UVCS LED Conveyor Systems User Guide
Contents
1. lt lll Gsazaxz zxxxas aiagln UVCS LED Light Curing Conveyor Systems User Guide Figure 1 Light Spectrum Portion of the spectrum that DYMAX primarily emits Germicidal Sunburns UVC UVB UVA gt 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 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 1 mW cm limit into perspective cloudless summer days in Connecticut regularly exceed 3 mW cm of UVA light and also include the more dangerous UVB light primarily responsible for suntans sun burns and skin cancer as well Checking the Workstation The human eye cannot detect pure UV light only visible light A radiometer should be used to measure stray UV light to confirm the safety of a UV light curing process A workstation that exposes an operator to more than 1 mW cm of UVA continuously should be redesigned 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 UV exposure shield the operator and or shield the sour2. The Conveyor also has a Power Switch located on the front panel Plug in all the Power Cords and turn the Conveyor on Conveyor belt speeds can be adjusted by turning the Speed Control Knob located on the side of the Conveyor Control Panel Belt speed is indicated on the Speed Display Indicator The Belt Speed Knob is a ten turn potentiometer and is equipped with a lock UVCS LED Light Curing Conveyor Systems User Guide Figure 10 Conveyor Control Panel A Orporation gion CT 06790 860 482 10 0 www dyrnax comi ght Curing Conveyor E o The Blower controls the amount of air flowing through the inside chamber of the Conveyor A small percentage of the air is also diverted downward through the Conveyor Belt This air flow provides a small hold down force to keep light objects from moving while traveling on the Belt The speed of the Exhaust Blower is set at the factory during final system testing for the conveyor model ordered If the speed of the Exhaust Blower requires adjustment remove the Access Panel from the front of the Exhaust Blower Housing unlock the Blower Speed Control Potentiometer and adjust the speed setting Relock the Blower Speed Control Potentiometer The range of the Blower Speed Control Potentiometer is 0 0 to 0 85 turns Figure 11 Remove Access Panel Figure 12 Blower Speed Control The height of the LED Array can be adjusted using the knobs located on both si
3. E T 20 Spare Parts and Accessories 22 Spare Replacement Pars uu uuu l l l ill aasan apaun aasma aqasimiuqamisp quan aayqa iE 22 Option ACCESS OES esei a a a a i ean i S i a a aia 23 SPECO i E E A E mapa AOE E A 24 PE O S ea E A s 24 Definition OF Te isuu u lu aane n TEN TEE 26 Wanranty caasiiscascstiaaesetinacsedsicevensatuessaneadadanseauacnaubdmadaailasuousaedccenanebeuaaaabadewausbaneuasedieesniubiueaadeimadeeseinecsdieicessaces 27 UVCS LED Light Curing Conveyor Systems User Guide Introduction Introduction to the User Guide This guide describes how to assemble use and maintain Dymax UVCS LED light curing conveyor systems 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 sources and do not understand the instructions contact Dymax Application Engineering to answer your questions before using the equipment Where to Get Help Dymax Customer Support and Application Engineering teams are available 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 Contact information for additional Dymax locations can be found on the back cover of this user guide Additional resources are available to
4. a time via the interconnect cable The power supply is designed to be interchangeable and can be used with any of the three different wavelength LED flood arrays BlueWave LED flood systems feature an intensity adjustment allowing the output intensity level to be adjusted from 5 to 100 to meet process and adhesive requirements LED technology within the BlueWave LED Flood System allows for instant on off activation without the need for a warm up period but is also rated for continuous operation A switch on the conveyor is provided to keep the LED array always active Fans in the LED flood power supply and array provide cooling and must not be covered or blocked Fan Filters must be maintained regularly to ensure reliable operation Thermal sensors in the LED flood power supply and array shut the unit down to protect the components if the internal temperature exceeds maximum limits Please refer to the BlueWave LED Flood System User Guide for further description and explanation UVCS LED Light Curing Conveyor Systems User Guide WARNING If you block the air flow from the LED flood array or the power supply vents equipment damage and malfunction can result To prevent damage and malfunction ensure 1 2 54 cm of clearance is provided around the power supply and at least 6 15 24 cm of clearance is provided around the cooling fan inlets to allow the free flow of air All UVCS conveyors have adjustable belt speeds and lamp to belt distanc
5. it from moving during conveyor operation Figure 27 UVCS LED Light Curing Conveyor Systems User Guide Figure 27 Install Fiberglass Splice Rod and Apply Adhesive 7 Tighten the belt tension knobs finger tight to remove excess slack from the belt The belt should be loose enough to be moved across the two rollers by hand when the conveyor is not running Figure 28 CAUTION Excessive tightening of the belt will result in early belt failure Since the two conveyor rollers have a crown in the middle only minimum tightening is necessary Figure 28 Tighten Tension Knob and Check Belt Tension 8 Start the conveyor and adjust the belt tensioning knobs until the belt runs in the center of the loading end The belt should be able to be stopped by hand when the conveyor is running If stopping the belt stalls the conveyor motor the belt is too tight and must be loosened 9 When the belt runs in the center of the loading end observe belt position at the motor end If the belt runs to far to one side on the motor end adjust the motor pulley as follows a Turn the conveyor off b Remove belt tension by loosening the two tensioning knobs c Loosen the two drive roller shaft support fasteners located on the front of the conveyor frame enough to slightly move the shaft assembly UVCS LED Light Curing Conveyor Systems User Guide Figure 29 Loosen Drive Shaft Rollers Move the shaft assembly slightly to realign the dr
6. onto the Conveyor Cradle as required by your application need UVCS LED Light Curing Conveyor Systems User Guide Figure 4 Cradle Adapter Orientation 3 Take the Two Side Plates and insert one on each side of the Cradle Adapter Plate The Side Plate bend will fit over and into the Adapter Plate Secure both Side Plates with M4 x 8 mm screws 4 Figure 5 Figure 5 Side Plate Installation UVCS LED Light Curing Conveyor Systems User Guide Interconnect Cables Attach and fasten the 37 Pin Interconnect Cable from the back panel of the Power Supply to the top of the LED Flood Array Figure 6 Interconnect Cable to Power Figure 7 Interconnect Cable to LED Flood Supply Array gt The LED Arrays may be controlled using the Activation Switch on the front face of the Conveyor to toggle the LED Array on and off This allows the LED to remain on for as long as needed Connect the Footswitch Interconnect Cable one provided with each LED Array from the LED Array Controller to one of the Foot Switch Interconnect Jacks in the rear of the Conveyor Figure 8 Activation Switch Figure 9 Foot Switch Interconnect Jacks LED Array Activation Switch eo Corp UVCS Light Foot Switch Interconnect Jacks Operating the Conveyor The Conveyor and the LED Power Supply s each have a Power Cable that needs to be plugged into the wall outlet The LED Power Supply s has a Power Switch located in the back of the unit
7. 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 Bright Visible Light The bright visible light energy emitted by curing systems can cause eyestrain 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 eyestrain and address this concern Summary UV 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 spurious frequency transmission that this system produces make it even more user friendly Contact your Dymax representative for information regarding the proper use of Dymax light curing systems Product Overview Description of UVCS LED Light Curing Conveyors Dymax UVCS LED light curing conveyor systems use high intensity light sources for fast curing of light curable materials UVCS bench top conveyors can be outfitted with one of three different wavelength BlueWave LED flood systems 365 nm 385 nm or 405 nm The flood system consists of two main components an LED flood array and a power supply that contains the user interface Only one LED flood array can be connected to a power supply at
8. 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 insure 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 PN41397 MANO71 10 27 2014 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 1010 860 626 7006 49 0 611 962 7900 Equipment Shenzhen Co Ltd Equipment Shanghai Co Ltd Limited 82 2 784 3434 info dymax com oligomers amp coatings dymax com info_de dymax com 86 755 83485759 86 21 37285759 852 2460 7038 info dymax kr www dymax com www dymax oc com www dymax de dymaxasia dymax com dymaxasia dymax com dymaxasia dymax com www dymax com kr www dymax com cn www dymax com cn www dymax com cn
9. 17 Options Menu Figure 18 Adjust Intensity Menu SELECT MODE ADJUST TIMER ADJUST INTENSITY ADJUST INTENSITY O CANCEL 1 00 o PRESS lt J TO SELECT DIGIT PRESS AV TO SELECT PRESS AY TO ADJUST DIGIT PRESS SET TO ENTER PRESS SET TO ENTER UVCS LED Light Curing Conveyor Systems User Guide LED Operation It is recommended that the LED Controller be set to Manual Mode for conveyor operation Connect the LED Array to the Controller Connect the Controller to the Conveyor via the Foot Switch Interconnect Cable Activate the LED Array using the LED Activation Switch on the front of the Conveyor If the Controller is set to Timer Mode the LED Activation Switch will toggle the LED Array to turn on and it will turn off after the timer runs down The LED Array will not activate again until the Activation Switch is toggled off and back on Validation Tests should be conducted prior to production to determine the time and light intensity required to fully cure your resin The following approaches may be used to validate the curing process Set Exposure Time Determine Intensity Users can specify an exposure time and through empirical testing determine the intensity required and duration of exposure to achieve a full cure Intensity can be adjusted using the front control screen on the LED Power Supply Duration of exposure can be adjusted by adjusting the conveyor belt speed As with any manufacturing process it is advisable to incorporate a safety f
10. UVCS LED Light Curing Conveyor Systems User Guide UVCS Conveyors Outfitted with BlueWave LED Flood Arrays Instructions for Safe Use Setup and Operation Maintenance Ordering Spare Parts and Accessories UVCS LED Light Curing Conveyor Systems 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 insure that desired performance criteria ar
11. actor Control Process validation confirms a minimum acceptable intensity Users can then choose to operate at full intensity using the excess intensity as an additional safety factor or adjust the output to a specific intensity level To ensure consistent and repeatable process results intensity levels should be monitored with a radiometer This enables users to identify changes in light intensity and take corrective action either adjusting the light intensity or performing maintenance Cleaning and Maintenance Inspect and Replace Fuses The LED Flood Power Supply has two Fuse Holders located on the rear Figure 19 Fuse panel Figure 19 Follow these steps to inspect and replace the fuses if Holders indicated as a corrective action based on troubleshooting 1 Unplug the unit PLC ACCESS 2 Remove the Fuse Holders using a screwdriver Figure 20 3 Remove and inspect the fuses Figure 21 Replace blown fuses with AP SWITCH O new ones as specified in the Specifications section 4 Place the Fuse Holder back into the rear panel and tighten using a screwdriver Be careful not to overtighten UVCS LED Light Curing Conveyor Systems User Guide Figure 20 Remove Fuse Holder Figure 21 Remove Fuse from Holder Cleaning the Quartz Optic Plate Based on the cleanliness of your operating environment establish a schedule for cleaning the LED array optic plate When cleaning is required shut the unit down and al
12. can be cancelled at any time during the exposure cycle by pressing the run button PLC Mode An external PLC Programmable Logic Controller controls the unit The PLC provides input signals to the BlueWave LED Flood to control the LED The PLC monitors the status of the unit by reading output signals provided by the BlueWave LED Flood The PLC is typically programmed to start other machinery when the unit becomes ready or perhaps start the unit when other machinery is ready The input signals and output signals are present through the 25 pin connector on the power supply s back panel marked PLC Please consult the User manual for the BlueWave LED Flood System for further details about each operation mode Choosing an Operating Mode NOTE Upon power up your BlueWave LED Flood System will default to its last configuration settings Figure 14 Mode Start up Screens Left to Right Manual Mode Timer Mode PLC Mode MANUAL MODE TIMER MODE PLC MODE PLC INTERFACE ENABLED NO 0000 0 LED ARRAY INHIBIT NO m LED ARRAY COMMAND OFF LED ARRAY INTENSITY 100 LED INTENSITY CONTROL PLC INTENSITY 100 INTENSITY 100 PrimeCure PrimeCure PrimeCure B NOTE If the BlueWave LED Flood System powers up in PLC Mode you cannot change any settings via the front panel controls until you press the PLC Access Switch on the back panel UVCS LED Light Curing Conveyor Systems User Guide To Switch Between Manual and Timer Mode From the main page p
13. ce Shield the Operator UV Blocking Eye Protection UV blocking eye protection is recommended when operating UV light curing systems Both clear and tinted UV blocking eye protection is available from Dymax UV Blocking Skin Protection Where the potential exists for UV exposure upon skin opaque UV blocking clothing gloves and full face shields are recommended Shield the Source of UV Any substrate that blocks UV light can be used as a shield to protect workers from stray UV light The following materials can be used to create simple shielding structures Rigid Plastic Film Transparent or translucent UV blocking plastics typically polycarbonate or acrylic are commonly used to create shielding where some level of transparency is also desired UVCS LED Light Curing Conveyor Systems User Guide Flexible Film Translucent UV blocking flexible urethane films can be used to quickly create workstation shielding This UV 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 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
14. connect Cable m UVCS Conveyor Adapter Plate and Cradle Assembly m UVCS LED Light Curing Conveyor Systems User Guide a UV Protection Goggles UVCS LED Light Curing Conveyor Systems User Guide PQ Conveyor System Setup Conveyor Setup Figure 2 Exhaust Ventilation 1 If purchased uncrate and assemble the optional Conveyor Stack Mounting Cart prior to unpacking the Conveyor 2 Remove the protective coverings from the Conveyor Place the Conveyor on the Conveyor Mounting Cart or ona convenient work surface Install the Exhaust Ventilation Stack on the Blower Motor s Outlet Flange Secure the Exhaust Ventilation Stack with the 3 fasteners provided 3 Unpack the LED flood System s Each Flood System includes an LED array a power supply a power cord and interconnect cables There may be one or two LED Array systems inside the crate depending on the conveyor system ordered Mounting the LED Flood Array s 1 Mount the LED Head s into the Cradle Adapter Plate using 2 M5 x 8 mm screws Figure 3 a Forasingle head assembly install the Filler Plate to the other side of the Cradle Adapter b Fora dual head configuration install the two heads face to face with the logos facing each other Figure 3 Single amp Dual Head Configurations 2 Place assembled LED Flood Array s and Cradle Adapter Plate onto the Conveyor Housing The Cradle Adapter can be placed in two different orientations in line or side by side
15. d of the visible region Wavelength ranges in general from 1 0 to 400 nm Dymax Arrays 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 ozone blocking quartz bulb envelope See Ozone Ultraviolet is used beneficially in various fields of industry and medicine In order to standardize light sources used in medicine the International Congress on Light in Copenhagen in 1932 recommended dividing the ultraviolet spectrum into three spectral parts a Ultraviolet A UV A UV of long wavelength from within approximately 400 to 320 nm of the spectral band 4000 to 32009 predominately produced by Dymax flood arrays a Ultraviolet B UV B UV of medium wavelength from within approximately 320 to 280 nm Dymax LED flood arrays produce some amount of their energy within this bandwidth a Ultraviolet C UV C UV of short wavelength below 280 nm we say from 280 to 200 nm a large amount of this energy is present in the sunlight OSHA 1910 145 Regulation of Accident prevention Signs and Tags defines the following headers as WARNING is used when there is a hazardous situation that has some probability of severe injury m CAUTION is used to indicate a hazardous situation that may result in minor or moderate injury NOTICE is used to convey a message related directly or indirectly to the safety of personnel or
16. des of the Conveyor Cradle The height indicator can be used as a reference to adjust both sides to the same height The height indicator does not reflect the actual height of the LED Arrays Figure 13 LED Array Height Adjustment UVCS LED Light Curing Conveyor Systems User Guide Operating the LED Light Operating Modes There are three basic operating modes Manual Mode Timer Mode and PLC Mode PLC and timer mode are not recommended for use with a conveyor Manual Mode Manual mode allows the user to activate the LED Array with the use of the run button on the front panel or with a signal provided to the footswitch port in the back of the controller The LED remains active only as long as the run button is pressed When the run button is released the LED shuts off A cable to connect the power supply to the conveyor is provided with each LED Array system This will allow the user to turn on and off the Array using the front controls on the conveyor Manual mode is recommended for use with a conveyor Timer Mode The LED is active for a specific time period each time the run button is pressed Users set the specific time by adjusting the timer s value on the screen Momentarily pressing the run button starts the timer and activates the LED When the timer counts down to zero the LED Array deactivates The timer resets the countdown and is ready for another exposure cycle The activation
17. e 1 Troubleshooting Chart for UVCS LED Conveyor Systems LED Array Issues Problem Unit does not power up Unit powers up but LED is not producing light Unit is operating normally and LED suddenly stops producing light LED Array provides only low intensity light Possible Cause The Power Cord is not plugged in or damaged The Onboard Fuse is blown There is no electrical power at the Receptacle The LED intensity adjustment is set to the minimum The Interface Cable connections are loose or damaged The activation switch on the conveyor is not in the on position The over temperature shutdown was triggered The LED intensity adjustment is set to the minimum The Lens Optics are contaminated dirty Lamp height may have changed since last operated Corrective Action Check the connections and condition of the Power Cord Check Onboard Fuse Test the Receptacle for power Increase the LED intensity setting Check the connections and condition of the Interface Cable Verify that they activation switch is in the on position Check that the flow of cooling air into the Power supply or LED Flood Array is not restricted Check that the Filter is clean If the LED does not illuminate after restarting contact Dymax Application Engineering Increase the LED intensity setting Clean the surface of the Lens Verify the lamp height and adjust as needed UVCS LED Light Curing Conveyor Systems Use
18. e 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 UVCS LED Light Curing Conveyor Systems User Guide Contents BAEC UO ao u 5 i o es 4 introduction to the User a Sassi cashes erii EE ETE REENE E EE EEE EEEE EEVEE AEE 4 Who 06 GETE uu N E T 4 S AEA AOA AA AA 4 General SAlety Gonsideralig uuu l u n a uwusaqkrathausywaqpanqhwsayasayusspasqusqquluqawashwsqyaytyiaayinayauqkakapwaqawashusukuasqhaaqaiawpuaqhaqa 4 Specific Safety Considerations uu R L scusniuevenesdaiscubeduetandeisadcevniwataundieasdebaiualecbeseansennewelennstsaacebeaestndeesiaabsiconens 5 S 7 MUM NG Cu u u uu ee usus saree does ean E E E outta cas E A E A E EE 5 Dymax Light Curing System Safety Considerations r 5 Produet OVET ON u cine yey cc swe suite ens sain ec ov nse visa oe nnmnnn ann be maine nn ann eens 7 Description of UVCS LED Light Curing Conveyors rr 7 PSSEIIDIV ANG SC CUD sccctvecticcssassvacisnssonivnniannivanbunnacectcecssezisesavasiinsn sahbiasdjnadensiuabevessdsabiesa sentinel soalsaaisanbinsaunabeeeseas 8 Unpacking and Inspecting Your Shipment r rr rrssrrssssrssssssssssssiasss 8 P
19. e the unit safely it must be set up and operated in accordance with the instructions in this user guide Please also read and understand the safety considerations unique to light curing systems as described below Safety Symbol Index The following symbols are displayed on the curing system Please see below for their meanings Referto Manual Nl of Eye Protection Required Warning Warning UV Light Hazard Electrostatic Sensitive Device gt gt gt WARNING Looking directly at the UV light emitted by an LED flood array can result in eye injury To prevent eye injury never look directly at the high intensity light and always wear protective goggles provided Dymax Light Curing System Safety Considerations Operators must understand these three concepts to use the LED light source safely light exposure high temperature surfaces and bright visible light Each is described below Light Exposure The BlueWave LED Flood s PrimeCure and RediCure models emit energy in the UVA portion of the spectrum while the VisiCure model emits energy in the visible portion of the spectrum UVA light is generally considered the safest of the three UV ranges UVA UVB and UVC 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 X a lt
20. e to address a variety of application requirements Standard height clearance is 4 inches optional risers increase clearance to either 6 or 10 inches When combined the UVCS conveyors consistent intensity fast curing and adjustable line speeds create an optimized light curing process that enables high throughput Features amp Benefits Features Complete UV shielding Built in exhaust fan and stack Controlled and consistent cure times Integral vacuum hold down and cooling system Accepts parts up to 12 x 36 Accurate digital belt control and readout 4 6 or 10 vertical clearance available Adjustable array to belt distance 12 belt width guides available to channel parts into Bench top conveyor with optional transportation carrying center 6 cart Assembly and Setup Unpacking and Inspecting Your Shipment Your UVCS LED light curing conveyor will arrive in one or two crates Inspect the crates and 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 a BlueWave LED Flood System s LED Array Power Supply Power Cord Inter
21. ensure a trouble free experience with our products m Detailed product information on www dymax com Dymax adhesive Product Data Sheets PDS on our website m Material Safety Data Sheets MSDS provided with shipments of Dymax adhesives Safety WARNING If you use a Dymax LED light curing conveyor system without first reading and understanding the information in this user guide injury can result from exposure to UV light To reduce the risk of injury read and ensure you understand the information in this user guide before assembling and operating the system General Safety Considerations All users of Dymax UVCS LED light curing conveyor systems should read and understand this user guide before assembling and using the system To learn about the safe handling and use of light curable formulations obtain and read the MSDS for each product Dymax includes an MSDS with each adhesive sold In addition fluid product MSDS can be requested on the Dymax website UVCS LED Light Curing Conveyor Systems User Guide CAUTION Always wear protective goggles or face shield when working near UV light Never look directly at light WARNING Always observe safety requirements Do not open the cover of the LED Array or Power Supply There are no user serviceable parts inside Specific Safety Considerations Dymax UVCS LED light curing conveyor systems are designed to maximize operator safety and minimize exposure to light curing energy To us
22. iption of energy in the visible region of the spectrum approximately from 400 to 700 nm and recorded in photometric units Intensity see below of visible light energy is called Illuminance 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 Flood Array System set of components arranged to generate collect condition and direct UV radiant energy to perform curing of engineering adhesives coatings and inks within a safe and controlled process It includes an array housing and power supply and may also include a shutter workstation UV enclosure Dymax light shield and or accessories IIluminance Luminous flux energy of visible light incident per unit area and measured in Lx lux or Lumen cm Intensity a measure of light energy over the unit of surface area usually the surface at the specified working distance from the bottom of the reflector housing in W cm or mW cm Array LED light source generating ultraviolet visible and infrared radiant energy from burning matter stimulated by electrical power conditioned by a proper power supply Ozone oxidizing agent O produced by the action of ultraviolet radiant energy below 185 nm or electrical corona discharge of oxygen on air Ultraviolet UV The invisible region of the spectrum just beyond the violet en
23. ive roller and center the belt Tighten the bolts when adjustment is complete Figure 30 Adjust Shaft Assembly Turn the conveyor on and adjust the belt tension knobs until the belt is properly tightened Make sure that the belt runs in the center of the conveyor on both the loading and unloading end Repeat this step as necessary to align the belt Reinstall the pinch guards on both ends of the conveyor This step is critical to belt soeed sensor operation The pinch guard on the unloading side of the conveyor contains a shield for the sensor to prevent damage if the belt contacts it while operating Figure 31 Reinstall the Pinch Guards UVCS LED Light Curing Conveyor Systems User Guide Troubleshooting The BlueWave LED Flood System constantly verifies the performance of the power supply and LED head If a problem is detected a diagnostic screen is displayed Figure 32 Please take note of the contents of the screen and contact Dymax for support If a screen like Figure 33 appears the LED Head has overheated The system will attempt to cool the LED Head for approximately 5 minutes If the head cools down within this time period the LED Flood system will continue to operate normally Otherwise the diagnostic screen Figure 32 will be shown Figure 32 Diagnostics Screen ss POWER NO ARRAY E0000 CONTACT LOCAL DYMAX SUPPORT OR GO TO WWW DYMAX COM Figure 33 LED Head Has Overheated WAIT Tabl
24. l iri Lu uuu EAE ett ct ae eases u ua u u n un u na 8 SoA E tel Sel uu uuu un suu A A T E O T 9 CONE VOF l u uu u pein acs teas ain San pu nu pause Sau ons acey sind aac ps secu sss eaueeenas 9 Mounting the LED Flood Array s sicssiesccscssctesccctecevaaavecanecdpncesecave sevaresacencsoussasesdbesesssavedanceeseeassdauedeusrasnudacsasedaesaadecaussnertends 9 ahd I Ons IC O D uu E ann nn RTE ee E E rc NES NTR ana su ee Cane N eee eee 11 Operating the CONVEY ON ciris 11 Operating the LED VIG scsecoscccicsscestanadecsssatciecerssepancesssectnaasexaaseuaseaienndeagvoraasisemeatuasndsaisvsasunvesaceaneaauevadusuutonds 13 Oe sI il 5 IV CSS uuu unu aaa anaku ae acess ONN AEAN NE 13 Choosing an Operating MOde ccccsssscccccesscccccesececcaseccecseseceeceeeeeesaeueecessuesecessuaeeceeseaseceesueseceesseeecessuaueeessaaceesaggsees 13 PRES a VSO E EEA A ET AE A EE A A AN EAN EN E AE 14 LED ODEI il T u u EEEN E AT EENE EEO A AE EEEE O O O OANE NEE ONE A ENEO ES 15 vana a E E E A SE O E a O eae eee eee eens 15 Cleaning and Maintenance 15 Inspect and Replace FUSES cccccsssscccceesscccceeseececseseececseeseceeseeeeceeeseeceesseseceeseeeeceesaeeeeeeeseusecessuasecessuneecessuaaeeessaeaeeeeseges 15 Bek Ira kis AG Im O uu u EE EE E E E EOT a tre ere 16 Conveyor Bek Replacement uu y uu u m ns aaa Ai A a 17 Troupes NOOTE errira
25. low it to cool Then clean the quartz optic plate surface Figure 22 with a clean lint free cloth and isopropyl alcohol Figure 22 Quartz Optic Plate Belt Tracking Adjustment All Dymax UVCS conveyors are factory adjusted to provide proper tracking of the belt Should further adjustments become necessary this is done via two knurled adjustment knobs located at the input end of the conveyor To adjust tracking simply tighten the side to which the belt is tracking DO NOT OVER TIGHTEN THE BELT this will lead to accelerated degradation of the belt Figure 23 Belt Adjustment UVCS LED Light Curing Conveyor Systems User Guide Conveyor Belt Replacement 1 Remove the pinch guard from the motor side of the conveyor by removing the two M4x8 screws on the front side of the conveyor and the M4x25 screw from the motor drive side of the conveyor Remove the motor box cover to obtain access to the M4x25 screw Figure 24 Remove Pinch Guard 2 Remove all tension from the belt by fully backing off the belt adjustment knobs Figure 25 Figure 25 Remove Tension from Belt 3 Position the belt splice to the end of the conveyor Remove the fiberglass rod that ties the ends of the belt together Remove the belt Figure 26 Remove Fiberglass Rod 4 Run the new belt around the conveyor frame 5 Install the fiberglass splice rod through the belt loops 6 Apply some adhesive to both ends of the fiberglass rod to prevent
26. ntiometer Conveyor Speed 40006 Potentiometer Exhaust Blower Speed 40149 Red Lion Counter Timer 50020 39132 Red Lion 12V Power Supply 39133 Shield Solid Acrylic 2 Required 39205 Speed Controller Knob 40143 UVCS LED Light Curing Conveyor Systems User Guide Options Accessories Item Part Number Personal Protection Equipment Protective Goggles Green 35286 Protective Goggles Gray standard model included with unit 35285 Face Shield 35186 Radiometers Power Puck II Radiometer UVA UVB UVC amp Visible 38129 Dymax ACCU CAL 150 UVA 40550 Misc Power Supply to Irradiator Head Power Cable 115 292 1 cm 41228 Retro Fit Kit For Use with UVCS Conveyors 41340 Conveyor Conveyor Rolling Cart Kit 39215 Riser Kit 2 39218 Riser Kit 6 39280 Shield Extension Kit 39209 Temperature Strip Indicator Kit 38693 UVCS LED Light Curing Conveyor Systems User Guide Specifications Specifications Property Part Numbers Typical Initial Output Intensities Output Frequency Power Requirements Fuse LED Timer LED Activation Cooling Hour Meter Dimensions W x D x H Interconnect Cable Length I O Port Weight Unit Warranty Operating Environment Sound Level Specification aes 41260 Power cord NOT included pn 41288 North American power cord with 120V plug 41291 Asian Power cord f 41261 Power cord NOT included el 41287 North American power cord with 120V plug i 41290 Asian Power cord Redi
27. protection of property UVCS LED Light Curing Conveyor Systems 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 LED array with proof 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 WITHOUT WRITTEN AUTHORIZATION FROM DYMAX THOSE CORRECTIVE ACTIONS LISTED ABOVE ARE LIMITED TO THIS AUTHORIZATION Index Adjustments Safety Intensity 14 Safety Symbol Index 5 Assembly and Setup 8 Safety of UV Light Curing System Safety 5 Bright Visible Light 7 Damaged Parts 8 High Temperature Surfaces 7 Definition of Terms 26 AV EXPOSUTE 3 P A ies 22 Fuse Replacement 15 Spare Parts and Accessories Specifications 24 Fuses 15 Glossary 26 Support 4 Help 4 Troubleshooting 20 Intensity Adjustment 14 Unpacking 8 UV Exposure 5 UV Light Shielding 6 Validation 15 Warranty 27 Missing Parts 8 Operation 13 Optional Equipment 22 Product Overview 7 amp DYMAX 2014 Dymax Corporation All rights
28. r Guide Table 2 Troubleshooting Chart for UVCS LED Conveyor Systems Conveyor Issues Problem Foot Switch does not function Unit appears to run hot Conveyor Not Operating Belt Tracks to One Side Possible Cause The Foot Switch is not connected The Foot Switch is defective The Cooling Fan Filter is dirty or blocked There is insufficient clearance around the Power supply The Fan is not operating The power supply is contaminated with dust or debris Main Line Circuit Breaker deployed Improperly fastened connections Fuses for Motor Controller blown Belt is hung up Tension too low on Belt Power Switch lights and Motor turns but Belt does not move Belt Adjustment Knobs are out of position Corrective Action Connect the Foot Switch Activate the unit using the Front Control Panel Replace the Foot Switch if the unit operates from the Front Control Panel Replace the Cooling Fan Filters Remove items that are blocking the Filter and Air Inlet Ensure 1 2 54 cm of clearance is provided around the Power Supply and at least 6 15 24 cm of clearance is provided around the Cooling Fan Inlets Ensure that the Fan is operating Contact Dymax Application Engineering Contact Dymax Application Engineering Toggle Power Switch off then on to reset the Circuit Breaker Check the amp rating of the Breaker Compare it to Specifications Check all connections Verify that the power cord is P
29. ress the button to open the Options Menu Figure 15 Use the and amp buttons so that the SELECT MODE option is flashing and press the button to open the Select Mode Menu Figure 16 Using the and amp buttons highlight the desired mode and press the button The mode has now been set and the screen should return to the main page Figure 15 Options Menu Figure 16 Select Mode Menu SELECT MODE TIMER MODE ADJUST TIMER MANUAL MODE ADJUST INTENSITY CANCEL CANCEL PRESS AV TO SELECT PRESS AV TO SELECT PRESS SET TO ENTER PRESS SET TO ENTER Adjusting Intensity The output intensity can be adjusted from 10 depending on the LED Flood configuration ordered to 100 in 1 increments To adjust the intensity 1 From the main screen press the button on the front control panel to enter the Options Menu Figure 17 Use the and the amp so that the Adjust Intensity option is flashing and press the button to enter the Adjust Intensity Menu Figure 18 Use the Q amp 2 lt j or Q keys to adjust the intensity setting Press the Set button to enter the value and exit to the main page NOTE If you enter intensity that is too low for the LED Flood Array attached the unit the unit will beep for 5 seconds and the intensity will not change If you are operating in PLC mode a PLC input signal allows intensity to be selected from this menu or allows intensity to be controlled directly by the PLC Figure
30. roperly fastened Remove the Fuses from the Fuse Holders located in the left side of Control Box and check with an Ohmmeter replace if defective Inspect the Belt for any signs of a mechanical bind Tighten the Belt if it is slipping on the Drive Roller Use the Tracking Adjustment Knobs to increase the tension on the Belt Both Knobs will have to be turned the same amount to not affect the alignment Tighten the Adjustment Knob located on the side to which the Belt is tracking towards until the Belt tracks straight Only minor adjustments should be made at one time UVCS LED Light Curing Conveyor Systems User Guide Spare Parts and Accessories Spare Replacement Parts Item Part Number Key System Components LED Flood Power supply 41276 PrimeCure LED Flood Array 385 nm Wavelength 41210 VisiCure LED Flood Array 405 nm Wavelength 41211 RediCure LED Flood Array 365 nm Wavelength 41212 Quartz Optic Lens 41331 Air Filter Assembly 41330 Fuses 12 Amp 41271 AC Power Cords Power Cord North American 41274 Power Cord China 41275 Conveyor Blower 115 VAC 40146 Blower 220 VAC 40147 Circuit Breaker 115 VAC 39128 Curtain Assembly 2 Required 39207 DC Motor Controller 40179 DC Motor Controller Resistor 40178 DC Motor Speed Indicator Sensor 39136 Gear Motor 90 VDC 39285 Hour Meter 35981 Mesh Belt 39134 Mesh Belt Fine 39772 Pinch Guard Conveyor Discharge 39119 Pinch Guard Conveyor Inlet 39118 Pote
31. te 41262 Power cord baa included 41289 North American power cord with 120V plug Ppa 41292 Asian Power cord VisiCure 950 mW cm2 PrimeCure 850 mW cm2 RediCure 450 mW cm2 365 nm 385 nm or 405 nm 100 240 V 50 60 Hz auto ranging 12 amp 0 1 to 9999 9 seconds Foot switch front panel or PLC Forced air filtered fan Unit operation and exposure non resettable Power Supply 13 00 x 18 25 x 4 50 33 0 cm x 46 4 cm x 11 4 cm Array 6 50 x 5 75 x 7 50 16 5 cm x 14 6 cm x 19 1 cm 115 292 1 cm 25 Pin D Sub Power Supply 15 Ibs 6 8 kg Array 8 lbs 3 6 kg 1 year from purchase date 20 40 C non condensing 68 decibels at 36 91 cm distance at full power For European customers the appropriate power cord is added When measured at 1 in 25 mm distance with an ACCU CAL 50 LED radiometer in flood mode UVCS LED Light Curing Conveyor Systems User Guide Figure 34 PrimeCure Wavelength Intensity counts Wavelength nm Figure 35 VisiCure Wavelength 60000 ee ee H lt J p lt 40000 450 500 550 600 650 Wavelength nm Figure 36 RediCure Wavelength oe U Snn s sos 400 460 500 SDS 650 Wavelength nm UVCS LED Light Curing Conveyor Systems User Guide Definition of Terms Brightness also known as Luminance Descr
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