February 2016
AutoCure 6000 Portable Repair Arm
Assembly and Operating Manual
AC6-4238-480-SP
Contents
Warnings ................................................................................................................................................................. 3
Equipment Safety Guidelines .................................................................................................................................. 4
Operating Instructions ............................................................................................................................................ 5
Temperature Controller Single or Double Ramp Operation (See Figure 1) ..................................................... 5
Lamp Installation and Replacement Instructions ................................................................................................... 7
Heater Position Instructions ................................................................................................................................... 8
Maintenance ......................................................................................................................................................... 11
Pivot Points ....................................................................................................................................................... 11
Lamps, Reflectors and Heat Sensor (Pyrometer) Lens ................................................................................. 11
Trouble Shooting Guide ...................................................................................................................................... 12
Heater Power Problems .................................................................................................................................. 12
Temperature Controller Problems ................................................................................................................. 12
Temperature Problems ..................................................................................................................................... 13
Temperature Controller Error Codes .................................................................................................................... 14
Ramp/ Soak Errors............................................................................................................................................. 14
Service Instructions ............................................................................................................................................... 15
Replacement of new Pyrometer Sensor ........................................................................................................... 15
Replacement of Pyrometer Controller .............................................................................................................. 16
Mechanical Drawings and Parts Lists .................................................................................................................... 17
Pyrometer.......................................................................................................................................................... 17
Heater Head Assembly (AC6-4238) ................................................................................................................... 24
AC6 Stand .......................................................................................................................................................... 34
ACH6-4238-480- SP Lamp Wiring Schematic .................................................................................................... 58
Spare Parts Recommendations ............................................................................................................................. 59
Warranty ............................................................................................................................................................... 60
2
Warnings
DANGEROUS VOLTAGES ARE
PRESENT IN THIS EQUIPMENT!
CONTACT WITH LIVE PARTS
COULD CAUSE
SERIOUS INJURY OR DEATH!
CONNECTION, INSTALLATION, MAINTENANCE,
ADJUSTMENT, SERVICING AND OPERATION TO BE DONE BY
QUALIFIED PERSONNEL ONLY.
ENSURE THAT EQUIPMENT IS COMPLETELY
AND PROPERLY GROUNDED BEFORE APPLYING
SUPPLY POWER AND BEFORE EQUIPMENT
OPERATION.
3
Equipment Safety Guidelines
(Read and understand this manual before operating equipment.)
CAUTION!!

Turn power off at source before servicing equipment or attempting any interior maintenance.

If the main power switch is ON, voltage may exist at the lamps even though the lamps are not lighted. A
FATAL ELECTRICAL SHOCK COULD POSSIBLY RESULT!

This is an automatic piece of equipment. Heater can instantly come on to full intensity without warning to
unaware personnel.

Heater surfaces can become hot when used at high power for extended periods. Use caution
whenever handling heater head.

Do not move heater when in operation.

Heater contains high voltage. Do not insert metallic objects into cooling louver openings.

Ensure that equipment is properly grounded before applying supply power and before equipment
operation.

Use care when positioning heater. Avoid possible pinch points.
LAMPS
All lamp end covers and grills must be installed.
Do not handle infrared lamps with bare hands. Remove any contamination with alcohol and a clean, soft cloth.
Contamination on quartz tubes allows the quartz to overheat, which leads to premature lamp failure.
ENVIRONMENT
Heater head contains high voltage connections that are open to atmosphere. These units are not air-purged.
Ensure use of unit is acceptable in the area in which it will be used.
4
Operating Instructions
Temperature Controller Single or Double Ramp Operation (See Figure 1)
Single Ramp Operation: The temperature ramps in a predetermined amount of time from ambient to a set
point temperature and holds at that temperature for a required amount of time.
Double Ramp Operation: The temperature ramps in a predetermined amount of time from ambient to the first
set point temperature and holds at that temperature for a required amount of time, it then ramps in a
predetermined amount of time to a second set point temperature and holds at that temperature for a required
amount of time.
Temperature Controller Displays
The upper display indicates the mode of the heating cycle and the process temperature. During the Ramp mode
the upper display will toggle between the process temperature and ramping. Once the cure temperature (set
point) has been reached the upper display will toggle between the hold time remaining (in minutes) and the
process temperature. When the hold time becomes less than one minute the upper display will toggle between
the hold time remaining (in seconds) and the process temperature. The lower display indicates the cure
temperature (set point).
Cycle Start Button
The product will heat to the set point temperature and remain there for the time selected. The hold time will
start when the temperature reaches 15°F/ 10°C before set point.
Heater Position
If the heater is too far from the product, the temperature will not be reached and the hold timer will not be
activated.
5
Setting the Temperature Controller Parameters (See Figure 2)
Single Ramp
1. Turn power on.
2. Turn positioning beam on and position heater.
3. Set controller parameters
4. Hold the
button for 1-2 seconds
a. Set rp1 (ramp time) in minutes
Press
b. Set ct1 (cure temp) in degrees
Press
c. Set hd1 (hold time) in minutes
Press
d. Set rp2 = 0 (this disables 2nd ramp)Press
5. Press the
to exit setup menu
6. Set auxiliary heater off or on
7. Press the cycle start
Double Ramp
1. Turn power on.
2. Turn positioning beam on and position heater.
3. Set controller parameters
4. Hold the
button for 1-2 seconds
a. Set rp1 (ramp time) in minutes
Press
b. Set ct1 (cure temp) in degrees
Press
c. Set hd1 (hold time) in minutes
Press
d. Set rp2 (2nd ramp time) in minutes
Press
nd
e. Set ct2 (2 cure temp) in degrees
Press
nd
f. Set hd2 (2 hold time) in minutes
Press
5. Press the
to exit the setup menu
6. Set auxiliary heater off or on
7. Press cycle start
Figure 2
6
Lamp Installation and Replacement Instructions
Danger!!
Turn power off at source before removing end covers and servicing lamps. A fatal electrical shock could
possibly result.
Precautions for Handling Quartz Infrared Lamps
Do not handle infrared lamps with bare hands. Remove any contaminations with alcohol and a clean, soft cloth.
Contaminations on quartz tubes cause the quartz to overheat, which may lead to premature lamp failure.
Caution!!
If lamps are replaced with lamps having metal ends, metal ends must be removed to permit proper assembly and
prevent the possibility of arcing or shorting.
Lamp Installation/Replacement Procedure
Make sure main system circuit breaker is OFF.
Rotate heater so lamps are horizontal.
Remove end covers to gain access to lamp leads.
Disconnect wire from the ceramic terminal block and remove lamp that is being replaced.
Carefully slide the lamp through the lamp support.
Remove electrical insulation sleeves from the old lamp on both lamp leads and install them on the new lamp
leads. Push the sleeve to the ceramic end of the lamp (see drawing below).
7. Secure the lamp lead to the power wire coming into the heater at the ceramic terminal block.
8. Install end covers.
1.
2.
3.
4.
5.
6.
NOTE: If lamp leads are too tight, damage to lamp may result.
Make sure lamp sleeving is
pushed all the way into
ceramic end of lamp
Lamp Support
(outer reflector)
End Cover
Ceramic terminal
in heater head
Ensure all bare wire is
contained up to terminal
(trim lead if necessary)
Heater Power Cord
7
Heater Position Instructions
Important: Precautions and Instructions
General Instructions (Read All)
1.
The "Positioning Beam" (red dot) is an aid for proper placement of the heat sensor. The heat
Sensor reads an area of 0.8 to 1.2" diameter depending on the heater's distance from the
surface. The sensor takes an average temperature reading of the area and displays it on the
temperature controller. Note: the red dot is not at the exact center of the sensing area. As
you face the control panel the dot is 3/4" to the left of the heat sensor.
2.
Make sure the heat sensing area is reading a painted surface. If the sensing area is positioned
incorrectly and is partially reading tape, masking, trim, plastic, rubber, a window, or a wheel
well, It will measure an average temperature much higher or lower than the actual temperature
of the painted surface. Thus, the heater will possibly overheat the area and scorch the paint, or
not heat the part enough and the paint will not be cured.
3.
The heater head distance from the product is important. If the heater head is too far away, the
product will not reach cure temperature and will run indefinitely trying to get to temperature. If the
heater head is to close "striping" may occur. The recommended distance of the heater face to the
product is 8 -12". The heater should be as parallel as possible to the product surface, which helps
maintain uniform heating over the heated area.
4.
Before heating a repair, determine if there are any types of reinforcements or extra thicknesses of
metal in the area to be cured. These areas will heat at different rates and not achieve the same
temperature as the single thickness metals without reinforcements. Aim the heat sensor on, or
near, the multiple thickness or reinforced areas so they will be fully cured.
5.
Once the cycle has started, do not move the unit. This will cause the temperature sensor to "see" a
different area, which may be cooler. If the temperature drops 18°F/ 10°C, it will reset the timer and run
another complete cycle. To help the unit's stability, be sure to lock the casters on the base of the
arm after positioning the heater to lock it in place.
6.
Check the control panel 3 to 5 minutes into the cycle. See if the temperature has risen to set point
and if the timer has started. If it hasn't, determine the problem and correct it. If there is a problem
with the position or setup of the arm where it cannot achieve the set point temperature, the timer
will not turn on. The heater will run at full intensity indefinitely.
7.
To achieve a full cure on a repair area, including overspray, the "effective cure area" of the heater
must be considered. The "effective cure area" of the rectangular shaped heater heads is an oval
shape that is just slightly smaller than the heater head. A general rule for the "effective cure area"
dimensions are 1" in from the sides and end covers of the heater head, which creates the outer
boundaries of the oval. When main and auxiliary heater heads are used together, add the two areas
together.
8
Heat Masking
1.
Any heat sensitive materials or surfaces (including plastic, rubber, trim, pin stripes, decals, light lenses,
mirrors, door handles, interior materials, etc.) in the heating area must be masked or removed during
the heating cycle. High temperature/reflective masking material approved for this type of
application is required.
2.
When curing small areas, it is not recommended to use heat masking around the area except to cover
heat sensitive materials. The heat sensor "sees" an area approximately 1" in diameter, a heating area
that is 1.5" or smaller could result in a false reading if the heat sensor is reading the masking.
Positioning/Set-Up of Heater Head Instructions
Positioning/Set-Up of an arm on flat surfaces (doors, hood, roofs, trunk lids, etc.)
1.
2.
3.
4.
5.
6.
7.
8.
Follow any of the instructions previously mentioned in the precautions and instructions section.
Always position heaters parallel and 8 to 12" from the surface.
Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive
materials.
Recheck heat sensor aim with the positioning beam.
Set the temperature and time settings.
Start heat cycle.
Approximately 3-5 minutes after start, check that the temperature is at set point and the timer has
started.
When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.
Positioning/Set-Up of a heater on a curved or contoured surfaces (fender, hood, roof, trunk corners)
1.
2.
3.
4.
5.
6.
7.
8.
Follow any of the instructions previously mentioned in the precautions and instructions section.
Always position heaters parallel and 8 to 12" from the surface. Adjust the A and B heaters to the contour
of the curve, with the most direct heat radiation in the area of the repair.
Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive
materials.
Recheck heat sensor aim with the positioning beam.
Set the temperature and time settings.
Start heat cycle.
Approximately 3-5 minutes after start, check that the temperature is at set point and the timer has
started.
When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.
9
Positioning/Set-Up of an arm on roof posts (heavy reinforcements/multiple metal thickness)
1.
2.
3.
4.
5.
6.
7.
8.
Follow any of the instructions previously mentioned in the precautions and instructions section.
Position heaters parallel to the surface, the length of the heater along the length of the roof post. Do not
put the heater 90° to the post, unless the repair area is very small. The heater should be about 8" from
the surface for the heavy reinforcement in the posts.
Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive
materials. The post is very narrow, so carefully position the heat sensor where it will "see" the post.
Recheck heat sensor aim with the positioning beam.
Set the temperature and time settings.
Start heat cycle.
Approximately 3-5 minutes after start, check that the temperature is at set point and the timer has
started.
When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.
Positioning/Set-Up of an arm on rocker panels (heavy reinforcements/multiple metal thickness)
1.
2.
3.
4.
5.
6.
7.
8.
Follow any of the instructions previously mentioned in the precautions and instructions section.
Position heaters parallel to the surface, the length of the heater along the length of the rocker panel. If
there is an auxiliary heater head, use both heaters and bend them at about a 135° angle to focus more
direct heat around the curve of the rocker panel. The heater should be spaced about 8" from the surface
for the heavy reinforcement in the rocker panel.
Aim the positioning beam on spot being repaired; make sure that the beam is not aimed at heat sensitive
materials
Recheck heat sensor aim with the positioning beam.
Set the temperature and time settings.
Start heat cycle.
Approximately 3-5 minutes after start, check that the temperature is at set point and the timer has
started.
When the timer and the heater lamps shut off, the cycle is complete and ready for the next repair.
NOTE: These are procedures that give reliable results for most repairs. Unusual or complex repairs might need
modified procedures. Contact BGK service for assistance.
10
Maintenance
The AutoCure™6000 will require some basic maintenance when used on a regular basis. Failure to do so may
degrade the performance of the unit.
Disconnect main power at the source before performing any maintenance procedures.
Pivot Points
1. Single head units have three (3) castle nut/spring combinations and two (2) shoulder bolts with Nylock nuts.
If pivot points become loose, heater positioning will not be maintained. Check these points monthly.
2. Dual head units have seven (7) castle nut/spring combinations and two (2) shoulder bolts with Nylock nuts. If
pivot points become loose, heater positioning will not be maintained. Check these points monthly.
3. To adjust spring tension; remove cotter pin, tighten castle nut (usually one or two notches) and replace cotter
pin through bolt.
Lamps, Reflectors and Heat Sensor (Pyrometer) Lens
Clean with soft cloth and alcohol monthly. Heat sensor accuracy is dependent on a clean lens.
Single
Dual Head
Head
Tension Spring/
Castle Nut (2)
Tension Spring/
Castle Nut
Nylock Nut
Pyrometer
Tension Spring/
Castle Nut (4)
(under heater skin)
Tension Spring/
Castle Nut (2)
11
Trouble Shooting Guide
Heater Power Problems
Problem
Heater lamps come on immediately when disconnect is closed.
Possible Cause and Corrective Action

With power OFF, measure the resistance from the lamp wires to ground. The measurement should be
more than 100 K ohms. If it is less than 100 K, check the lamp wiring and heater head for shorts to ground.
Check for a bad firing circuit board or a shorted SCR by: exchanging the firing circuit board with one from
a known good control. Does the problem follow the firing circuit board or does it stay with the SCR – replace
the defective component.

Contactor held closed – failed ON. Replace the contactor.
Problem
Heater lamps do not come on.
Possible Cause and Corrective Action



Is the Power On/Off button illuminated, is the temperature controller on? – Check that
incoming line power is present; transformer fuses, primary and secondary are good.
 Do the contactors energize when the Cycle Start button is pressed? – Check for loose wires
associated with the contactors, change the temperature controller.
 Check that the set point (bottom display) is higher than the process temperature (top
display).
Are the line fuses (FU 101 & 104) in front of the contactors good – check voltage on the load side of the
fuses or remove the fuses and check with an ohmmeter.
 Is the green LED on the firing circuit lit? – Check that the firing circuit has 24 vac, with an ammeter
check that the 4-20ma input signal is present from the temperature controller. If the 4-20ma
signal is not present, see the section “No Output Signal from Temperature Controller”.
 Do any of the zones function? – If the above points have been checked, confirm that there is a
complete circuit through the lamps and all wiring is tight – change the SCR.
Are all zones dead? – There is only one firing circuit for all zones - change the firing circuit
Temperature Controller Problems
Problem
Temperature controller has no display.
Possible Cause and Corrective Action
Check the supply voltage (24 VAC) to the unit at terminals 11 and 12. If voltage is present, replace the controller. If
voltage is not present, check source of power (fuses, transformers, wiring, etc.)
12
Problem
No output signal from temperature controller.
Possible Cause and Corrective Action



Check that the set point (bottom display) is higher than the process temperature (top
display).
Check the 0-5v input to the temperature controller at pins 9 & 10. If the 0-5v signal is not
present, confirm that the Raytek pyrometer is functioning.
Open the Raytek cover. Is the LCD display in side, lit? If not check that the Raytek input
power (12 vdc) is present, check that the power supply board is supplying 12 vdc (TB 4). –
replace the temperature controller, Raytek or the power supply board.
Problem
Temperature controller output signal is present, but heater lamps do not come on.
Possible Cause and Corrective Action
Possible defective power controller firing circuit board and/or SCR. Check for a bad firing circuit board or SCR
by exchanging the firing circuit board with one from a known good control. Does the problem follow the firing
circuit board or does it stay with the SCR – replace the defective component.
Temperature Problems
Problem
The heater reaches set-point temperature, but the paint isn’t cured properly or is darkened or the heater does
not reach set-point temperature.
Possible Cause and Corrective Action



Read the instructions in the manual on how to position and run the heater.
Clean the temperature sensor lens as described in maintenance section.
The optical pyrometer is not seeing the surface of the object being heated. The pyrometer
has about a 1-inch diameter field of view on the objects’ surface. Position the heater head
with the pyrometer so it sees the surface being heated. Make sure the pyrometer is not
seeing parts of a window, wheel well, tape, masking, etc.
Problem
The temperature display jumps up or down many degrees within a second.
Possible Cause and Corrective Action
13

Check for loose connections on the heat sensor (pyrometer) wiring.

While the heater is running at temperature, gently wiggle the pyrometer cable and have
someone watch for sudden temperature changes. If this happens – replace the cable.
Problem
Positioning Beam does not work
Possible Cause and Corrective Action
Check that the power supply board is supplying approximately 3.25 vdc (TB 3). Check that the wires are secure
on the power supply board and on the push button. Open the cover on the heat sink assembly on the back of
the heater and retest for the 3.25 v. If the power supply is functioning and there is no voltage at the heat sink
assembly open the Raytek pyrometer and test for the voltage (the 2 wire nuts). – replace the Positioning
Beam.
Temperature Controller Error Codes
Display
Err.H
Problem
Open Sensor
Err.L
LPbr
Reversed Sensor
Loop Break
0100
0101
0202
0303
3865
Checksum Error
RAM Error
Defaults Loaded
EEPROM Write Failure
Power Fail Resume
Feature Disabled
36 Plus other 2 digit code Unexpected or invalid
interrupt
Actions
Check sensor, wiring,
and input
Check Sensor polarity
Correct problem and
Reset controller
Press Any Key to
perform a soft reset
and reinitialize
controller
No further resume
actions available
Reset Controller
Ramp/ Soak Errors
02= Recipe Empty (i.e. no non-zero ramp times)
05= Insufficient Setpoint- Process Value Deviation
14
Service Instructions
Replacement of new Pyrometer Sensor
1. Open Cover for Raytek Sensor, loosen and remove wire from terminals shown below.
2.
3. Undo wires from two wire nuts, as shown.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Loosen nut on pyrometer side, and remove wires from housing.
Open enclosure on top of heat sink, and isolate wires for laser (black/ red leads)
Clip leads, leaving enough wire to strip and re-connect with crimp connections
Loosen and remove standoffs
Remove Insulating plate
Remove heat sink, then remove Pyrometer.
Install new pyrometer into heat sink, making sure to adjust fit using varnish tape wrapped on the outside.
Install heat sink onto lower insulators
Install intermediate plate
Crimp laser leads to leads in pyrometer bundle – red to green and brown to black.
Install standoffs
Replace cover and tighten nuts.
If new pyrometer, replace grommet into side of housing.
15
17. Reconnect leads in Raytek sensor housing using schematic in Step 1.
18. Reconnect wires in wire harness as shown above.
Replacement of Pyrometer Controller
1. Open Housing and loosen 4 terminals to remove pyrometer. Loosen 4 terminals to remove connection to
AutoCure Arm as shown below.
2. Open New Housing, and loosen 4 terminals as shown above to remove pyrometer.
3. Disconnect wires in wire nuts.
4. On New Housing, Loosen and remove nut, grommet, and three washers on thermocouple side. Loosen and
remove nut and all washers on AC arm side.
5. Unmount housing and replace with new housing.
6. Install nut, grommet and 2 washers onto Thermocouple leads, as shown below.
7.
8.
9.
10.
11.
12.
Once installed, insert leads for thermocouple into terminals indicated in Step 1.
Insert and tighten down to 20 Nm
From AC arm, insert nut, AC-200104 Nylon washers and Grommet, similar to diagram in step 5.
Insert leads into terminals indicated in step 1. Reconnect leads into wire terminals.
Tighten down nut to 20 Nm
Verify calibration per SI-B-11-02.1
16
Mechanical Drawings and Parts Lists
Pyrometer
17
18
CAUTION
Pyrometer Parts Listing
Item
Number
7
8
9
10
11
12
13
14
Quantity Part No.
Description
1
1
1
1
1
1
1
2
SENSOR
LASER
PLATE, INTERMEDIATE
INSULATOR, PYROMETER
MOUNT, INSULATOR, PYROMETER
HOUSING, PYROMETER
COVER, PYROMETER
SCREW, MACH, FL.HD, SLOT, 8-32 X 2.750
15
16
17
18
2
2
2
1
42936
AC-65427
AC-61229
AC-61228
AC-61227
AC-611232
AC-61230
AC-2000993
AC-200032
AC-13938
AC—10142
AC-200088
STANDOFF, HEX, 8-32 X .750
WASHER, LOCK, EXTERNAL TOOTH, #8 SST
SCREW, MACH TRUSS PH 8-32X3/8
CAUTION LABEL
19
20
Item No.
4
19
20
21
22
23
24
25
27
Qty.
2 X 2”
2
2
2
28”
35”
35”
2
2
Pyrometer parts Listing Continued
Part Number
Description
TR-SSEM-283
SHRINK TUBING
AC-200031
FEMALE CONNECTOR
AC-200030
MALE WIRE CONNECTOR
AC-200033
CABLE SLEEVE
AC-200052-1
MESH
AC-200077
BROWN WIRE
AC-200078
GREEN WIRE
72591-01
WHITE CABLE SLEEVE
AC-200034
WIRE NUTS
21
22
Assembly Notes:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
WRAP COPPER TAPE 2-3 TURNS FOR LOOSE RUNNING FIT
APPLY THERMAL JOINT COMPUND USING APPLICATOR AND SPREAD ACROSS ENTIRE CIRCUMFERENCE
CENTER PYROMETER AND LASER TO THROUGH OLES WHILE ASSEMBLING PLATES
STRIP BACK 5/16” MINIMUM
ASSEMBLE WITH TOOL HEYCO NO. 29
ASSEMBLE WITH WEIDMUELLER P24 OR SIMILAR
ASSEMBLE WITH CLINE CRIMPER 1005
STRIP BACK ¼” MINIMUM
USE TOOL TO INSTALL TERMINALS INTO WIRES
INSTALL FLEXIBLE CONDUIT AROUND WIRES
INSTALL SHRINK WRAP
INSTALL CABLE THROUGH PYROMETER HOUSING
INSTALL GROMMET OVER SHINK WRAP INTO PYROMETER HOUSING
APPLY SHRINK TUBING ONTO MESH AFTER TRIMMING WIRES TO SAME LENGTH AS FLEXIBLE CONDUIT
MOVE NUT UP TO SHRINK TUBING TO ALLOW FOR GROMMET INSTALLATION
CUT 1/8 X 1/8” V-NOTCH TO SRINK TUBE
INSTALL GROMMET ONTO SHRINK TUBE USING BULLET TOOL OR PLIERS
INSTALL 2 WASHER AS SHOWN
INSTALL NUT ASSEMBLY
Parts Listing
Item No
1
3
4
7
8
9
10
11
12
13
14
QTY
1
1
2 X 2”
1
1
1
1
1
1
1
2
Part No.
42936
AC-200026
TR-SSEM-283
42936
AC-65427
AC-61229
AC-61228
AC-61227
AC-611232
AC-61230
AC-200099-3
15
16
2
2
AC-200032
AC-13938
17
18
19
20
21
22
23
24
25
26
2
1
2
2
2
28”
35”
35”
2
2
AC—10142
AC-200088
AC-200031
AC-200030
AC-200033
AC-200052-1
AC-200077
AC-200078
72591-01
AC-200034
Description
PYROMETER SENSOR
PYROMETER WIRE CLIP
SHRINK TUBING
SENSOR
LASER
PLATE, INTERMEDIATE
INSULATOR, PYROMETER
MOUNT, INSULATOR, PYROMETER
HOUSING, PYROMETER
COVER, PYROMETER
SCREW, MACH, FL.HD, SLOT, 8-32 X
2.750
STANDOFF, HEX, 8-32 X .750
WASHER, LOCK, EXTERNAL TOOTH, #8
SST
SCREW, MACH TRUSS PH 8-32X3/8
CAUTION LABEL
FEMALE CONNECTOR
MALE WIRE CONNECTOR
CABLE SLEEVE
MESH
BROWN WIRE
GREEN WIRE
WHITE CABLE SLEEVE
WIRE NUTS
23
Heater Head Assembly (AC6-4238)
24
ACH5-4238 Parts List
ITEM
5
6
8
9
10
11
12
14
15
21
22
23
24
27
32
33
34
36
44
59
61
62
QTY
6
4
28
4
2
6
6
8
4
1
1
1
1
2
2
4
2
REF
2
2
12
12
PART NUMBER
AC-39487
AC-39917
AC-3775
AC-54583
AC-200125-2
AC-54585
AC-58833
39328
AC-50869
AC-60821
AC-60824
AC-61231
AC-61657
AC-61936
AC-64227
AC-64237
AC-64238
AC-42936
AC-50686-1
AC-200189
AC-50686-3
AC-3903-1
DESCRIPTION
NUT,HEX,SLOTTED,1/2-13
3/8 STUD HANDLE
WASHER,FLAT,1/2" ID,SST
SPRING,COMPRESSION (RED)
YELLOW COMPRESSION SPRING
PIN,COTTER,1/8 X .750
TERMINAL,3 POLE,CERAMIC,600V
LAMP,IR,3800W,570V,CER,CL,41.7OAL,38.0LL
WASHER,1.5 OD X .531 X .125 THK
YOKE WELDMENT
YOKE,MAIN
ASSY,PYROMETER
PLATE,MOUNT,RAYTEC
REFLECTOR,OUTER,4 LAMP,3800
SPACER,"E" BRACKET
MOD,HEX BOLT,1/2-13 X 2.00
MOD,HEX BOLT,1/2-13 X 2.500
REFER TO PYROMETER ASSY
SCREW CAP HD #8-32 X 5/8" SST
LABEL "CAUTION HOT"
SCREW, CAP SOC HD, #8-32 X 1", SST
NUT, HEX, FLG, SERRATED,NONLOCK, #8-32
25
26
ACH5-4238 Parts List
ITEM
2
12
16
18
19
20
21
22
25
29
30
31
37
40
52
53
54
58
60
61
62
QTY
4
6
168"
4
4
4
1
1
2
1
2
4
48
48
1
1
1
4
REF
12
12
PART NUMBER
AC-4012
AC-58833
AC-200049
AC-60817
AC-60818
AC-60819
AC-60821
AC-60824
AC-61934
AC-63210
AC-63940
AC-64098
AC-3887
AC-2455
78404-56C
AC-3772
AC-3903
AC-200163
AC-200112
AC-50686-3
AC-3903-1
DESCRIPTION
3/8-16 AVK,1ST GRIP
TERMINAL,3 POLE,CERAMIC,600V
WIRE 10 AWG
BRACKET,PIVOT,HEATER,4 LAMP DUAL
ENDCOVER,4 LAMP
INSULATOR,END COVER,4 LAMP
YOKE WELDMENT
YOKE,MAIN
SKIN,4 LAMP,3800
COVER,SKIN,PRYO OPENING
J-BOX,HEATER
PLATE,REINFORCEMENT,HANDLE
#10 EXTERNAL LOCK WASHER
#10-32 X 3/4 TRUSS HEAD SCREW
SCREW, HEX HD, ¼-20X2
WASHER, FLAT ¼ SST
NUT, HEX SERRATED ¼-20
LABEL "CAUTION SHOCK
LABEL "PINCH POINT"
SCREW, CAP SOC HD, #8-32 X 1", SST
NUT, HEX, FLG, SERRATED,NONLOCK, #832
27
28
ACH5-4238 Parts List
ITEM
12
19
20
26
27
38
42
43
45
46
47
48
61
62
QTY
6
4
4
2
2
52
56
60
4
4
6
4
12
12
PART NUMBER
AC-58833
AC-60818
AC-60819
AC-61935
AC-61936
AC-200098-1
AC-11799
AC-13938
AC-200017
AC-70476
AC-200018
AC-200091-1
AC-50686-3
AC-3903-1
DESCRIPTION
TERMINAL,3 POLE,CERAMIC,600V
ENDCOVER,4 LAMP
INSULATOR,END COVER,4 LAMP
REFLECTOR,INNER,4 LAMP,3800
REFLECTOR,OUTER,4 LAMP,3800
AVK, 1ST GRIP, #8
SCREW,MACH,TRUSS,PH,8-32
WASHER,LOCK,EXTERNAL TOOTH,#8,SST
BLUE TIE
NUT HEX MACH 6-32
4" WIRE TIE
SCREW 6-32
SCREW, CAP SOC HD, #8-32 X 1", SST
NUT, HEX, FLG, SERRATED,NONLOCK, #832
29
Parts List
ITEM
4
11
13
14
15
16
45
49
QTY
26
3
5
2
26
2
1
1
PART
NUMBER
AC-200098-1
AC-58833
AC-3903-1
AC-200091-2
AC-13938
AC-200108
AC-10142
AC-3903-1
DESCRIPTION
AVK, 1ST GRIP, #8
TERMINAL,3 POLE,CERAMIC,600V
NUT, HEX, FLG, SERRATED,NONLOCK, #8-32
SCREW,TRUSS,#8-32 X 3/4,SST
WASHER,LOCK,EXTERNAL TOOTH,#8,SST
SCREW, HEX HD, GREEN, 4MM X 16MM
#8-32 SST TRUSS HEAD
NUT, HEX SERRATED FLANGE
30
PARTS LISTING
DESCRIPTION
Item
QTY
PART NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
4
8
6
4
10
30
4
2
6
6
4
4
4
86"
18"
4
1
1
4
2
2
2
1
1
2
1
2
4
4
2
4
2
48
28
REF
28
28
50
8
52
2
4
4
6
AC-4012
AC-50686-3
AC-39487
AC-39917
AC-3903-1
AC-3775
AC-54580
AC-54583
AC-54585
AC-58833
AC-47799
39330
AC-50869
AC-200048
AC-200047
AC-59463
AC-61231
AC-61657
AC-61923
AC-61930
AC-61931
AC-61932
AC-61938
AC-61940
AC-61949
AC-63210
AC-63940
AC-64095
AC-64097
AC-64227
AC-64237
AC-64238
AC-11799
AC-3887
AC-42936
AC-2455
AC-4002
AC-200098-1
AC-200097
AC-13938
AC-50686-1
AC-200017
AC-70476
AC-200018
3/8-16 AVK,1ST GRIP
SCREW,CAP,SOCKET HD,8-32 X 1
NUT,HEX,SLOTTED,1/2-13
3/8 STUD HANDLE
#8-32 SERRATED NUT
WASHER,FLAT,1/2" ID,SST
SPRING,COMPRESSION (BLUE)
SPRING,COMPRESSION (RED)
PIN,COTTER,1/8 X .750
TERMINAL,3 POLE,CERAMIC,600V
NUT 8-32 SST
LAMP,IR,2500W/480V,CER,CL,28.70OAL,25.0L
WASHER,1.5 OD X .531 X .125 THK
WIRE 12 AWG
WIRE 14 AWG
COVER,END,2 LAMP,3" CENTER
ASSY,PYROMETER
PLATE,MOUNT,RAYTEC
INSULATOR,END COVER,2 LAMP,3" CTR
SKIN,HEATER,2 LAMP,2500
REFLECTOR,INNER,2 LAMP,2500
REFLECTOR,OUTER,2 LAMP,2500
WELD,PIVOT,DUAL,2 LAMP
WELD,PIVOT,MAIN,DUAL,2 LAMP
GUARD,2 LAMP,25OO
COVER,SKIN,PRYO OPENING
J-BOX,HEATER
PLATE,REINFORCEMENT,HANDLE
BRACKET,PIVOT,DUAL HEATER,2 LAMP
SPACER,"E" BRACKET
MOD,HEX BOLT,1/2-13 X 2.00
MOD,HEX BOLT,1/2-13 X 2.500
SCREW,MACH,TRUSS,PH,8-32 X .500,SST
#10 EXTERNAL LOCK WASHER
REFER TO PYROMETER ASSY
#10-32 X 3/4 TRUSS HEAD SCREW
10-32 AVK,1ST GRIP
AVK, 1ST GRIP, #8
RIVET, BLACK, ALUMINUM, #43
WASHER,LOCK,EXTERNAL TOOTH,#8,SST
SCREW CAP SOC HD 8-32 X 5/8" SST
BLUE CABLE TIE
NUT 6-32
4" WIRE TIE
31
45
46
47
51
52
53
54
55
56
4
2
2
2
4
2
2
4
REF
AC-200091-1
AC-200108
AC-200192
AC-200099-2
AC-200091-2
AC-10142
AC-200189
AC-200163
AC-200112
SCREW 6-32
GREEN SCREW 6-32
GROUND WIRE
C' SINK SCREW
8-32 x .750
8-32 x 3/8
LABEL "CAUTION HOT"
LABEL "CAUTION SHOCK"
LABEL "PINCH POINT"
32
THIS PAGE INTENTIONALLY LEFT BLANK
33
AC6 Stand
34
Item No.
1
7
8
9
14
15
17
19
20
22
25
37
45
46
58
59
68
69
76
77
79
99
110
Quantity
4
11
8
8
1
6
15
6
5
2
7
1
1
1
1
1
1
2
24
1
1
1
8
Part No.
8156-24C
AC-3772
AC-3881
AC-3741
AC-200083
AC-3831
AC-3903
AC-3801
7734-07
AC-4158
AC-3710
AC-76480
AC-68241-1
AC-68241-2
AC-69779
AC-72008
AC-91369
AC-91370
AC-3887
AC-200085
AC-200073
7957-80C
AC-4090
Description
BOLT, HEX, 5/16-18X3/4",ZINC
WASHER,FLAT,1/4",SS
WASHER,FLAT,3/8",SS
SCREW, TRUSS HEAD,#10-32 X .500 SST
NUT,HEX NYLOCK #10-24
NUT,HEX NYLOCK,3/8-16
NUT,HEX,FLG,SERRATED,1/4-20
NUT,HEX,5/16-18,ZINC
WASHER,LOCK,5/16,ZINC
BUSHING,BRONZE,1/2" ID X 1/2 LG
SCREW, HD,HEX,1/4-20 X .750,SERRATED
WHEEL,RUBBER,1 3/4 DIA
BRACKET,PIVOT
BRACKET,PIVOT
GUARD,ACTUATOR
COVER,BACKPANEL,AC6
BRACKET,MOUNT,IDLER WHEEL
BRACKET,PIVOT BOLT
#10 EXTERNAL LOCK WASHER
SHOULDER BOLT
BRKT,CORNER,4 HOLE
BOLT HEX HEAD,3/8-16X2-1/2"
WASHER FLAT
35
36
ITEM NO.
2
5
6
8
10
13
15
16
17
18
27
28
30
32
33
40
41
42
50
57
61
63
64
66
67
70
73
74
76
83
84
85
86
87
88
89
91
92
96
103
104
105
106
QTY
2
2
6
8
2
10
6
2
15
8
1
16
1
8
1
4
4
4
1
2
REF.
1
1
1
1
1
1
3
24
1
1
1
1
1
1
2
1
1
24
1
AF1
AD1
AD1
PART NO.
AC-3508
AC-3672
AC-3706
AC-3881
AC-3777
AC-3818
AC-3831
AC-3832
AC-3903
AC-3909
AC-46770
AC-48081
AC-200084
AC-62086
AC-69314
AC-30469
AC-50869
AC-52841
AC-68277
AC-69766
AC-72192
AC-75588
AC-76702
AC-84902
E-981
AC-95909
AC-200105
AC-2455-3
AC-3887
AC-200024
AC-74816
AC-200012
AC-200011
AC-200020
AC-200022
AC-200021
AC-200089
AC-200019
AC-2455-1
TABLE-AAA COLUMN-AB
TABLE-AAA COLUMN-AF
TABLE-AAA COLUMN-AD
TABLE-AAA COLUMN-AD
DESCRIPTION
BOLT,HEX,1/2-13 X 2.500
SHOULDER SCREW,1/2"X4.25"
HEAD HEX BOLT,1/4-20X.5",SERRATED
WASHER,FLAT,3/8",SS
WASHER,FLAT,3/4",ZINC, SEE NOTE 1
NUT,HEX,1/2X13
NUT,HEX NYLOCK,3/8-16
NUT,NYLON LOCK,1/2-13
NUT,HEX,FLG,SERRATED,1/4-20
NUT,JAM,LOCK,FLEX,1/2-13,AIRCRAFT LOCK
NUT SLOTTED
WASHER,FLAT,1/2" ID,SST
WASHER
SCREW,CAP,SOCKET,BUTHD,1/2-13 X .750
WASHER,FLAT,3/4",SS,SEE NOTE 1
WASHER,3" OD X .562 ID X .125 THK
WASHER,1.5 OD X .531 X .125 THK
SPACER,ARM TUBE
BRACKET,STOP,PIVOT
WASHER,ODX 1.00" IDX 1/8"THK
BRACKET,MOUNT,CORD GRIP
SCREW,CAP,HEX,3/4-10 X 1.750,5,Z
COVER,ATHENA OPENING
WELD,PLATE,SWIVEL
TRANSFORMER 250 VA
BRACKET,PROX. SWITCH
CAUTION LABEL
SCREW,TRUSS HD,1/4-20X1/2",SS
#10 EXTERNAL LOCK WASHER
PROX SWITCH AMI-AP-4P
CONTROLLER BGK
SWITCH 2 POSITION 800FP-SM22
LATCH AND CONTACT BLOCK 800F-PX10
SWITCH,3 POS,800FP-SB 32N
LATCH BLOCK,800F-ALP
CONTACT BLOCK,800F-X10V
LABEL,SET,BEAMON/START
LABEL,SET,AC6
TRUSS HD,#10-32X3/8"
POWER PANEL SEE AC-6 PRINT
LINE CORD GRIP, MAIN POWER SEE AC-6 PRINT
CORD GRIP + LOCK NUT HEATER HEAD SEE AC-6 PRINT
CORD GRIP + LOCK NUT HEATER HED SEE AC-6 PRNINT
AUX HEAD
37
107
108
112
114
117
118
119
120
AF1
AG1
1
2
1
2
2
1
TABLE-AAA COLUMN-AF
TABLE-AAA COLUMN-AG
AC-200190
TABLE-A COLUMN-AJ1
AC-200206
AC-54585
AC-73479
CORD GRIP + LOCK NUT SEE AC-6 PRINT
FUSES
AUX HEATER OFF/ON LABEL
VOLTAGE LABEL
BRAKE ASSEMBLY AC6, HD
PIN, COTTER 1/8 X .750
WASHER, ¼
BACK PANEL, OVERHEADS
38
THIS PAGE INTENTIONALLY LEFT BLANK
39
40
ITEM NO.
3
4
6
8
11
12
15
17
21
23
24
25
26
28
31
34
35
36
38
40
41
42
47
48
49
51
52
55
56
60
61
62
64
65
72
76
93
96
97
109
116
QTY
6
2
6
8
4
4
6
15
6
1
2
7
1
16
1
1
2
4
1
4
4
4
1
1
1
1
1
1
1
1
REF.
1
1
1
1
24
1
24
6
3.25
8
PART NO.
AC-3632
AC-3670
AC-3706
AC-3881
AC-3790
AC-3803
AC-3831
AC-3903
AC-4008
AC-4420
AC-8671
AC-3710
AC-35106
AC-48081
AC-62054
AC-73709
AC-74466
AC-74935
AC-21728
AC-30469
AC-50869
AC-52841
AC-68270
AC-68275
AC-68276
AC-68277
AC-69223-1
AC-69226
AC-69238
AC-72114
AC-72192
AC-73130
AC-76702
AC-84901
AC-200118-1
AC-3887
AC-200121
AC-2455-1
AC-200095-1
AC-200094
AC-3775
DESCRIPTION
SCREW,CAP,SOCKET HD,BUTHD,5/16-18 X .750
SHOULDER SCREW,1/2"X3.75"
HEAD HEX BOLT,1/4-20X.5",SERRATED
WASHER,FLAT,3/8",SS
WASHER MASTER LOCK SPRING
5/8-11 HEX NUT
NUT,HEX NYLOCK,3/8-16
NUT,HEX,FLG,SERRATED,1/4-20
AVK,1ST GRIP,5/16-18
SCREW,SHOULDER,SOCKET HD,1/2 X 1.500
COLLAR,SHAFT,STEEL,0.500 BORE
SCREW, HD,HEX,1/4-20 X .750,SERRATED
COLLAR,SHAFT,TWO-PIECE,2" BORE
WASHER,FLAT,1/2" ID,SST
HOOK,PENDANT
ACTUATOR,12",24 DC
BEARING,4 BOLT,FLANGE
SCREW CAP HEX 5/8-11 X 3.0
WASHER,UHMWP,25/32 ID X 4.5 OD X 1/8
WASHER,3" OD X .562 ID X .125 THK
WASHER,1.5 OD X .531 X .125 THK
SPACER,ARM TUBE
ARM,DRAG LINK,LOWER
BRACKET,PIVOT,90 DEG
CLEVIS BRACKET
BRACKET,STOP,PIVOT
WELD,BRACKET,ARM
ROD,ACTUATOR
WELD,BRACKET,ACTUATOR,LOW MOUNT
PANEL,MOUNT,ATHENA CONTROLLER
BRACKET,MOUNT,CORD GRIP
ARM,MAIN
COVER,ATHENA OPENING
WELD,PLATE,HANGER
BOLT,SHOULDER,5/16"X3/8"
#10 EXTERNAL LOCK WASHER
LABEL
TRUSS HD,#10-32X3/8"
BLACK WIRE MOUNT
U-CHANNEL VINYL STRIP
WASHER
41
42
ITEM NO.
8
15
QTY
8
6
PART NO.
AC-3881
AC-3831
58
92
93
113
1
1
2
1
AC-69779
AC-200019
AC-200121
TABLE A – COLUMN AJ
115
1
AC-3502
DESCRIPTION
WASHER, FLAT, 3/8” SS
NUT, HEX NYLOCK, 3/816
GUARD, ACTUATOR
LABEL, SET, AC6
LABEL
CAUTION LABEL
VOLTAGE
.375 CAP SCREW
43
44
ITEM NO.
QTY
5
2
9
2
41
1
42
1
47
1
58
TABLE-B COLUMN-BD
59
6
76
2
110
8
ITEM
2
3
4
5
6
7
8
11
QTY
2
2
1
1
1
1
1
2
PART NO.
AC-3663
AC-3772
AC-60831
AC-61219
TABLE-C, COLUMN-CD
AC-200161
AC-200091-2
AC-200099-1
AC-4090
PART NUMBER
AC-54585
AC-46770
AC-3777
AC-3777
TABLE AAA– COLUMN AA
AC-64242
AC-200084
AC-21728
DESCRIPTION
SCREW SHOULDER HD 1/2 X .5
1/4 FLAT WASHER
ARMCLEVIS
BAFFLE,ELECTRICAL CORD
BRACKET,POST
CLIP, SAFETY TO GAS SPRING
SCREW,TRUSS HD,#8-32X3/4",SST
SCREW FLAT HEAD 8-32 X 3/8
WASHER, FLAT
DESCRIPTION
COTTER PIN
NUT, ¾ CASTELLATED
WASHER, FLAT ¾ ZINC
WASHER, FLAT ¾ ZINC
SPRING - COMPRESSION
MOD HEX BOLT ¾-10 X 5
WASHER, BELLEVUE, ¾
UHMQP WASHER
45
46
47
ITE
M
1
2
3
4
5
6
7
9
10
11
12
Parts List
PART NUMBER
QTY
10
2
2
1
2
2
5
2
2
7
4
14
4
15
10
16
1
17
2
18
8
19 TABLE-B COLUMNBC
20 TABLE-B COLUMNB1
21
1
22
4
23
2
24
6
25
2
26
2
27
12
28
1
29
1
30
1
31
2
32
2
33
1
34 TABLE-B COLUMNBA
35
1
36
4
37
1
38
4
39
1
DESCRIPTION
AC-2455
AC-3481
AC-3502
AC-200118-2
AC-3663
AC-3670
AC-3672
AC-3772
78405-06
AC-3773
AC-3903
SCREW, TRUSS HD,#10-32 X 3/4
SCREW, HEX HD,1/4-20 X 2-1/4"
SCREW, HEX CAP,3/8-16 X 5.000
BOLT, SHOULDER,5/16 X .625
SCREW SHOULDER HD 1/2 X .5
1/2 X 3.750 SHOULDER SCREW
1/2 X 4.25 SHOULDER SCREW
1/4 FLAT WASHER
WASHER FLAT USS .312Z
3/8 FLAT WASHER
NUT,HEX,SERRATED,1/4-20
AC-3831
AC-3887
AC-4025
AC-3905
AC-4004
AC-4033
3/8 HEX NYLOCK NUT
#10 LOCK WASHER
NUT,HEX,NYLON LOCK,1/4-20
NUT FLANGE 3/8-16
8-32 AVK 1ST GRIP
STUD,BALL
TABLE-B COLUMN-B1
SPRING
AC-5780
AC-10142
AC-12695
AC-13938
AC-39917
AC-200090-4/AC-47643
AC-3775
AC-48904
AC-49155
AC-49442
TABLE-D, COLUMN-DA
TABLE-D, COLUMN-DA
AC-59981
AC-20439
BUSHING,HEYCO,7/8"
8-32 SST TRUSS HEAD
1/4 X 5/8 FLAT HEAD
WASHER, LOCK, EXTERNAL TOOTH, #8, SST
3/8 STUD HANDLE
BUSHING,HEYCO,1"
WASHER FLAT 1/2" ID SST
GAS SPRING
NUT METRIC GAS SHOCK
5/16 X 3.000 SHOULDER BOLT
CASTER,SWIVEL,4"
BRAKE,CASTER,4"
KIT ACTUATOR/RELEASE
BRACKET,GAS SPRING CONNECT
F711-022
AC-50869
AC-52823
AC-52841
AC-57416
CALIBRATION LABEL
WASHER 1.5 OD X .531 X .125 THK
STUD FEMALE THREAD 5/16 18 X 1 DEEP
SPACER,ARM TUBE
HOOK,CABLE
48
40
41
42
43
44
45
46
47
48
49
1
1
1
1
1
1
1
1
1
1
50
1
51
1
52
1
54
2
55 TABLE-B COLUMNBE
56
13
57 TABLE-B COLUMNBD
58 TABLE-B COLUMNBD
59
6
65
6
66
2
67 1 SET
68
1
70
2
71
2
73
2
74
1
76
2
78
2
79
2
80
1
84
2
85
1
86
1
87
1
88
2
89
2
90
1
91
3
92
6
93
1
AC-60830
AC-60831
AC-61219
AC-61220
AC-61221-1
AC-61221-2
TABLE-C, COLUMN-CC
TABLE-C, COLUMN-CD
AC-61241
TABLE-AAA, COLUMNAA
TABLE-C, COLUMN-CB
TABLE-C, COLUMN-CA
AC-65844
AC-68268
AC-70346
HEATERCLEVIS
ARMCLEVIS
BAFFLE,ELECTRICAL CORD
COVER,ACCESS,CONTROLS
BRACKET,GAS SPRING
BRACKET GAS SPRING
BRACKET
BRACKET,POST
WELD,BASE
POST MOUNT, CONTROLS
AC-4090
AC-3903-3
WASHER,FLAT,#10,SST
NUT,HEX,SERRATED,5/16-18
AC-200161
CLIP, SAFETY TO GAS SPRING
AC-200091-2
AC-200098-1
TABLE-B, COLUMN-BF
AC-200112
AC-200185-2
AC-200122
AC-3741
AC-3903-2
AC-200119
AC-200099-1
7734-07
AC-68266
AC-4025
AC-3706
AC-200212-1
AC-200212-2
TABLE AAA COLUMAK
AC-200038
AC-200097
AC-64248
A13380-03
AC-200230
7969-16
SCREW,TRUSS HD,#8-32X3/4",SST
AVK 8/32 SHOWN ON SHEET #2
COUNTER WEIGHT BOLT
LABEL SET AC5 UNIT COMPLETE
LABEL AC5000 UNIT
BGK FINISHING SYSTEMS LABEL (ARM)
SCREW, TRUSS HEAD,#10-32 X .500 SST
NUT,HEX,FLG,SERRATED, #10-32
5/16 HEX NUT
SCREW FLAT HEAD 8-32 X 3/8
5/16 REG L/W ZINC
SPACER, SO CABLE
NUT,HEX,NYLON LOCK,1/4-20
SCREW HEX FLANGE 1/4 - 20 X .5
CAUTION LABEL W/ARROW
CAUTION LABEL W/O ARROW
VOLTAGE LABEL
INSULATOR
BLACK ALUMINUM RIVETS
FIBER GLASS INSULATOR
SERIAL NUMBER LABEL
¼-20X 5/8 SER FLG BOLT
LOCTITE
ARM LOWER EXTENDED
ARM,UPPER,EXTENDED
PLATE,TAPPING,GAS SPRING
TUBE,SPACER,GAS SPRING
COUNTER WEIGHT AC5
49
94
95
4 20827-00
4 27141-044
PANDUIT TYWRAP MOUNT
TYWRAP
50
THIS PAGE INTENTIONALLY LEFT BLANK
51
52
Parts List
ITEM QTY PART NUMBER
DESCRIPTION
1
1
101861
ASSY, AC5, CRS, CRL, CTE, STE
2
1
103622
ASSY, HEATER, 2306
Parts List
ITEM QTY PART NUMBER
DESCRIPTION
2
1
Ac-3924
PIN, COTTER
3
1
AC-46770
NUT SLOTTED ¾-10
4
4
AC-69314
WASHER FLAT ¾”
5
4
AC-3777
WASHER FLAT ¾” ZINC
6
1
TABLE AAASPRING, COMPRESSION
COLUMN AA
7
1
TABLE AAAMOD HEX BOLT ¾-10 X 5
COLUMN AB
8
1
AC-200084
WASHER BELLEVUE ¾”
11
2
AC-21728
UHMQP WASHER 25/32 ID X 4.5
X 1/8
53
VOLTAGE
OPTION
2116-240-PL
2116-380-SP
2116-480-SP
2116-575-SP
2125-240-PL
2125-480-PL
4125-240-PL
4125-480-PL
4138-240-PL
4138-480-PL
2216-240-PL
2216-480-SP
2216-575-SP
2225-240-SP
2225-380-SP
2225-480-PL
2225-575-SP
4225-240-PL
4225-380-PL
4225-480-PL
4225-480-SP
4225-575-PL
4225-575-SP
4238-240-PL
4238-240-SP
4238-380-PL
4238-480-PL
4238-480-SP
4238-575-SP
AC6BREAKDOWN
DESCRIPTION
2116-240V 1600 Watt
Single Head
2116-380V 1600 Watt
Single Head
2116-480V 1600 Watt
Single Head
2116-575V 1600 Watt
Single Head
2125-240V 2500 Watt
Single Head
2125-480V 2500 Watt
Single Head
4125-240V 2500 Watt
Single Head
4125-480V 2500 Watt
Single Head
4138-240V 3800 Watt
Single Head
4138-480V 3800 Watt
Single Head
2216-240V 1600 Watt
Dual Head
2216-480V 1600 Watt
Dual Head
2216-575V 1600 Watt
Dual Head
2225-240V 2500 Watt
Dual Head
2225-380V 2500 Watt
Dual Head
2225-480V 2500 Watt
Dual Head
2225-575V 2500 Watt
Dual Head
4225-240V 2500 Watt
Dual Head
4225-380V 2500 Watt
Dual Head
4225-480V 2500 Watt
Dual Head
4225-480V 2500 Watt
Dual Head
4225-575V 2500 Watt
Dual Head
4225-575V 2500 Watt
Dual Head
4238-240V 3800 Watt
Dual Head
4238-240V 3800 Watt
Dual Head
4238-380V 3800 Watt
Dual Head
4238-480V 3800 Watt
Dual Head
4238-480V 3800 Watt
Dual Head
4238-575V 3800 Watt
Dual Head
A1
AA
TOTAL
AMP
DRAW
LAMP
WIRING
DETAIL
USE SUBASSY
UNIT
HEATER
HEAD PRINT
COMPRESSION
SPRING- HEATER
HEAD
13.33
AC-68248
ACH6-2116
AC-54945
AC-68248
ACH6-2116
AC-54945
AC-68248
ACH6-2116
AC-54945
7.35
Parallel
SeriesParallel
SeriesParallel
SeriesParallel
AC-68248
ACH6-2116
AC-54945
7.16
Parallel
AC-68248
ACH6-2125
AC-54945
10.42
Parallel
AC-68248
ACH6-2125
AC-54945
14.33
Parallel
AC-68248
ACH6-4125
AC-200125-3
20.83
Parallel
AC-68248
ACH6-4125
AC-200125-3
16.72
Parallel
AC-68248
ACH6-4138
AC-200125-3
24.3
Parallel
AC-68248
ACH6-4138
AC-200125-3
26.67
Parallel
SeriesParallel
SeriesParallel
SeriesParallel
SeriesParallel
AC-68248
ACH6-2216
AC-54945
AC-68248
ACH6-2216
AC-54945
AC-68248
ACH6-2216
AC-54945
AC-68248
ACH6-2225
AC-54945
AC-68248
ACH6-2225
AC-54945
AC-68248
ACH6-2225
AC-54945
7.90
Parallel
SeriesParallel
AC-68248
ACH6-2225
AC-54945
28.66
Parallel
AC-68248
ACH6-4225
AC-200125-3
36.73
Parallel
AC-68248
ACH6-4225
AC-200125-3
41.67
Parallel
SeriesParallel
AC-68248
ACH6-4225
AC-200125-3
AC-68248
ACH6-4225
AC-200125-3
Parallel
SeriesParallel
AC-68248
ACH6-4225
AC-200125-3
AC-68248
ACH6-4225
AC-200125-3
AC-68248
ACH6-4238
AC-200125-3
11.5
Parallel
SeriesParallel
AC-68248
ACH6-4238
AC-200125-3
42.85
Parallel
AC-68248
ACH6-4238
AC-200125-3
48.61
Parallel
SeriesParallel
SeriesParallel
AC-68248
ACH6-4238
AC-200125-3
AC-68248
ACH6-4238
AC-200125-3
AC-68248
ACH6-4238
AC-200125-3
5.88
6.67
13.33
14.7
14.33
18.36
20.83
14.33
45.93
15.8
33.43
16.72
18.43
54
AA1
AB
AC
AD
VOLTAGE
OPTION
BOLT HEATER
HEAD AC64242
POWER
PANEL W/O
J-BOX AC6
HEAD
CORD
PART NO.
HEAD CORD +
LOCK NUT POWER
PANEL
2116-240-PL
2116-380-SP
2116-480-SP
2116-575-SP
2125-240-PL
2125-480-PL
4125-240-PL
4125-480-PL
4138-240-PL
4138-480-PL
2216-240-PL
2216-480-SP
2216-575-SP
2225-240-SP
2225-380-SP
2225-480-PL
2225-575-SP
4225-240-PL
4225-380-PL
4225-480-PL
4225-480-SP
4225-575-PL
4225-575-SP
4238-240-PL
4238-240-SP
4238-380-PL
4238-480-PL
4238-480-SP
4238-575-SP
-01
-01
-01
-01
-01
-01
-02
-02
-02
-02
-01
-01
-01
-01
-01
-01
-01
-02
-02
-02
-02
-02
-02
-02
-02
-02
-02
-02
-02
AC-200007
AC-200007
AC-200007
AC-200194-1
AC-200007
AC-200007
AC-200007
AC-200007
AC-200007
AC-200007
AC-200006
AC-200006
AC-200194-2
AC-200006
AC-200006
AC-200006
AC-200194-2
AC-200006
AC-200006
AC-200006
AC-200006
AC-200194-2
AC-200194-2
AC-200006
AC-200006
AC-200006
AC-200006
AC-200006
AC-200194-2
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-5
AC-200081-5
AC-200081-5
AC-200081-5
AC-200081-5
AC-200081-7
AC-200081-7
AC-200081-5
AC-200081-5
AC-200081-7
AC-200081-7
AC-200081-5
AC-200081-5
AC-200081-5
AC-200081-7
AC-200081-5
AC-200081-7
AC-200081-5
AC-200081-7
AC-200081-5
AC-200081-5
AC-200081-7
AC-200081-7
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AC-200115-3,AC-200117-1
AD1 AC1
HEAD
CORD
LENGTH
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
15
15
15
15
15
15
15
15
15
15
15
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
15 (X2)
55
AE
AF
AF1
VOLTAGE
OPTION
LINE CORD PART
NO. SEE TABLE
"E" FOR LENGTH
LINE CORD GRIP
2116-240-PL
2116-380-SP
2116-480-SP
2116-575-SP
2125-240-PL
2125-480-PL
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
1
1
1
1
1
1
4125-240-PL
4125-480-PL
4138-240-PL
4138-480-PL
2216-240-PL
2216-480-SP
2216-575-SP
2225-240-SP
2225-380-SP
2225-480-PL
2225-575-SP
4225-240-PL
4225-380-PL
4225-480-PL
4225-480-SP
4225-575-PL
4225-575-SP
4238-240-PL
4238-240-SP
4238-380-PL
4238-480-PL
4238-480-SP
4238-575-SP
AC-200081-7
AC-200081-5
AC-200081-7
AC-200081-4
AC-200081-4
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-7
AC-200081-5
AC-200081-7
AC-200081-4
AC-200081-3
AC-200081-2
AC-200081-7
AC-200081-2
AC-200081-7
AC-200081-3
AC-200081-7
AC-200081-2
AC-200081-2
AC-200081-7
AC-200081-5
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-2,AC-200117-2
AC-200115-2,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4, AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
AC-200115-2,AC-200117-2
AC-200114-3,AC-200117-3
AC-200114-2,AC-200117-3
AC-200115-4,AC-200117-2
AC-200114-2,AC-200117-3
AC-200115-4,AC-200117-2
AC-200114-3,AC-200117-3
AC-200115-4,AC-200117-2
AC-200114-2,AC-200117-3
AC-200114-2,AC-200117-3
AC-200115-4,AC-200117-2
AC-200115-4,AC-200117-2
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
AG
AG1 AH1 AH2
CONTROL
PANEL
FUSES
CORD
GRIP
LOCK
NUT
2
2
2
2
2
2
1
1
1
1
1
1
3
3
3
3
3
3
2
2
2
2
2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
AC-200039
AC-200042
AC-200042
AC-200042
AC-200042
AC-200039
AC-200037
AC-200038
AC-200037
AC-200040
AC-200037
AC-200042
AC-200042
AC-200037
AC-200038
AC-200039
AC-200041
AC-200037
AC-200038
AC-200038
AC-200037
AC-200038
AC-200042
AC-200037
AC-200042
AC-200038
AC-200040
AC-200042
AC-200039
56
AJ
AJ1
2116-240-PL
2116-380-SP
AC-200191-4
AC-200191-2
AC-200019
REF
AC-200193-2
2116-480-SP
2116-575-SP
AC-200191-3
AC-200191-5
2125-240-PL
AC-200191-4
2125-480-PL
AC-200191-3
4125-240-PL
AC-200191-4
4125-480-PL
AC-200191-3
4138-240-PL
AC-200191-4
4138-480-PL
AC-200191-3
2216-240-PL
AC-200191-4
2216-480-SP
2216-575-SP
AC-200191-3
AC-200191-5
2225-240-SP
AC-200191-4
2225-380-SP
2225-480-PL
AC-200191-3
AC-200191-5
2225-575-SP
4225-240-PL
AC-200191-4
AC-200191-2
4225-380-PL
AC-200191-3
4225-480-PL
4225-480-SP
4225-575-PL
AC-200191-3
AC-200191-5
AC-200191-5
4225-575-SP
AC-200191-4
4238-240-PL
4238-240-SP
AC-200191-4
AC-200191-2
4238-380-PL
AC-200191-3
4238-480-PL
4238-480-SP
4238-575-SP
AC-200191-3
AC-200191-5
AC-200191-5
VOLTAGE
OPTION
AC-200019
REF
AC-200093-3
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200019
REF
AC-200193-3
AC-200019
REF
AC-200019
REF
AC-200193-3
AC-200019
REF
AC-200193-2
AC-200019
REF
AC-200019
REF
AC-200193-3
AC-200191-3
AC-200019
REF
AC-200019
REF
AC-200193-2
AC-200019
REF
AC-200019
REF
AC-200193-3
AC-200193-3
57
ACH6-4238-480- SP Lamp Wiring Schematic
58
Spare Parts Recommendations
Reference Number
Spares Qty
110
110, 111
110B,110A,116,
105
109C,109D,
109A,109B,
116
116
116
123
1
1
1
4
4
4
1
1
1
1
Part
Number
0620021
005898
062486
E-178
E-471
E-305
E-223
074441
063884
E-224
13
104
103,104
118
114
1
1
2
1
1
003320
002985
018196
E-833
064558
Part Description
RECTIFIER BRIDGE, 25A, 50V
CONTACTOR, 40A, 2-POLE, 24 COIL
RELAY,1 POLE,24VDC/AC
FUSE,2A,600V,CLASS CC
FUSE,10A,250V,5x20mm,TIME DELAY
FUSE,2A,250VAC,TIME DELAY
TEMPERATURE CONTROLLER
PROXIMITY SWITCH,24VDC,12MM,
CABLE,PROX,QUICK CONNECT,5 MET
POWER SUPPLY,24VAC - 12VDC &
3.25VDC
POWER CONTROLLER,4-20MA
POWER CONTROLLER,SCR,40A
POWER CONTROLLER THERMSTRATE,H
SWITCH,2POS,2 NO
SELECTOR SW OP, 2 POS,MAINT
59
Warranty
BGK Finishing Systems warrants custom products, manufactured by BGK to be free from defects in material
and workmanship under normal conditions of use and service for a period of one year from date of shipment.
Any such defect discovered by the Buyer shall be repaired or replaced by BGK Finishing Systems. All costs of
shipping, installation, removal labor, customs clearance and any other related charges are excluded from the
warranty. If, after inspection, BGK Finishing Systems determines that the equipment is not defective within the
terms of this warranty, Buyer shall pay the cost of all replacement materials.
THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO,
ALL WARRANTIES OR MERCHANTGABILITY AND FITNESS FOR PURPOSE.
This warranty shall not apply to any equipment manufactured by BGK Finishing Systems which shall have been
repaired or altered outside its factory in any way so as to affect its use and operation, as determined by BGK
Finishing Systems nor shall it apply to any such equipment which has been subject to misuse, negligence or
accident, or has been operated contrary to printed instructions. This warranty shall not apply to fuses and
lamps or other items, which are expendable by nature unless otherwise provided.
BGK Finishing Systems shall under no circumstances, be liable for any special, indirect or consequential
damages, expenses of connecting or disconnecting, or any losses or damages resulting from a defect of
equipment manufactured by it.
Unless otherwise agreed in writing by an authorized representative at the company headquarters in
Minneapolis, Minnesota, products sold hereunder are not intended for use in connection with any nuclear
facility or activity. If so used and , due to the hazardous properties of nuclear material, any damage, injury or
contamination occurs, BGK Finishing Systems disclaims any responsibility of every kind, and Purchaser shall
indemnify BGK Finishing Systems harmless from any and all liability for any such damage or contamination
whatsoever arising out of any such use, including negligence.
60