TECHNICAL BULLETIN # 151 FROM: Legacy Engineering BY: Steve McMahon DATE: 28 October 2014 Approvals V.P. Aftermarket and Legacy Engineering M. Nichols SUBJECT: New Key HID Ballast Revision: B Affected Products: Manta 16, Manta 20, Optyx 3000, Optyx 3000 Raptor, Optyx 6000, Optyx 6000 Raptor, TSIII 240/480/720 All products manufactured from April 2014 onward have new ballasts installed at the factory. Introduction Due to obsolete part availability old style ballasts (Key #020939) from Magnetek and other suppliers can no longer be sourced. A new ballast has been designed and validated that has good part availability with excellent reliability. These new ballasts can be AC or DC powered with no image degradation. Also, the new ballast has an onboard health status contact that can be wired in normally open or closed configurations. Replacement Process Due to physical differences between old and new assemblies, a process must be followed to replace the ballast(s). 1) Determine and record the manufacturing date of the sorter. 2) Determine and record ballast type. 3) Determine and record the ballast operating input voltage. 4) Determine additional documentation to order using the Change Definition Table. 5) Obtain appropriate parts from Key and perform the replacement or upgrade Limitations A. The new ballast consumes more volume than the old; this is due primarily to regulatory agency required trace spacing constraints on the printed circuit board. The increased size forces certain products to require additional kits and wiring adaptations to replace one or more failed ballasts. B. Existing power supplies cannot supply sufficient current to reliably power the new ballasts. When replacing old ballasts, all products require a full per side or per right/left half upgrade with wiring changes to eliminate DC power supplies. Removal of the DC power supplies leads to a more reliable system in the long term. C. New ballast input operating voltage must remain under 240VAC to properly regulate lamp performance. Input voltage range higher than 240VAC causes sorting performance degradation. CAUTION SECTION:
WHEN REWIRING, ALL BALLASTS WITHIN THE SAME CIRCUIT (Upstream/Downstream or Left/Right) MUST BE OF THE NEW TYPE, ALL #826762. ONCE NEW BALLASTS ARE INSTALLED AND AC POWERED, OLD STYLE BALLASTS CANNOT BE USED TO REPLACE NEW BALLASTS. NEW BALLST INPUT OPERTING VOLTAGES HIGHER THAN 240VAC CAUSES DEGRADATION OF IMAGE QUALITY LEADING TO PERFORMANCE PROBLEMS. Step 1: Determine Manufacture Date of System Determine the manufacture date on the sorter by reading and recording the information on the sorter name plate. Identify Sorter Production Date a. Production dates prior to April 2014 = old ballast b. Production date of April 2014 = mixed old/new ballasts in products Note: No products were manufactured with both old and new ballasts within the same unit. c. Production date after April 2014 = new ballast INSERT PRODUCT NAME PLATE EXAMPLE(S) HERE Manufacture Date: Determining old versus new ballast types: Step 2: Determine Ballast Type 1) Identify and Record Part Number Old Ballast: #020939 New Ballast: #826762 2) Identify and Record Shape of Circuit Card Assembly Old Ballast: Round New Ballast: Rectangular
Old Style Model : #020939 New Style Model : #826762 Figure 1: Part Number Location on Label Figure 2: Old ballast shape is round Figure 3: New ballast shape is rectangular
Step 3: Determine and Record Ballast Input Operating Voltage EXTREME CAUTION STATEMENT: EXTREME SHOCK HAZARD EXISTS WHEN MEASURING VOLTAGE WITH SYSTEM POWER APPLIED. For all products except TSIII, measure the output terminals of the input transformer T2 and record below. For TSIII, measure the output of input transformer T3 and record below. If the voltage is above 240VAC, call Key Technology Service for revision instructions. Refer to Step 5 section for Key Technology Service contact information. T2 Output voltage (all products except TSIII) T3 Output voltage (TSIII Only) VAC VAC Step 4: Additional Documentation Prior to replacing ballast, consult the Change Definition Table below for additional documentation that could be of benefit to the associate performing the work. Figure 4: Change Definition Table Product Production Cross Over Date Full Side Upgrade Service Kit Schematic SchematicOld Rev. Schematic New Rev (w/o TROG) New Wiring Diagram Manta Manta 1600 April 2014 Manta 2000 April 2014 Left Hand 1096430 Right Hand 1096431 720050.1 R T Left Hand 1096432 Right Hand 1096433 720040.2 P R 710462-8 REV F 710462-9 REV D Optyx3K Optyx 3K Top Camera April 2014 Infeed 1097957 1097960 701282-4 S T Infeed 1091925.1 1091925.2 Optyx 3K Bottom Camera April 2014 1097958 701282-4 S T 1091925.3 Optyx 3K Raptor Top Camera April 2014 Infeed 1097957 1097960 Optyx 3K Raptor Bottom Camera April 2014 1097958 701282-12 M N Infeed 1091925.1 1091925.2 701282-12 M N 1091925.3
Figure 4: Change Definition Table (cont.) Product Production Cross Over Date Full Side Upgrade Service Kit Schematic SchematicOld Rev. Schematic New Rev (w/o TROG) New Wiring Diagram Optyx6K Prism2 Optyx 6K Top Camera April 2014 Infeed 1090308.1 1090308.2 720001.1 H I 1091927 Optyx 6K Bottom Camera April 2014 1097959 720001.1 H I 1091926 Optyx 6K Raptor Infeed 1090308.1 Top Camera April 2014 1090308.2 720000.2 X Y 1091927 Optyx 6K Raptor Bottom Camera April 2014 1097959 720000.2 X Y 1091926 Infeed 1090308.1 Prism2 Top Camera April 2014 1090308.2 720001.1 H I 1091927 Prism2 Bottom Camera April 2014 1097959 720001.1 H I 1091926 TSIII TSIII-240 April 2014 1096436 701690.1 H I 701698.1 TSIII-480 April 2014 1097955 701690.1 H I 701698.2 TSIII-720 April 2014 1097956 701690.1 H I 701698.3 *= Systems configured with two 300VDC power supplies, remove one and rewire per 1091927
Step 5: Ordering Parts Call Key Technology Parts to order the required parts for your system. Revision Sheet Revision Revision Date Author Comments 0.1 5/13/2014 S. McMahon Initial Release 0.2 5/19/2014 S. McMahon Incorporated review feedback 0.3 6/2/2014 S. McMahon Changed to full replacement kit strategy. Changed definition table to remove single items and when to rewire columns and add full side service kits for all products. 0.4 6/19/2014 S. McMahon Added circuit card assembly terminology 0.5 6/25/2014 S. McMahon Corrected typographical error of service part kit for TSIII 240 product. 1.0 6/25/2014 S. McMahon Published in Technical Bulletins in R&D SharePoint. Rev B 01/27/2014 McMahon/Nichols Updated Figure 4 in Step 4.
TECHNICAL BULLETIN # 4 SYMETIX FROM: BY: Ken Carambot DATE: September 24, 2014 VP of Aftermarket Approvals M. Nichols SUBJECT: New Lamp Ballast Bulletin for Optyx SG and Full-size VeriSym systems Revision: 1.2 Effective Date: September 24, 2014 Affected Products: All Optyx SG and full-size VeriSym inspection systems (excludes the VeriSym SE). All products manufactured from June 1, 2014 onward will have new ballasts installed at the factory. Introduction Due to obsolete part availability old style ballasts (Key Part #: 020939) from Magnetek and other suppliers can no longer be sourced. A new ballast has been designed and validated that has good part availability with excellent reliability. These new ballasts MUST be AC powered only. The impact this will have on your system is that some electrical circuits may be bypassed, removed altogether or still used for some lamps and not for others. The important thing to note is that there is no optical performance difference between lamp ballasts powered by AC or the old ballasts still powered by the original DC circuits. While it is possible to mix old and new ballasts within the same piece of equipment it is Symetix recommendation that the complete system be retrofitted and converted over to have all new ballasts rather than have some old style ballasts powered by the original DC circuit and the new ballasts powered by AC circuits. We also strongly recommend that if you choose to mix old and new within your system, that you consider retrofits/updates in banks or groups of four (4). Both the VeriSym and Optyx SG systems incorporate lighting banks with four lamps per bank already. DO NOT mix old and new ballasts within any one bank of four. Replacement Process Due to physical differences between old and new assemblies, a process must be followed to replace the ballast(s). 1) Determine and record the manufacturing date of the sorter. 2) Determine and record ballast type. 3) Determine and record the ballast operating input voltage. 4) Determine additional documentation to order using the Change Definition Table. 5) Obtain appropriate parts from Key and perform the replacement or upgrade Limitations A. The new ballast consumes more volume than the old; this is due primarily to regulatory agency required trace spacing constraints on the printed circuit board. The increased size forces certain products to require additional kits and wiring adaptations to replace one or more failed ballasts. Page 1 of 4
B. Existing DC power supplies cannot supply sufficient current to reliably power the new ballasts. When replacing old ballasts, always replace all four ballasts in any one bank. Note: Removal of the DC power supply circuits can lead to a more reliable system in the long term. C. New ballast input operating voltage must remain under 240VAC to properly regulate lamp performance. Input voltage range higher than 240VAC causes sorting performance degradation. CAUTION SECTION: ONCE NEW BALLASTS ARE INSTALLED AND AC POWERED, OLD STYLE BALLASTS CANNOT BE USED TO REPLACE NEW BALLASTS. NEW BALLST INPUT OPERTING VOLTAGES HIGHER THAN 240VAC CAUSES DEGRADATION OF IMAGE QUALITY LEADING TO PERFORMANCE PROBLEMS. Step 1: Determine Manufacture Date of System Determine the manufacture date on the sorter by reading and recording the information on the sorter name plate. Identify Sorter Production Date a. Production dates prior to April 2014 = old ballast b. Production date after April 2014 = only new ballasts were used Equipment Model#: Equipment S.N.: Step 2: Determine Ballast Type Determining old versus new ballast types: 1) Identify and Record Part Number Old Ballast: #020939 New Ballast: #826762 2) Identify and Record Shape of Circuit Card Assembly Old Ballast: Round New Ballast: Rectangular Page 2 of 4
Old Ballast Part #: 020939 New Ballast Part #: 826762 Figure 1: Part Number Location on Label Figure 2a: Old ballast shape is round. Figure 2b: New ballast shape is rectangular. Step 3: Determine and Record Ballast Input Operating Voltage EXTREME CAUTION STATEMENT: EXTREME SHOCK HAZARD EXISTS WHEN MEASURING VOLTAGE WITH SYSTEM POWER APPLIED. For all Optyx SG systems measure the output terminals of the input transformer T2 and record below. For the full-size VeriSym, measure the voltage at CB20 on Panel 4 and record below. If the voltage is above 240VAC, call Key Technology Service for revision instructions. Refer to Step 5 section for Key Technology Service contact information. T2 Output voltage (Optyx SG) VAC T3 Output voltage (VeriSym) VAC NOTE: If the output voltages identified above exceed or are very close to the max. recommended input voltage for the new lamp ballasts there may be was this can be adjusted down in order to comply with the proper operating voltage. Optyx SG: Check the transformer taps on T2 first, then check T1 to see if there are options for dropping the voltage. Page 3 of 4
VeriSym: These units are powered by a fully configurable UPS and whose output can be specified through parameter selection. Please consult the technical manual or contact Symetix for assistance. Step 4: Additional Documentation Prior to replacing ballast, consult the electrical schematic that was provided with your equipment and please review them together with current redlines that apply to your system or call Symetix for copies of your original drawing sets and any applicable redlines. The table below should help you identify what is needed for each equipment type and application. Equipment New Lamp Ballast Change Definition Table Original Schematic Schematic Redlines Full change Partial change Optyx SG/N 830346 830346.R1 830346.R2 Optyx SG/P 830159 830159.R1 830159.R2 VeriSym 830680 830680.R1 830680.R2 Circuit breaker 15A Single Ballast kit Top Lamp Kit Bottom Lamp Kits EFC Backlight Kits 1100054** (2) (4) Direct* N/A 1100054** (2) (4) Direct* (2) Direct* 1090808 1090311 (2) (2) N/A 026568 Needed for full and partial changes to the Optyx SG systems only. 1090809 Included are new ballast and the required Molex connector. Service 826762 Includes just the ballast. Replacement *Direct: This means the new ballast installs in the same place the original ballast mounted. ** Reference DWG: 1090305 for example assy. Table 1: Change Definition Table. Numbers in parenthesis are quantities needed of each. Step 5: Ordering Parts or Supporting Documentation Call or email Symetix/Key Technology Parts Sales to order the required parts for your system. Symetix: service@symetix.com Phone: +1 800 941-3701 Parts Sales email: partsales@key.net Phone: +1 877 878-4631 (US) Fax: +1 509 394-3386 Revision Revision Date Author Comments 1.0 7/30/2014 K. Carambot Initial Release 0.1 8/18/2014 K. Carambot Corrected Optyx SG top lamp kit #. 0.2 9/24/14 K. Carambot Clarified quantities needed for each system. 0.3 0.5 (End of Document) Page 4 of 4