module plate and the 2002 Martin Professional A S Denmark Updated November 12 2002 inside black face of the blade Slightly tighten a set screw to hold the position Fig 56 Top blade spacing 1 5 mm 7 Install a replacement dimmer blade on the bottom motor with a distance of 7 mm from the module plate to the out side face of the shaft adaptor Slightly tighten a set screw to hold the position r a iL Fig 57 Bottom blade spacing 7 mm 8 Connect a 4 pole motor extension cable to dimmer junction PCB and cable 16 in the head or the dimmer out put on the P
4. outside of the head forward of the yoke Fig 6 Place wires forward of yoke 2002 Martin Professional A S Denmark Updated November 12 2002 3 Lower the module into the chassis working it past each sticking point in turn Fasten Fig 7 Sticking points 4 Reconnect the wires to the left and right junction prints Fig 8 Right junction connections 5 Plug connector 16 into the dimmer junction print Fig 4 6 Insert the CMYC wire bundle into the slot in the zoom module Connect the wires to the junction print Secure the bundle under the flexible tie D Al Fig 9 CMYC wire bundle path Zoom belt replace 1 Remove the zoom module p 2 2 Remove the belt clamp screws N Pg r a as p o Pe Fig 10 Belt clamp screws 3 Loosen the set screws and remove the belt clamp from the belt 4 Flip the module over and loosen the zoom motor screws Push the motor in to loosen and remove the old belt Fig 11 Loosen the belt 5 Pull the belt tension pulley forward and loop the new belt over it as shown in Fig 12 Fig 12 Loop belt over tensioner MAC 2000 Wash Service Manual 6 Lead the belt to the motor and loop it over the gear Loop the other end of the belt over the front pulley Fig 13 Zoom belt 7 Tighten the belt by moving the zoom motor back until the tension pulley starts to move Tighten the motor screws 8 Place the belt
5. starter Fig 34 Cable path 10 Replace the cable tie at the bottom fan screw Keep the wires and thermo switch clear of the fan to maintain maxi mum airflow Fig 35 Tie bundle at bottom screw Right lamp fan replace 1 Remove the zoom module p 2 and CMYC module p 4 Remove the front and rear covers from the right side of the head p 6 2 Remove the fan attachment screws 3 Work 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 4 Unplug the thermo switch Fig 36 Thermo switch connections 5 Cut cable ties as required and remove the old fan cable Remove the fan assembly from the head 6 Prepare 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 7 Remove the old fan from the heat shield and install the new fan Fig 37 Right lamp fan assembly 8 Lead 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 Fig 38 Right fan cable path 9 Connect 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
6. the clamp from the bottom slide move the filter 1 tooth closer to the microswitch and re clamp Fig 80 CTC motor Fig 76 Flag must engage microswitch 2002 Martin Professional A S Denmark Updated November 12 2002 1 2
7. 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 Zoom module remove The color wheel module remains attached to the zoom module in this procedure 1 Remove the top and bottom head covers and the front lens Fully back out the thumbscrew for the lens retaining wire 2 Unplug cables from the outside row of the left side zoom module junction print Unplug the unlabeled 2 pin con nector from socket 38 Fig 1 Unplug left junction print 3 Unplug 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 Fig 2 Unplug right junction print 4 Unplug the wires from the back row of the CMYC module junction print and the thermo sensor which is in front of the junction print Fig 3 CMYC thermo sensor PCB MAC 2000 Wash Service Manual 5 Unplug connector 16 from the dim mer junction print 4 ee Fig 4 Dimmer junction PCB 6 Remove the 4 zoom module fasten ing screws Fig 5 Zoom module screws 7 Pull the zoom module and attached color wheel module up out of the head Zoom module install 1 Lock the head in the horizontal top up position 2 Place the ends of the wire bundles
8. CB Apply power and can cel pan tilt reset from the control panel Marti Fig 58 Cancel P T reset 9 When the reset is complete select UTIL gt AdJ gt HEAd gt dIM gt AdJ dimmer adjustment position from the menu Press each blade against its stop and tighten the set screws i Fig 59 Press blade against stop 10 Select STRO strobe from the menu and check dimmer movement 11 Switch off the fixture and discon nect the motor extension cable 12 Reinstall the V shaped plate and the heat shield 13 Reassemble Dimmer motor replace 1 Remove the dimmer blade as described under Dimmer blades replace amp adjust on page 9 2 Unplug and remove the motor 3 Place the spacer on the face of the replacement motor and install with the plug oriented as shown Connect Fig 60 Dimmer motor orientation 4 Install and adjust the dimmer blade p 9 MAC 2000 Wash Service Manual CMYC module separate 1 Remove the CMYC module p 4 2 Remove the heat shield Fig 53 and the V plate over the top dimmer blade Fig 54 3 From the dimmer side of the mod ule remove the 8 screws that fasten the module plate to the stand offs Fig 61 Stand off screws 4 Unplug the dimmer motors the light sensor 41 the cyan and magenta motors and the microswitches on the dimmer half of the module Fig 63 Unplug microswitches 2002 Martin Professional A S Denmark Updated Nove
9. MAC 2000 Wash service manual Procedures CMYC belts and flags replace 11 CMYC module install 4 CMYC module remove 4 CMYC module separate 10 CMYC motors replace 12 Color wheel 1 belt replace 4 Color wheel 1 motor replace 5 Color wheel 2 belt replace 5 Color wheel 2 motor replace 5 Color wheel module install 6 Color wheel module remove 4 Color wheels adjust 5 Dimmer blades replace amp adjust 9 Dimmer motor replace 10 Effect fans replace 6 Head side covers remove and install 6 Heat filter assembly remove amp install 7 Heat filter replace 7 Left lamp fan replace 6 Reflector replace 8 Right lamp fan replace 6 Starter replace 8 Zoom belt replace 3 Zoom lens assembly replace 3 Zoom module install 2 Zoom module remove 2 Zoom motor replace 3 Zoom rail replace 4 Risk of electrical shock Always disconnect the fixture from AC power before and while servicing Removal of any cover exposes connectors that carry lethal electric currents While working on a fixture under power e Make sure the fixture is electrically grounded e Usea supply with ground fault inter rupt protection e Never touch a
10. 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 MAC 2000 Wash Service Manual Heat filter assembly remove amp install 1 Remove the zoom module p 2 and CMYC module p 4 2 Bend open the cable retention tabs and move the cables out of the way Fig 39 Move wires out of way 3 Remove the four heat filter module screws and remove the module Fig 40 Module attachment screws 4 Installation is the reverse Heat filter replace 1 Remove the heat filter assembly p 7 2 Remove the damaged filter s Clean and degrease the metal plates with an alcohol cleaner 3 Apply a dab of red high tempera ture silicone adhesive about the size of a 1mm ball on each corner of the heat 2002 Martin Professional A S Denmark Updated November 12 2002 filter holder Place the middle frame on the holder and align the screw holes Fig 41 Apply adhesive 4 Place 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 red
11. anual 7 Apply 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 8 Hook the tension spring onto the motor bracket and connect the motor wires Fig 28 Color wheel 1 motor 9 Reinstall and connect the Hall sen sor circuit board 10 Reinstall the drive belt 11 Install the color wheel module p 6 Color wheel 2 belt replace 1 Remove the color wheel module p 4 2 Unscrew and remove the wheel 3 Remove the old belt Place the new belt over the motor gear and the axle Fig 29 Color wheel 2 belt 4 Reinstall the color wheel and loop the belt onto the color wheel gear 5 Place the open position over the tension pulley pull the pulley in and loop the belt over the pulley 6 Install the color wheel module 2002 Martin Professional A S Denmark Updated November 12 2002 Color wheel 2 motor replace 1 Remove the color wheel module 2 Remove the belt from the tension pulley and motor gear 3 Unscrew and unplug the old motor 4 Transfer the standoffs to the replacement motor Do not open the new motor 5 Transfer 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 6 Place the motor on the plate with the socket towards the other motor Fasten
12. 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 Fig 14 Belt clamp 9 Fasten the belt clamp to the lens car 10 Install the zoom module p 2 Zoom motor replace 1 Remove the zoom module p 2 2 Unplug the motor wires and remove the motor screws Loosen the bracket enough to remove the motor A Fig 15 Loosen bracket to remove motor 2002 Martin Professional A S Denmark Updated November 12 2002 3 Transfer the gear to the new motor with 0 6 mm 0 025 in clearance between the motor and the gear Tighten the set screw Fig 16 0 6 mm 0 025 in 4 Position the motor in the bracket with the socket facing out Tighten the bracket screws Start the motor screws but do not tighten 5 Place 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 6 Plug in the motor wires 7 Install the zoom module p 2 Zoom lens assembly replace When removing the zoom car do not remove the slide from the rail 1 Remove the zoom module p 2 2 Remove the belt clamp screws Fig 10 3 Remove the 4 screws that fasten the zoom car to the zoom slide Do not remove the slide from the rail Fig 17 Do not remove slide from rail 4 Fasten the replacement zoom lens assembly to the slide 5 Fasten the belt clamp 6 Install the zoom
13. dish tint When the coated side is down the edges have a more gray or black appearance Fig 42 Insert glass filters 5 Place the top frame over the glass and fasten with four screws 4 2x13 self tap Torx black Fig 43 Install top frame that extends beyond the metal corners and clean the glass 6 Remove any excess glue 7 Reinstall the heat filter assembly Allow the glue to harden for at least 12 hours before use Reflector replace 1 Remove the heat filter assembly p 7 2 Remove the outer screws from the reflector spring clips loosen the inner screws and turn the clips away from the rim Fig 44 Turn clips to free reflector 3 Remove the reflector and install the the replacement carefully aligning the opening with the lamp 4 Secure the reflector with the spring clips Tighten all 8 screws and verify that the reflector cannot turn 5 Reassemble Starter replace 1 Remove the zoom module p 2 CMYC module p 4 and the front and rear left side head covers p 6 2 Remove the lamp 3 Turn the lamp in out adjustment screw fully counterclockwise EM UW a WU hd S Fig 45 Turn fully CCW MAC 2000 Wash Service Manual 4 Pry the lamp socket assembly off the lamp access plate pull them out at the back Adjust the sleeve as shown in Fig 49 Fig 46 Pry out the adjustment plate 5 Remove the starter wires from the lamp socket terminals 6 Loosen the w
14. in Professional A S Denmark Updated November 12 2002 Fig 71 Y filter on top 11 Cyan and yellow only Clamp the belt to the inside slot of the X slide Position the flag pair in the mod ule with the X filter on top Skip to step 13 Fig 73 X filter on top 12 Install the idle rail for the top flag set 13 Arrange the belt and make sure the ends are outside the rail clips Center the rail on the clips and snap it into the 11 MAC 2000 Wash Service Manual clips on each end Work the belt onto 17 Reassemble and install the module the pulleys 14 Set the filters an equal distance CMYC motors replace from the clip using any convenient spacer p 1 Remove and separate the CMYC module p 10 2 Unplug and remove the old motor 3 Measure the position of the gear along the motor shaft Transfer the gear to the replacement motor or install a new one 4 If replacing the cyan or magenta motors place the motor heat shield under the module plate 5 Orient the motor as shown with 3 springs between the motor and the plate Fasten 6 Reassemble the fixture gt So k i ae iil Ta Fig 81 Flag motor suspension 15 Clamp the belt in the outside slot of the slide for the bottom filter Fig 75 Clamp belt in outside slot 16 Verify that the flags slide smoothly in Opposite directions and that the bot tom flag engages the microswitch If the flag does not fully engage the switch remove
15. ire clamp at the base of the lamp access plate by removing Fig 47 Loosen the cable clamp 7 Pull the wires back to the starter cutting cable ties as you go 8 Unscrew unplug and remove the starter Fig 48 Starter screws 9 Plug in the replacement starter and fasten it to the bracket with the lamp wires towards the front and bottom Lead the wires up through the hole in the top of the chassis and towards the back as shown in Fig 48 10 Place a 30 cm 12 in length of 6 mm sleeve P N 15802007 on each lamp wire Insert the lamp wires through the hole under the thermo switch and 2002 Martin Professional A S Denmark Updated November 12 2002 Fig 49 Lamp wires with sleeve 11 Lead the wires up through the hole in the lamp access plate and then to either side The lamp wires are not polarized d OS 4 dl Fig 50 Lamp wires at access plate 12 Connect the lamp wires to the lamp socket terminals Make sure the con nections are secure 13 Snap the lamp socket and adjust ment assembly back into place 14 Gather the white lamp wires together with the black and blue starter wires and tie them to the chassis at point 1 in Fig 51 Tie the wires that lead to the back at point 2 K Fig 51 Tie starter wires 15 Tie the wires under the left fan as shown in Fig 52 Keep the wires and thermo switch clear of the fan to main tain maximum airflow P pP Fig 52 Cable ties at left
16. mber 12 2002 5 Separate the module into 2 parts Fig 64 Separate into 2 parts 6 Assembly is the reverse 10 CMYC belts and flags replace Magenta X Cyan Y Yellow X Dimmer R Fig 65 Color flag order Magenta Y 1 Remove and separate the CMYC module p 10 2 Place the module half that needs servicing on a clean surface with the fil ters up 3 Starting with the top set of filters cyan or yellow release tension and lift the belt off the pulleys 4 Gently pry the drive rail out of its clip on one end Pull the rail lengthwise out of the other clip Fig 67 Gently pry out drive rail MAC 2000 Wash Service Manual 5 Lift the drive rail filters and belt out of the assembly Lay the flag pair one the rails with the Y filter on top Skip to step 12 Fig 68 Remove flags rail amp belt 6 If you need to remove the bottom set of filters magenta or CTC first remove the idle rail for the top filters Then repeat steps 3 4 and 5 to remove the bottom filters 7 If replacing the belt or filters unlock and remove the belt clamp from each slide Remove the belt Fig 69 Remove clamp from slide 8 Clean the rails and lubricate with a drop of high viscosity silicone oil 9 Slide the flags onto the rail with the coated text true sides facing each other 10 Magenta and CTC only Clamp the belt to the inside slot of the Y slide 2002 Mart
17. module p 2 Zoom rail replace 1 Remove the zoom lens assembly p 3 2 Separate the color wheel module from the zoom module p 4 3 Remove the white plastic plate at the back of the module Fig 18 Zoom lens car stop 4 Unscrew and remove the zoom rail 5 Starting 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 6 Place 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 Fig 19 Zoom slide stop 7 Install the zoom lens car stop Fig 18 8 Install the color wheel module p 6 9 Install the zoom lens assembly p 3 10 Install the zoom module p 2 MAC 2000 Wash Service Manual CMYC module remove 1 Remove the zoom module p 2 2 Remove the module fastening screws there are two on the top and two on the bottom Fig 20 1 of 4 CMYC module screws 3 Slide the module forward as far as it will go then lift it out of the top of the head CMYC module install 1 Lock the head in the horizontal top up position 2 Move the wire bundles forward and out of the way 3 Orient 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
18. ng in To avoid strip ping the threads use M4x30 metric screws P N 008070410 instead of the Original taptites 4 If replacing the left fan connect the plug to the front 2 pins of socket 38 Fig 1 5 If replacing the right fan connect the plug to the rear 2 pins of socket 37 Fig 8 6 Install the zoom module p 2 MAC 2000 Wash Service Manual Left lamp fan replace 1 Remove the zoom module p 2 and CMYC module p 4 Remove the left rear side cover p 6 2 Cut the cable tie if required to access the lower fan screw Remove the fan attachment screws 3 Work the fan assembly free of the reflector housing 4 Remove the metal heat shield and the ceramic insulation from the old fan 5 Cut cable ties as required and free the fan cable Remove the fan 6 Prepare 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 Fig 32 Apply foil to fan 7 Install the insulation and heat shield on the foil backed side of the prepared fan Fig 33 Fan heat shield and insulation 8 Work the fan assembly back into place and fasten 9 Lead the fan cable forward through the holes in the side chassis Slide the 2002 Martin Professional A S Denmark Updated November 12 2002 cable insulation fully back to the fan and then retie the bundle above the
19. ny connector that carries voltage e 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 MAC 2000 Wash Service Manual them to explode To eliminate the risk of injury from the discharge lamp e Never operate the lamp with covers or lenses removed e 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 e 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 e 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
20. with 4 M38x6 mm countersunk screws Plug in the wires Fig 30 Color wheel motors 7 Loop the belt over the motor gear and tension pulley Verify that the wheel turns smoothly without binding 8 Install the color wheel module p 6 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 1 Insert the module in the head mak ing sure that the bottom flaps straddle the chassis plate Fasten Fig 31 Bottom flaps straddle plate 2 Connect 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 1 Remove the screws that fasten the cover each cover has two screws 2 Pull front covers straight out to remove The rear covers must be pulled out 1 cm at the back before pulling back 3 When reinstalling the front covers verify that the air filter lies flat 4 When reinstalling the rear covers it helps to tilt the head down Effect fans replace 1 Remove the zoom module p 2 2 Unplug unscrew and remove the defective fan 3 Install the replacement fan with the air flow arrow pointi
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