MAN056 - BlueWave LED VisiCure User Manual
Contents
1. Re insert the footswitch into the unit Dymax BlueWave LED VisiCure User Guide Frequently Asked Questions Q My BlueWave LED VisiCure will not turn on A Check the power cord connection B Check the fuses located where the power cord plugs into the unit Q The LED will not light but the unit is powered up A Check that the lightguide is fully seated in the lightguide mount B Confirm that the intensity adjustment is not at the minimum setting C Check the condition of the signals on the DB9 connector 24V Safety Interlock and Intensity Input Q have low intensity A The end of the lightguide may have a build up of adhesive Carefully remove any build up with isopropyl alcohol or for heavier deposits gently scrape it with a razor blade B The condition of the lightguide can also affect the intensity All lightguides degrade with time but intensity will also drop if the lightguide is bent or compressed The intensity reading from the lightguide should be compared to the intensity reading from a lightguide simulator to determine the efficiency C The intensity adjustment is set incorrectly Turn the knob fully clockwise for the maximum intensity out D The connections or signals applied to the DB9 connector are incorrect Verify that the safety and intensity input lines are not shutting down current to the LED Q Why does my BlueWave LED VisiCure unit seem to run very hot A Replace the fan filter media2. as much light as possible Cured adhesive can be carefully removed from liquid filled lightguide ends with a razor blade Avoid sharp bends with the lightguide since this reduces light output and permanently damages the guide Fan Filter The external fan filter should be inspected and cleaned periodically to prevent dust buildup from affecting airflow through the unit Spare filters are provided with each unit The fan filters are washable and may be reused Remove the fan filter by removing the snap on cover from the rear of the fan Figure 10 Cooling Fan Figure 11 Cooling Fan Cover and Filter Fuse Replacement The unit is supplied with two Fuses that are installed in the Power Receptacle To remove the Fuses unplug the unit and remove the Fuse Holder with a small screwdriver Remove the Fuses from the Fuse Holder and install new Fuses Replace the Fuses with 2 0 Amp fast blow types Dymax PN 37236 or equivalent Reinstall the Fuse Holder into the Power Receptacle Figure 12 Power Receptacle Figure 13 Fuse Holder Figure 14 Fuses PN 37236 Dymax BlueWave LED VisiCure User Guide Troubleshooting WARNING Only qualified maintenance personnel should attempt the following procedures Table 1 Troubleshooting Chart for BlueWave LED VisiCure Problem The unit s LED will not illuminate The unit has low output intensity or The unit fails to cure the material in the allotted time The footswitch is not
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4. Adjustment Screw or using the Intensity Input on Pin 5 will cause a change in the signal seen on Pin 8 This output can be used to verify step or ramped changes in the intensity for customized profiles or to alert the remote controller when the system has reached maximum intensity in a closed loop system Pin 9 Over Temp Out A sensor constantly monitors the temperature of the LED in the system If for any reason the reading rises above a predetermined limit the control PCB will shut off current to the LED to prevent damage When the measured temperature drops to a lower threshold the PCB will re enable current to the LED NOTE If this fault occurs check for proper airflow into and out of the unit Also verify that the air filter is clean Figure 9 9 Pin D Connector I O Signals CUSTOMER SUPPLIED PLC CONNECTOR LED UNIT 24V 24VDC SUPPLY COM SHUTTER IN SAFETY INTERLOCK IN INTENSITY IN PWM pi LIGHT GUIDE ENGAGED OUT pE US A aa GREEN ELLUN LED LIT OUT fE INTENSITY OUT PWM oe UB A OVER TEMP OUT TE U6 8 POSSIBLE CONNECTIONS TQ THE 9 PIN CONNECTOR Dymax BlueWave LED VisiCure User Guide Cleaning and Maintenance The BlueWave LED VisiCure was designed to operate with minimum maintenance Follow the schedule below to assure top unit performance Lightguide Clean the lightguide ends monthly or as required The ends of the lightguide should be kept clean to transmit
5. as well as a variety of dispensing equipment Our products are perfectly matched to work seamlessly with each other providing design engineers with tools to dramatically improve manufacturing efficiency and reduce costs LISTEN ENVISION DELIVER Dymax is committed to providing the best chemistry curing equipment and dispensing systems that offer customers complete manufacturing solutions for their challenging applications 2013 Dymax Corporation All rights reserved All trademarks in this guide except where noted are the property of or used under license by Dymax Corporation U S A Please note that most dispensing and curing system applications are unique Dymax does not warrant the fitness of the product for the intended application Any warranty applicable to the product its application and use is strictly limited to that contained in Dymax s standard Conditions of Sale Dymax recommends that any intended application be evaluated and tested by the user to ensure that desired performance criteria are satisfied Dymax is willing to assist users in their performance testing and evaluation by offering equipment trial rental and leasing programs to assist in such testing and evaluations Data sheets are available for valve controllers or pressure pots upon request PN41065 MANO56 5 21 2013 Dymax Corporation Dymax Oligomers amp Coatings Dymax Europe GmbH Dymax UV Adhesives amp Dymax UV Adhesives amp Dymax Asia H K Dymax Korea LLC 860 482
6. operating Possible Cause There is an incorrect connection The main line fuse is blown nothing in unit operates The lightguide is not fully inserted The intensity adjustment is set too low The transmission loss in the lightguide is too great There are contaminants on the lightguide The system has inadequate cooling There is an incorrect connection Testing Visually inspect all input output connections i e power cord foot switch lightguide Remove the fuse from the power receptacle and check it with an ohmmeter Remove the lightguide Use a radiometer Dymax ACCU CAL 50 LED to measure the output intensity Compare the lightguide output against a new lightguide or use a Dymax lightguide simulator to determine the transmission loss Visually examine ends of lightguide for contaminants Check the air filter for debris and blockages at the exit vents Check the connection of the footswitch into the unit Corrective Action Secure all connections Replace the fuse if defective Re insert the lightguide into the lightguide mount Adjust the setpoint to the desired intensity Replace the lightguide Clean the lightguide ends with isopropyl alcohol or an equivalent Heavy deposits on liquid lightguides may be carefully removed using a razor blade Replace the lightguide if it cannot be cleaned Clean or replace the filter Remove all air blockages from around the unit
7. present on Pin 1 In addition to removing power from the LED if the system is being operated in the TIMED mode breaking this connection will reset the timer to zero A second shutter signal will reactivate the LED for the timed duration Pin 5 Intensity In PWM This input is supplied as a means to actively control the output intensity of the BlueWave LED VisiCure unit It can be used to Pulse Width Modulate PWM the power to the LED This input cannot increase the intensity over the set point of the front panel intensity adjustment but can only reduce it The front panel adjustment should be set fully clockwise to give Pin 5 the greatest range A high level 24V on Pin 5 will turn off the LED and a low level OV will allow maximum LED intensity A signal of 1 K Hz should be used with a duty cycle of 0 to 60 NOTE A 10 duty cycle will generate a greater intensity than a 50 duty cycle This input can be used with an external controller to create any number of customized step cure profiles or with an additional sensor to regulate the output Output Signals The output signals are all opto isolated signals Each signal has an NPN output transistor The emitters of all output transistors are tied together and connected to the PLC common on DB9 Pin 2 Each individual output signal line is connected to the collector of each transistor When the transistor is turned on this provides a ground to the PLC system that can be used to ena
8. requirements AA CAUTION Risk of electrical shock if cover is removed To use a BlueWave LED VisiCure system safely it must be set up and operated in accordance with the instructions given by Dymax Using the system in any other manner will impair the protection of the system Dymax assumes no liability for any changes that may impair the protection of the BlueWave LED VisiCure system Safety Recommendations m Use the goggles provided or an approved face shield for eye face protection Dymax BlueWave LED VisiCure User Guide Long sleeved shirts or a lab coat are recommended for arm protection The use of opaque gloves will protect the hands NOTE The BlueWave LED VisiCure emits high intensity light Never look directly at the light emitting end of the lightguide while the unit power is on Dymax Light Curing System Safety Considerations Dymax light curing technology has been used successfully for over 30 years The fast cure one component nature of our curing technology has made it the process of choice for many manufacturers requiring a Cure on Demand assembly process There are four common questions concerns related to light curing systems UV exposure high temperature surfaces ozone and bright visible light NOTE The energy emitted from the Dymax BlueWave LED VisiCure spot curing system is in the Visible portion of the spectrum To ensure that all safety aspects regarding operations of this equipment are addre
9. spot lamp that generates curing energy using high intensity Light Emitting Diodes LEDs The relatively narrow frequency band produced by LEDs generates cooler curing temperatures and makes the BlueWave LED VisiCure an excellent choice for spot curing various coatings and adhesive bonding of polycarbonate PVC PET metal glass and many other substrates LED light curing systems offer many advantages over conventional spot curing systems including no bulbs to change cooler cures no warm up and constant intensity for thousands of hours The BlueWave LED VisiCure is rated for continuous operation and can run in either timed or manual operating modes The power supply operates on line voltages of 100 to 240 VAC 50 60 Hz The BlueWave LED VisiCure unit is comprised of an anodized aluminum housing which contains an electronic power supply circuit protection an LED assembly cooling fans a lightguide mount a lightguide safety interlock and a control PCB with connections for a remote operation system Cooling fans are provided to keep the housing and internal components of the unit at the optimum operating temperature The fan filter should be changed or cleaned frequently to prevent blockage and reduced ventilation airflow The air vents must not be covered or otherwise blocked A thermal shutdown sensor is provided for internal temperature control of the unit The unit s curing energy is emitted from a lightguide This guide can be hand held for c
10. BlueWave LED VisiCure User Guide LED Spot Curing System Instructions for Safe Use Setup and Operation Maintenance Ordering Spare Parts and Accessories amp DYM LS E MAX Dl AA K N Dymax BlueWave LED VisiCure User Guide About Dymax UV Visible light curable adhesives Systems for light curing fluid dispensing and fluid packaging Dymax manufactures industrial adhesives light curable adhesives epoxy resins cyanoacrylates and activator cured adhesives We also manufacture a complete line of manual fluid dispensing systems automatic fluid dispensing systems and light curing systems Light curing systems include LED light sources spot flood and conveyor systems designed for compatibility and high performance with Dymax adhesives Dymax adhesives and light curing systems optimize the speed of automated assembly allow for 100 in line inspection and increase throughput System designs enable stand alone configuration or integration into your existing assembly line Please note that most dispensing and curing system applications are unique Dymax does not warrant the fitness of the product for the intended application Any warranty applicable to the product its application and use is strictly limited to that contained in the Dymax standard Conditions of Sale Dymax recommends that any intended application be evaluated and tested by the user to ensure that desired performance criteria are satisfied Dym
11. Cable Connections Install the Lightguide Remove the protective cover from the unit s Lightguide Mount Remove the protective end caps from the Lightguide a Visually inspect the two ends of the Lightguide to verify that no foreign material is present NOTE Dymax liquid filled lightguide ends can be cleaned with isopropyl alcohol to remove foreign material and outgassing deposits a Fully insert the large end of the Lightguide into the Lightguide Mount on the front panel NOTE When properly seated a light click may be heard and or felt Figure 5 Lightguide Mount Set Screw If desired the Lightguide may be fastened into place by lightly tightening the Securing Set Screw in the top of the Lightguide Mount A Hex Wrench is provided with the unit for this purpose The Set Screw should be tightened gently to prevent damaging the Lightguide Dymax BlueWave LED VisiCure User Guide NOTE Multi pole lightguides should be checked for leg to leg output uniformity Rotate the lightguide to verify the desired intensity of each leg before tightening the set screw a The Lightguide is now installed and ready for use The end of the Lightguide should be periodically cleaned with isopropyl alcohol Adhesive build up may be removed from the end of the Lightguide by gently scraping using a razor blade or razor knife Turn the Power Switch to the on position There is no need for a warm up or cool down period with th
12. D radiometer attached at the end of a Lightguide Simulator Measured with a UV Power Puck II at the end of a Lightguide Simulator Figure 15 BlueWave LED VisiCure Spectral Output ity o sy 0 6 0 5 0 4 0 3 wa c w w K w oc 0 2 0 1 4 O 300 320 340 360 380 400 420 440 460 480 500 Wavelength in nm CE Dymax BlueWave LED VisiCure User Guide Definition of Terms Light Emitting Diode LED A solid state semi conducting device that generates a specific narrow band wavelength of energy Intensity also known as Irradiance A measure of energy over the unit of surface area measured in W cm or mW cm Brightness also known as Luminance A description of energy in the visible region of the spectrum approximately 400 700 nm Brightness is recorded in photometric units The Intensity see below of visible light energy is called IIluminance illuminance Luminous flux energy of visible light incident per unit area Illuminance is measured in Lx lux or Lumen cm Ultraviolet UV The invisible region of the spectrum just beyond the violet end of the visible region Wavelength ranges in general from 1 400 nm Dymax bulbs burners do not radiate energy in deep Ultraviolet there are very minute amounts below 220 nm and practically nothing can be sensed below 200 nm This is due to the use of an ozone block
13. T 22 Dymax BlueWave LED VisiCure User Guide Introduction Introduction to the User Guide This guide describes how to assemble use and maintain the BlueWave LED VisiCure spot curing system safely and efficiently Intended Audience Dymax prepared this user guide for experienced process engineers technicians and manufacturing personnel If you are new to UV light curing and do not understand the instructions contact Dymax Application Engineering to answer your questions before using the equipment Where to Get Help Additional resources are available to ensure a trouble free experience with our products Detailed product information on www dymax com m Customer Support and Application Engineering teams available by phone and email in the United States Monday through Friday from 8 00 a m to 5 30 p m Eastern Standard Time You can also email Dymax at info dymax com See the back cover for worldwide contact information Dymax adhesive Product Data Sheets PDS on our website Material Safety Data Sheets MSDS provided with shipments of Dymax adhesives Safety Before continuing with the installation please read the following chapters of this manual for safety recommendations and installation operation and troubleshooting instructions A CAUTION Always wear protective goggles or face shield when working near the front of the unit which emits high intensity visible light A WARNING Always observe safety
14. ax is willing to assist users in their performance testing and evaluation by offering equipment trial rental and leasing programs to assist in such testing and evaluations Data sheets are available for valve controllers or pressure pots upon request Dymax BlueWave LED VisiCure User Guide Contents BEACON a ayocse as oe sing wives eu we eae seeps sive viv nc ais veins E A E A A A N 4 introduction to the User a Sassi cashes erii EE ETE REENE E EE EEE EEEE EEVEE AEE 4 METS GETE I eee E A N E T 4 SAE AAAA OAA A secs ae EAE A AAA E ueeee sane 4 Dymax UV Light Curing System Safety Considerations cccccccssssececeeeeeecseeseccesaesececsaeseceesaeseceeeaeuecesseaucessuaneeessaggases 5 Product OVVIE orsncrirrn nri eritre Eara nra EE NANEU NEESON ENA ENEAN NSE RENNENS 7 Description of the BlueWave LED VIsSICUTE cccccssecccccsnseceecsuseccecseueececcuusececsuaseceeauaseceesaeseceeeuuaeceesauaeceesauacessaaaeeeesaageses 7 ENS TGC OW Cis MS aI Cari ccccrshecvcse sce od aea eni AEE EEA NANEN AAAA AASE Eara 7 NIV VOU acs e nce nesusan sence E Sey nai uctau aniac sun ebur E A 8 Assempiy and SOUUD oacutceucedeiesecesn sin uiat ina EEE E OSEE EEEE AEN 9 Unpacking and Inspecting Your ShipmMent sssessssseesssseeeessrrresssrresserersssrersssrersssrersssrersssreressreressreressreressreressreresseeress 9 Parts Included in the BlueWave LED VisiCure Spot Lamp System ccccccccssseccccessecceceeseccceaeseccessaueceeseaeeceessaaeee
15. ble a relay coil signal to an opto coupler The conducting transistor can also function as a set of contacts that can initiate actions within the PLC When the transistor is on the signal is said to be enabled or asserted When the transistor is off the signal is said to be disabled or unasserted The transistors have a max current rating of 30 mA and a max power rating of 150 mW Only positive voltages with respect to the PLC common should be used to a maximum of 24 Volts DC Series limiting resistors should be used to ensure that the max conditions are not exceeded Pin 6 Lightguide Engaged Out When a lightguide is fully inserted into the unit an internal switch will allow the LED to operate The same switch will send a signal to turn on the transistor and connect Pin 6 to Pin 2 This output can be used to verify the condition of the system should an error occur or alert a user to the failure Dymax BlueWave LED VisiCure User Guide Pin 7 LED Lit Out Pin 7 will be shorted to Pin 2 when the LED is powered up and the set point is above a predetermined level Pin 7 will be open with respect to Pin 2 if the LED is off for any reason This output can be used as go no go confirmation that the array is engaged Pin 8 Intensity Out PWM An internal circuit monitors the current sent to the LED and generates a PWM signal whose frequency and duty cycle varies with the current Adjusting the front panel Intensity
16. esaeanses 9 installation Se System INTSFCONMO CE ca rescccscecscscetousessttvainesettasenscdonsintattwsnssanuesihsattw cesta Ensue ENNE sasi arabas kipi Kaka E Eininn 10 BELE a ET T O E NIT E T 12 9 Pin Connector I O Signals ssesssessssssssssssssssesssseosseosseossesssessseeosseosssosseosseosseossesosesosseosseosssosssosssessesosesssseose 13 E SUNN a A E E E ts eee 13 E N eE E E EA E E E A A TE 14 Cl aning ana VIGNE CNN CE sirsrrsriiiprsesisirrisraseres caina reS EE E T 16 LERTEGE n E A ak cases cat eee 16 P e A E E TE E TA A E N 16 Fuse Replacement c caissccaresvaccascaviasenddvectabaantadanedsnanabaasbasueddsieesabaassadunndsiecasivbuslensned ECAN E VINNAN evaneboabwanedddav aweiweddaneiseraawoaeed 16 TROUDIESNOOCING scrinia ST 17 Frequently Asked Questions ssesesecessesesecececscsesecececsesesesececscsesesecececsesesecececsesesecececsesesecececsesesesecessesesesecese 18 Spare Parts and ACCESSONIES cate catcccou sss sienatatuinintanntcatancertetscaceasintainnsienntiananetnmnscaae sea taan sini anne 19 OPON A e E nee ne E once te AE E nee en ee ene er ee eT ne eee ar eee 19 Spare Replacement Parts cccccccccccccccecececceccceeeeceeececeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseceseceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 19 SIC CINIC AL IONS a A TE 20 SG ea ES oases sos See essences tes canst secs cares stag nse be neste tennant nade nde urea 20 ELLE IAI n EE A E T EET E A A A A A A A vedios scence A PEE EE E A E
17. ing quartz bulb envelope See Ozone 1 Ultraviolet A UV A UV of long wavelength from within approximately 400 to 320 nm of the spectral band 2 Ultraviolet B UV B UV of medium wavelength from within approximately 320 280 nm 3 Ultraviolet C UV C UV of short wavelength below 280 nm typically 280 200 nm a large amount of this energy is present in sunlight 4 Visible Light that can be seen at 400 700 nm Dose Irradiance integrated over time or Irradiance W cm x Time s Dose Joules cm Note Watt is the power that gives rise to the production of energy at the rate of 1 joule J per second s Ozone An oxidizing agent O3 produced by the action of Ultraviolet radiant energy below 185 nm or electrical corona discharge of oxygen on air OSHA 1910 145 Regulation of Accident prevention Signs and Tags defines the following headers as WARNING Used when there is a hazardous situation that has some probability of severe injury a CAUTION Used to indicate a hazardous situation that may result in minor or moderate injury NOTICE Used to convey a message related directly or indirectly to the safety of personnel or protection of property Dymax BlueWave LED VisiCure User Guide Warranty From date of purchase Dymax Corporation offers a one year warranty against defects in material and workmanship on all system components excluding bulbs LEDs and Lightguides with pro
18. is LED system The unit may be powered down and powered up again immediately without causing any negative effects Activate an exposure cycle by pressing on the Footswitch With the Timer Manual Selector Switch located on the front panel of the unit in the manual position the exposure time is controlled directly from the Footswitch In the timed position operation is determined by the setting displayed on the electronic timer Simply push the timer setting buttons to enter the desired number of seconds the LED needs to be powered With the system exposure active adjust the Intensity Adjustment Screw as required to achieve the desired output intensity on an appropriate radiometer The Intensity Adjustment Screw is a 10 turn potentiometer Figure 6 Intensity Adjustment Screw Ja P aa A J MANUAL INTENSI ADJUSTME Dymax BlueWave LED VisiCure User Guide Operation The BlueWave LED VisiCure will arrive almost fully assembled Please refer to the installation section of this manual for installation of the lightguide power cord and footswitch The system should be positioned in a dry location that does not obstruct airflow around the unit IMPORTANT To ensure that exposure output of the system is obtained be sure that the lightquide is fully inserted and seated into the entrance fitting prior to tightening the set screw Be sure to lightly tighten the set screw to ensure the lightguide
19. ly 40004 Fan Filter and Holder 5097 Fan Filter Media 40008 Footswitch and AC Power Cords Footswitch 40402 Power Cord North American 35255 Power Cord China Type G Plug 40542 Tools amp Hardware 2 mm Hex Wrench 38656 Flat Blade Screwdriver 39695 Miscellaneous Rubber Feet 5039 Dymax BlueWave LED VisiCure User Guide Specifications Specifications Property Part Numbers Intensity Output Power Requirements Power Supply Temperature Humidity Timer Activation I O Port Signals PLC Integration Cooling Housing Dimensions Weight Unit Warranty Certifications Specification 41062 North American Version standard 120V plug 41063 Asian Version Type G plug 41064 Unit without a power cord 16 8 W cm typical 15 0 W cm typical 0 233 W cm typical Total 280 450 nm Visible 400 450 nm UVA 320 395 nm UVB 280 320 nm 100 240 V 50 60 Hz lt 100 Watts 0 mW cm typical Solid state 100 Watt 40 C maximum non condensing Digital timer up to 99 99 seconds manual or timed exposure Footswitch or PLC 9 Pin D sub miniature connector Inputs 24VDC activate safety interlock output adjust Outputs LED lit lightguide inserted output setpoint over temperature Filtered fan arrangement 5 4 x 8 5 x 8 8 13 7 cm x 21 6 cm x 22 3 cm 5 40 Ibs 2 45 kg 1 year from purchase date CE marked Contains the appropriate power cord for Europe Measured with an ACCU CAL 50 LE
20. of of purchase and purchase date Unauthorized repair modification or improper use of equipment may void your warranty benefits The use of aftermarket replacement parts not supplied or approved by Dymax Corporation will void any effective warranties and may result in damage to the equipment IMPORTANT NOTE DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES EXPRESSED OR IMPLIED DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON DYMAX EQUIPMENT WITH OUT WRITTEN AUTHORIZATION FROM DYMAX THOSE CORRECTIVE ACTIONS LISTED ABOVE ARE LIMITED TO THIS AUTHORIZATION Index Assembly and Setup 9 Cable Connections 10 Cleaning 16 Contact Information 4 Curing System Safety 5 Definition of Terms 21 Frequently Asked Questions 18 Front Panel Timer 12 Fuses 16 Help 4 I O Signals 13 Intensity Control Feature 7 Maintenance 16 Fan Filter 16 Fuse Replacemet 16 Lightguide 16 Operation 12 Optional Equipment 19 Dymax BlueWave LED VisiCure User Guide Parts Included 9 Product Overview 7 Safety 4 Safety of UV Light Bright Visible Light 6 High Temperature Surfaces 6 Ozone 6 UV Exposure 5 Spare Parts and Accessories 19 Specifications 20 Support 4 System Connections 10 Troubleshooting 17 Unpacking 9 UV Exposure 5 UV Light Shielding 6 Validation 8 Warranty 22 In addition to our light curing equipment Dymax also offers high performance oligomers adhesives and coatings DYMAXEDGE
21. omplete mobility positioned into a fixture for repetitive operations or mounted to automated equipment The lightguide is separate from the unit and plugs into the lightguide mount on the front panel of the unit WARNING insert the lightguide into the lightquide mount before the light is turned on and remove the lightguide ONLY AFTER the light is turned off To secure the lightguide lightly tighten the set screw located on the top of the lightquide mount after the lightquide is inserted If the lightquide is removed at any time during an exposure cycle the power is removed from the LED immediately Replacing the lightguide will automatically re energize the LED The unit also features an intensity control on the front panel which allows operators to adjust the output intensity during process validation and production Users can adjust and maintain the output intensity level from 0 100 to meet their process curing parameters Intensity Control Feature The components used in all curing systems degrade with use Intensity therefore decreases as the system ages The BlueWave LED VisiCure intensity control allows for compensation to address this slow degradation Users can eliminate this variation by manually increasing output intensity to offset this degradation The intensity can be adjusted with a tool as shown in Figure 2 The intensity adjustment is a 10 turn potentiometer and allows fine control of output intensity This feature is usef
22. on the intake fan located on the back panel This is your first line of defense against airborne dust and debris This filter media and several spares are supplied with new units and should be changed regularly B Ideal operation of this equipment suggests at least 6 inches of clearance around the unit for proper ventilation Also confirm that the intake fan is not feeding from the exhaust of other equipment C Confirm that the fan is operating D Your equipment may already be full of dust and debris causing over heating of the unit s internal electronics NOTE The internal fans do not activate until required If the setting of the intensity output is low or if the ambient air temperature is lower than normal the fans may not be active or they may take longer than usual to engage Dymax BlueWave LED VisiCure User Guide Spare Parts and Accessories Options Accessories Item Part Number Personal Protection Equipment Protective Goggles Green 35286 Protective Goggles Gray standard model included with unit 35285 Face Shield 35186 Radiometer Dymax ACCU CAL 50 LED Radiometer spot 40505 Lightguides Lightguide Simulator 5 mm 38408 Liquid D Lightguide 5mmx1M 5720 Liquid D Lightguide 5 mm x 1 5 M 5721 Liquid D Lightguide 8 mmx 1M 5722 Miscellaneous 1 40009 1 40010 Carry Case with Foam Inserts 2 40011 1 40012 Spare Replacement Parts Item Part Number Fuses Fuses F2 0 amp 37236 Fan Fan 40034 Fan Assemb
23. ramed value There are a few fault conditions that may shut off the LED during operation The LED will automatically shut off if the internal sensors reach an over temperature condition If an over temperature shutdown occurs check that the airflow is not restricted to the system and that the fan filter is clean If the condition persists consult Dymax Customer Service for further assistance If the lightguide is not fully seated into the unit or if it becomes dislodged by as little as from the Lightguide Mount the Safety Interlock Switch will terminate power to the LED Re seating the lightguide will automatically re activate it No user serviceable parts exist within the enclosure The LED does not employ an automatic life end shutdown circuit Position the curing end of the lightguide no closer than from material being cured Placing the lightguide end too close can cause the lightguide to become cloudy from vapors coming off of the curing material In a typical bulb based system lamp life is reduced each time it is started The new LED based systems have no such limitations They can be shut off and then immediately restarted with no cool down or warm up periods or loss of system lifetime 9 Pin Connector I O Signals The BlueWave LED VisiCure unit is equipped with a 9 pin D subminiature connector that provides interface between the device and a PLC or similar factory control equipment The following describes available inputs and outpu
24. remains in place during use position the power To energize the system turn the main power switch from the O position to the supply and timer should begin to function Figure 7 Main Power Switch Figure 8 Timer O CAUTION Always wear protective goggles or a face shield when working near UV or bright visible light Never look directly at the light emitting end of a lightguide The timer located on the front panel of the BlueWave LED VisiCure is factory set to the most common operating mode and recommended operation of the timer with the BlueWave LED VisiCure The front panel of the timer contains an LED display and keypad The LED display has a reset indicator key protect indicator output indicator preset value set value and timing operation indicator A brief description of each display and location Output Indicator Displays OUT in upper left corner of timer display Displayed when relay is switched on is not displayed when relay is switched to off Present Value Four digit segmented display in center of timer Shows current status of time Set Value Four digit segmented display in lower right corner of timer Shows set length of time Reset Indicator Display on the left of meter face Active when the timer is reset by pressing the RST button on the lower left face of timer Or when the rear panel PLC Safety Interlock is active RST can also be used to cancel a currently
25. running exposure cycle Dymax BlueWave LED VisiCure User Guide Key Protect Located on center left side of display Will always be lit because the timer function is programmed at the factory and locked before shipment To operate the timer select the TIMER option of the Timer Manual Selector Switch on the front panel In this mode the LED will remain powered on until the timer counts down to 00 00 To program the Timer press the appropriate key up or down until the corresponding digit increments or decrements in the set value By pressing the up key labeled 1 it will increment the left most digit on the set value By pressing the up key 2 it will increment the second digit of the set value The same will happen with the up key 3 and the third digit of the set display and up key 4 and the fourth digit of the set display The Timer will increment from 9 back to 0 The Timer comes programmed for a range of 00 01 seconds to 99 99 seconds Consult the factory for other time ranges and function options available Program the time into the Timer and depress the Footswitch to activate the LED Factory settings will power the LED and the programed value will begin to count backward When the Timer reaches 00 00 it will reset to the programed value and remove power from the LED The Timer can be stopped by pressing the RESET button on the lower left face of the Timer If power is removed from unit the Timer will reset to the prog
26. se in surface temperature In some cases exposed surfaces can reach temperatures capable of producing a burn or causing damage to a substrate In these cases care must be taken to ensure either a more moderate surface temperature or appropriate protection training for operators No infrared radiation is produced by these LED systems so surface temperatures will be lower than with conventional lamp systems Empirical testing should be used to verify the exact temperature rise in each application Ozone The Dymax BlueWave LED VisiCure does not generate UVB or UVC therefore no ozone is generated while operating this equipment Bright Visible Light The bright visible light energy emitted by curing systems can cause eye strain if proper eye protection or shielding is not used The proper use of tinted eye protection and or opaque tinted shielding can be utilized to reduce eye strain and address this concern Summary Light sources can be more worker friendly than many commonly accepted industrial processes provided the potential concerns are addressed Both the lower working temperature and lack of sourious frequency transmission that this system produces make it even more user friendly Contact your Dymax representative for information regarding the proper use of Dymax curing systems Dymax BlueWave LED VisiCure User Guide Product Overview Description of the BlueWave LED VisiCure The BlueWave LED VisiCure is a light curing
27. ssed please review and follow information and safety information listed below Light Exposure Standard Dymax VisiCure systems have been designed to primarily emit visible light as shown in Figure 1 Although OSHA does not currently regulate visible or ultraviolet light exposure in the workplace the American Conference of Governmental Industrial Hygienists ACGIH does recommend Threshold Limit Values TLV s for ultraviolet light The strictest interpretation of the TLV over the UVA range for workers eyes and skin is 1 mW cm intensity continuous exposure Unless workers are placing bare hands into the curing area it is unusual to exceed these limits To put the 1 mW cm limit into perspective cloudless summer days in Connecticut regularly exceed 3 mW cm of UVA light which includes the more dangerous UVB light primarily responsible for sun tans sun burns and skin cancer Figure 1 Light Spectrum Portion of the spectrum that DYMAX primarily emits Germicidal Sunburns preman A CC 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 Wavelength nm 3 001 nm 1 nm 1000 nr 1mm 1m 1km Wavelength nm Checking the Workstation A radiometer should be used to measure stray light to confirm the safety of a visible light curing process A workstation that continuously exposes an operator to more than 1 mW cm of UVA light should be redesigned GY Dymax BlueWa
28. ts Input Signals Each input signal is optically isolated from the internal circuit of the BlueWave LED VisiCure A positive 24V and maximum 10 milliamp current source is required to activate each signal input All inputs are returned to the common terminal and have built in current limiting resistors to protect the isolators Dymax BlueWave LED VisiCure User Guide Pin 1 24V Applying power to this pin enables the Safety Interlock 4 The safety interlock will not function unless 24V is applied to this pin Pin 2 Common All signals both inputs and outputs are returned to this pin Common may be used independently of 24V for all outputs and inputs except for the safety interlock 4 input Pin 3 Shutter In This signal line may be used to remotely activate the BlueWave LED VisiCure When it is being used the local footswitch on the rear of the BlueWave LED VisiCure box is still capable of operating the unit Similar to the footswitch if the timer manual selector switch is in Timer Mode the unit will power the LED for the time set on the timer In the Manual Mode the unit will power the LED for the duration of the remote activate signal Pin 4 Safety Interlock In A safety interlock can be connected between Pins 1 and 4 While 24V is applied to Pin 4 the system will allow activation of the LED If the connection is broken power is immediately removed from the LED The safety interlock relies on the 24V signal being
29. ul for both validation and control SS Dymax BlueWave LED VisiCure User Guide Figure 2 Intensity Adjustment Validation Tests should be conducted prior to production to determine the time and light intensity required to fully cure your light curable material in your specific application The following approaches may be used to validate the curing process Set Exposure Time Determine Intensity Users can specify a cure time and through empirical testing determine the intensity required to achieve a full cure As with any manufacturing process it is advisable to incorporate a safety factor Set Intensity Determine Exposure Time Users can specify light intensity and through empirical testing determine the exposure time required to achieve a full cure As with any manufacturing process it is advisable to incorporate a safety factor Control Process validation confirms a minimum acceptable intensity Users can then choose to operate at a higher available intensity level using the additional intensity as a cure safety factor or adjust the output to a specific intensity level To ensure consistent and repeatable process results it is advisable to monitor intensity levels with the use of a radiometer This allows identification of any potential maintenance requirements or intensity adjustment necessary Dymax BlueWave LED VisiCure User Guide PQ Assembly and Setup Unpacking and Inspecting Your Shipment Your BlueWa
30. ve LED VisiCure User Guide Protecting Operators Light curing technology can be a regulatory compliant worker friendly manufacturing process when the proper safety equipment and operator training is utilized There are two ways to protect operators from visible light exposure shield the operator and or shield the source Shield the Operator Tinted eyewear will shield the operator from high intensity visible energy and reduce eye fatigue Shield the Source of the Light Any substrate that blocks Visible light can be used as a shield to protect workers from stray light The following materials can be used to create simple shielding structures Sheet Metal Aluminum steel stainless steel etc Sheet metal should be coated black or black anodized to minimize reflection of UV and visible light toward operators Rigid Plastic Film Transparent or translucent light blocking plastics typically polycarbonate or acrylic are commonly used to create shielding where some level of transparency is also desired Flexible Film Translucent light blocking flexible urethane films can be used to quickly create workstation shielding This light blocking flexible urethane film is available from Dymax Call for assistance High Temperature Surfaces Surfaces exposed to high intensity curing lights will rise in temperature The intensity distance exposure time cooling fans and the type color of the surface can all affect the actual ri
31. ve LED VisiCure arrived in one or two boxes Inspect the boxes for damage and notify the shipper of box damage immediately Open each box and check for equipment damage If parts are damaged notify the shipper and submit a claim for the damaged parts Contact Dymax so that new parts can be shipped to you immediately Check that the parts included in your order match those listed below If parts are missing contact your local Dymax representative or Dymax Customer Support to resolve the problem Parts Included in the BlueWave LED VisiCure Spot Lamp System a BlueWave LED VisiCure Part Number Dependent on Power Cord Ordered 1 Footswitch PN 40402 2 a UV Protection Goggles PN 35285 3 2 mm Hex Wrench PN 38656 4 a Flat Blade Screwdriver PN 39695 5 a BlueWave LED VisiCure User Guide PN 41065 6 Snap in Clip PN 39667 a Filter Media PN 40008 Power Cord 7 Model 41062 Standard 120V North American Power Cord Model 41063 Type G Plug Model 41064 No Power Cord Note For European customers the appropriate power cord will be added Figure 3 BlueWave LED VisiCure Components 3 v lt Fi s Not included in Mis a Model 41064 Dymax BlueWave LED VisiCure User Guide Installation amp System Interconnect 1 2 3 Connect the Power Cord to the rear of the unit and plug into a grounded wall outlet Connect the Footswitch to the connection in the rear of the unit Figure 4 Rear Panel
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