MAN067 - BlueWave LED Flood System User Guide
Contents
1. The Interface Cable connections are loose or damaged The over temperature shutdown was triggered The LED intensity adjustment is set to the minimum The Lens Optics are contaminated dirty 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 The cooling fan filter on the LED head is dirty or blocked The cooling fan filter on the controller is dirty or blocked The system is being operated at a room temperature greater than 40 C 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 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 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 clearance2. Array Malfunction or Cable Problem Controller Board Failure Flashing Power Supply Thermal Warning Flashing Array Thermal Warning POWER NO ARRAY E0000 CONTACT LOCAL DYMAX SUPPORT OR GO TO WWW DYMAX COM Description The array overheated Verify the filter on the array is clean and replace if necessary Verify that the vents on the array are not blocked Verify the array is drawing room air which is less than 40 C Power down and restart the controller to reset If the problem persists note the number following the E and contact Dymax for further assistance There was a failure with the controller Verify that the filters on the side of the controller are not blocked Clean the vents with a vacuum if necessary Do not attempt to open the controller Power down and restart the controller to reset If the problem persists note the number following the E and contact Dymax for further assistance There was a problem with the connection between the array and the controller or LEDs which have failed Turn off the controller and very that the cable is firmly attached by screws on the controller and the array Power down and restart the controller to reset If the problem persists note the number following the E and contact Dymax for further assistance There was a failure with the controller board Power down and restart the controller to reset If the problem persists note the number following the
3. E and contact Dymax for further assistance Indicates that the power supply has exceeded the recommended temperature limit Check the filters on the controller for any clogs and if necessary clean the filters Verify that ambient temperature around the controller is below 40 C The unit will continue to operate normally unless the temperature in the controller continues to rise Indicates that the cooling air drawn into the array is has exceeded the recommended temperature limit of 40 C Check the filter on the array for any clogs and if necessary clean or replace the filter Operate the unit in an ambient temperature of 40 C or less Verify that hot air from other equipment is not being drawn into the array The unit will continue to operate unless the cooling air temperature continues to rise Dymax BlueWave LED Flood System User Guide Table 3 Troubleshooting Chart for BlueWave LED Flood System 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 Foot Switch does not function Unit appears to run hot LED or Power warning symbol is flashing in lower right hand corner of screen Possible Cause The Power Cordis not plugged in or is damaged The Onboard Fuse is blown There is no electrical power at the Receptacle The LED intensity adjustment is set to the minimum
4. Figure 10 2 Use the and amp buttons so that the SELECT MODE option is flashing and press the button to open the Select Mode Menu Figure 11 3 Using the and amp buttons highlight the desired mode and press the button 4 The mode has now been set and the screen should return to the main page Figure 10 Options Menu Figure 11 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 Dymax BlueWave LED Flood System User Guide Selecting the PLC Mode from the Timer or Manual Mode 1 Press the PLC Access Switch on the back of the unit Figure 12 2 Fromthe main page press the button to open the Options Menu Figure 13 within 30 seconds Figure 12 PLC Access Switch Figure 13 Options Menu SELECI MODE ADJUST TIMER ADJUST INTENSITY CANCEL PRESS AV TO SELECT PRESS SET TO ENTER E F120A 250 VAC 100 240 VAC 50 60 Hz 12A E Po 3 Use the and amp buttons so that the SELECT MODE option is flashing and press the button to open the Select Mode Menu Figure 14 4 Using the and amp buttons highlight PLC MODE and press the button NOTE If you do not see PLC Mode then select CANCEL using the and amp buttons and press the button Then follow the instructions starting at step 1 5 PLC Mode selection is successfu
5. amp Work Platform bench top mini flood mode 41294 Light Shield 41321 Shield 35306 Misc Power Supply to Irradiator Head Interconnect Cable 115 292 1 cm 41228 Retrofit Kit for use with UVCS Conveyors not available in Europe 41340 Dymax BlueWave LED Flood System User Guide Specifications Specifications Property Part Numbers Typical Initial Output Intensities Output Frequency Power Requirements Fuse LED Timer LED Activation Cooling Hour Meter Dimensions WxDxH Interconnect Cable Length 1 0 Port Weight Unit Warranty Operating Environment Sound Level Certifications Specification 41260 Power cord NOT included VisiCure 405 nm 41288 North American power cord with 120V plug 41291 Asian Power cord SR 41261 Power cord NOT included Hi si 41287 North American power cord with 120V plug 41290 Asian Power cord 1 41262 Power cord NOT included RediCure ace 41292 North American power cord with 120V plug nm 41289 Asian Power cord VisiCure 950 mW cm2 PrimeCure 850 mW cm2 RediCure 500 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
6. curitaire L installation finale ne doit pas bloquer les acc s pour la ventilation Pour utiliser en toute s curit le syst me BlueWave LED Flood le syst me doit tre install et utilis en suivant les instructions offertes par Dymax L utilisation du syst me de toute autre fa on peut diminuer sa protection Dymax n est pas responsable des changements pouvant diminuer la protection du syst me de s chage General Safety Considerations All users of Dymax equipment should read and understand this user guide before assembling and using the equipment 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 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 PRECAUTIONS Veuillez toujours porter des lunettes protectrices pour les yeux ou pour le visage lors de travail en contact avec la lumi re UV Ne jamais regarder la lumi re directement AVERTISSEMENT Toujours ob ir aux exigences de s curit Ne pas ouvrir les couvercles des lumi res LED ou pour l alimentation lectrique Il n y a aucune pi ce pour l entretien l int rieur Safety Recom
7. 3 Remove and inspect the fuses Figure 27 Replace blown fuses with 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 over tighten Figure 25 Fuse Holders Figure 26 Remove Fuse Figure 27 Remove Fuse from Holder Holder Dymax BlueWave LED Flood System User Guide 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 allow it to cool Then clean the quartz optic plate surface Figure 28 with a clean lint free cloth and isopropyl alcohol Figure 28 Quartz Optic Plate Dymax BlueWave LED Flood System User Guide Troubleshooting The BlueWave LED Flood System constantly verifies the Figure 29 Diagnostics Screen performance of the power supply and LED head If a problem is detected a diagnostic screen is displayed Please take note of the contents of the screen and contact Dymax for support Table 2 Fault Symbols Error Screen anne N E CONTACT LOCAL DYMAX SUPPORT OR GOTO 7 e CONTACT LOCAL DYMAX SUPPORT OR GO TO WWW DYMAX COM PD es CONTACT LOCAL DYMAX SUPPORT OR GO TO WWW DYMAX COM Ca CONTACT LOCAL DYMAX SUPPORT OR GO 10 gt Name Array Thermal Cutoff Controller Power Supply Failure Array Not Connected
8. 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 RoHS CE Marked 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 C Dymax BlueWave LED Flood System User Guide Figure 30 BlueWave LED Flood with PrimeCure Array 385 nm Spectral Output Intensity counts 500 550 Wavelength nm Figure 31 BlueWave LED Flood with VisiCure Array 405 nm Spectral Output Se ae et ee ed ee RN ee ee ce Intensity counts 20000 ele sels a e a lee e Oe 450 500 550 600 650 Wavelength nm Figure 32 BlueWave LED Flood with RediCure Array 365 nm Spectral Output l l I j l i I I I i j 60000 4 r i 1 f r i r a4 r i 1 l I i i i 1 i i i i i I 40000 e e e e me fun ne ne ne ne ne ne de ee o_o n mg on io Intensity counts 20000 400 450 500 550 600 650 Wavelength nm Warranty Dymax BlueWave LED Flood System User Guide From date of purchase Dymax Corporation offers a one year warranty against defects in material and workmanship on all system components with proof of purchase and purchase date Unauthorized repair modification or improper use of equipmen
9. button The timer mode allows the user to activate the LED array for a set amount of time PLC mode allows an external machine to control all functions of the unit 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 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 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 Assembly and Setup Safety S curit The BlueWave LED Flood System is not a stand alone unit and is intende
10. 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 Replace the cooling fan filters Remove items that are blocking the filter and air inlets Clean the filter on the base with a vacuum improve airflow around the system Dymax BlueWave LED Flood System 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 Foot Switch and AC Power Cords Foot Switch 40402 Power Cord North American 41274 Power Cord China 41275 Miscellaneous Silicone Pad for bench top stand base 41304 User Guide English 41264 Options Accessories Item Part Number Personal Protection Equipment Protective Goggles Green not available in Europe 35286 Protective Goggles Gray standard model included with unit 35285 Face Shield not available in Europe 35186 Radiometers Dymax ACCU CAL 50 LED Radiometer flood 40519 Stands amp Shields Standard Bench Top Stand amp Work Platform bench top mini flood mode 41268 Premium Bench Top Stand
11. 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 amp DYMAX 2014 2015 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 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 PN 41264 MANO67 6 12 2015 Dymax Corporation Dymax Oligomers amp Coatings Dymax Asia H K Limited 860 482 1010 info dymax com www dymax com 860 626 7006 info_oc dymax com www dymax oc com 852 2460 7038 dymaxasia dymax com
12. 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 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 and outlet to allow the free flow of air AVERTISSEMENT Vous pouvez endommager l quipement ou avoir des difficult s avec l utilisation si vous bloquez la ventilation pour les lumi res LED ou l alimentation lectrique Pour viter la d t rioration ou le mauvais fonctionnement du syst me veuillez vous assurer que l installation offre un retrait de 1 2 54 cm autour de l alimentation lectrique et au moins 6 15 24 cm de retrait avec la sortie de ventilation et assurez vous qu il y a une bonne circulation d air Dymax BlueWave LED Flood System User Guide Special Features and Benefits of the BlueWave LED Flood System The Dymax BlueWave LED Flood System is engineered for precise performance and long service life Key features include Feature Curing area up to 5 x 5 12 7 cm x 12 7 cm Flexible mounting options 100 duty cycle capability No mechanical s
13. the back panel Never attempt to unplug or attach a cable when the unit is turned on AVERTISSEMENT Assurez vous que l unit est hors tension et d branch avant d effectuer une connexion sur le panneau lectrique derri re l unit Ne jamais d brancher ou attacher un c ble lorsque l unit est aliment e NOTE The unit should be positioned so that the back panel of the power supply can easily be accessed should the power need to be disconnected Interconnect Cable The interconnect cable runs from the back panel of the power supply to the top of the LED flood array Figure 5 Connect Interconnect Cable to Figure 6 Connect Opposite End of Power Supply Interconnect Cable to LED Flood Array Operating the LED Light Adjusting Intensity The output intensity can be adjusted from 5 depending on the LED Flood configuration ordered to 100 in 1 increments To adjust the intensity 1 From the main screen press and hold the button on the front control panel for several seconds until the Options Menu Figure 7 appears 2 Use the and the amp so that the Adjust Intensity option is flashing and press the button to enter the Adjust Intensity Menu Figure 8 3 Usethe Q amp lt j or gt keys to adjust the intensity setting Press the Set button to enter the value and exit to the main page Dymax BlueWave LED Flood System User Guide NOTE If you enter intensity that is too l
14. working near UV light The PLC is capable of turning on the LED at any time or when a user selects PLC Mode from the front panel controls PRECAUTIONS veuillez toujours porter des lunettes protectrices pour les yeux ou pour le visage lors de travail en contact avec la lumi re UV Le PLC peut mettre sous tension le syst me DEL en tout temps ou lorsque l utilisateur s lectionne le mode PLC avec les commandes du panneau frontal PLC Mode means that an external PLC Programmable Logic Controller controls the system The PLC provides input signals to the flood unit to control the LED The PLC monitors the status of the flood unit by reading output signals provided by the unit The PLC is typically programmed to start other machinery when the flood unit becomes ready or perhaps start the flood unit when other machinery is ready The input signals and output signals are present on a connector on the back of the power supply labeled PLC NOTE Output signals are always provided in manual mode and timer mode to allow simple interfacing to alarms counters other interlocks etc even if a PLC will not be controlling the unit However the input signals will be ignored in manual mode and timer mode Dymax BlueWave LED Flood System User Guide Wiring the PLC Interface Figure 23 25 Pin D The BlueWave LED Flood System includes a 25 pin D subminiature Subminiature Connector connector Figure 23 on the rear panel of the power supply
15. www dymax com cn Dymax Europe GmbH Dymax UV Adhesives amp Equipment Shanghai Co Ltd Dymax Asia Pacific Pte Ltd 49 0 611 962 7900 info_de dymax com www dymax de 86 21 37285759 dymaxasia dymax com www dymax com cn 65 6752 2887 info_ap dymax com www dymax ap com Dymax Engineering Adhesives Ireland Ltd Dymax UV Adhesives amp Equipment Shenzhen Co Ltd Dymax Korea LLC 353 1 231 4696 info_ie dymax com www dymax ie 86 755 83485759 dymaxasia dymax com www dymax com cn 82 2 784 3434 info_kr dymax com www dymax com kr
16. BlueWave LED Flood System User Guide Large Area LED Light Source Instructions for Safe Use Setup and Operation a Maintenance Ordering Spare Parts and Accessories Dymax BlueWave LED Flood System 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 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 and conventional broad spectrum 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 Dymax is willing to ass
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18. a lumi re de haute intensit et porter des lunettes pour la protection des yeux fournies Safety Symbol Index The following symbols are displayed on the curing system Please see below for their meanings Refer to Manual Warning Eye Protection Required Warning UV Light Hazard Electrostatic Sensitive Device gt gt 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 System 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 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 1mW cm limit into perspective cloudless summer days in Connecticut regularly exceed 3 mW cm of UVA light which incl
19. ack Panel The back panel includes these components and connection points Power Cord Receptacle Connection point for the power cord I O On Off Switch Moving the switch to the I on position powers up the power supply Moving the switch to the O off position cuts power to the power supply Cooling Air Exhaust Cooling air enters the side vents and exhausts out the rear of the unit NOTE The exhaust vents on the rear of the power supply must not be blocked or the unit may overheat and shut down 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 and outlet Foot Switch Jack Connection point for the foot switch Pressing the foot switch starts a curing cycle In timed operation pressing and releasing the foot switch activates the curing array for the length of time displayed in the cycle time display A second press will terminate a timed cure cycle immediately In manual operation pressing and holding the foot switch activates the curing light until the foot switch is released PLC Access Switch Button used to temporarily unlock the option to access PLC mode PLC Connector Connection point for a user supplied cable to connect the unit to a PLC for remote operation Connection is a standard 25 pin D style connector Refer to page 19 for details on the connections to this port Array Cable Connector Connect
20. are always active in timer and manual mode 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 NOTE The run button can be used to activate the LED light without PLC commands to assist fixture troubleshooting Dymax BlueWave LED Flood System User Guide Choosing an Operating Mode NOTE Upon power up your BlueWave LED Flood System will default to its last configuration settings Figure 9 Mode Start up Screens Left to Right Manual Mode Timer Mode PLC Mode MANUAL MODE TIMER MODE PLC MODE PLC INTERFACE ENABLED NO 0000 O LED ARRAY INHIBIT NO LED ARRAY COMMAND OFF LED ARRAY INTENSITY 100 LED INTENSITY CONTROL PLC INTENSITY 100 INTENSITY 100 PrimeCure PrimeCure PrimeCure a 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 To Switch Between Manual and Timer Mode 1 Fromthe main page press the button to open the Options Menu
21. are not valid When this signal is asserted the system will respond to PLC Control The System Ready for signal will be unasserted if the system is not in PLC Mode or a user is PLC Control adjusting a menu while in PLC Mode When this signal is unasserted the system will not respond to actions commanded by the PLC When this signal is asserted the LED array or the power supply is being operated at a temperature in excess of its specification or airflow to the LED array or power supply is restricted If this signal is not asserted the flood Thermal Warning 8 system is being operated within specifications and airflow is not restricted Typically this signal is used to shut down an automated process in an orderly fashion so that corrections can be made before the flood system shuts down to overheating When this signal is asserted the system has detected a fault and will not System Fault 14 i respond to any PLC commands until an operator corrects the fault This signal indicates the state the LED unit When asserted the LED is on When this signal is not asserted the LFA is off LFA Activated 16 As a group these three signals indicate the part number of the LED array attached to the power supply 17 ID4 When a RediCure LED array is connected LFA ID4 and LFA ID1 are asserted LFA ID s 18 ID2 When a PrimeCure LED array is connected LFA ID4 is asserted 19 ID1 When a VisiCure LED array is connected LFA ID4 a
22. casessisnni RE TOR 29 CI 8 0 SE 110 ARR TA 29 Dymax BlueWave LED Flood System User Guide Introduction Introduction to the User Guide This guide describes how to assemble use and maintain the Dymax BlueWave LED Flood System safely and efficiently Intended Audience Dymax prepared this user guide for experienced process engineers technicians and manufacturing personnel If you are new to high intensity LED light curing systems 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 m Detailed product information on www dymax com m Customer Support and Application Engineering teams are 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 Please see the back cover for additional Dymax locations Dymax adhesive Product Data Sheets PDS on our website m Material Safety Data Sheets MSDS provided with shipments of Dymax adhesives Safety S curit WARNING If you use this curing system without first reading and understanding the information in this user guide injury can result from exposure to high intensity light To reduce the risk of injury read and ensure you understand the information in this user guide before a
23. d to be incorporated into a larger system This integrated system should provide adequate mechanical and electrical safeguards with sufficient light shielding and protection for safe operator use Final installation must not block vents To use a BlueWave LED Flood System safely it must be set up and operated in accordance with the instructions given by Dymax Using the flood 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 curing system Le syst me BlueWave LED Flood n est pas un syst me con u pour l utilisation simple mais pour tre incorpor e dans un plus grand syst me Ce syst me int gr doit offrir des mesures de s curit ad quate pour Dymax BlueWave LED Flood System User Guide le syst me m canique et lectrique obstruer totalement la lumi re et prot ger l op rateur pour une utilisation s curitaire L installation finale ne doit pas bloquer les acc s pour la ventilation Pour utiliser en toute s curit le syst me BlueWave LED Flood le syst me doit tre install et utilis en suivant les instructions offertes par Dymax L utilisation du syst me de toute autre fa on peut diminuer sa protection Dymax n est pas responsable des changements pouvant diminuer la protection du syst me de s chage Unpacking and Inspecting Your Shipment When your BlueWave LED Flood System arrives inspect any boxes for damage and n
24. ed The proper use of tinted eye protection and or opaque tinted shielding can be utilized to reduce eye strain and address this concern Dymax BlueWave LED Flood System User Guide D Product Overview Description of the BlueWave LED Flood System The BlueWave LED Flood System is a high intensity unit used for curing light curable materials The unit is designed to be integrated into a larger system such as an automated manufacturing system or with a light shielding enclosure to create a bench top curing station The BlueWave LED Flood System consists of two main components an LED flood array and a power supply that contains the user interface Dymax offers three different wavelength LED flood arrays VisiCure 405 nm PrimeCure 385 nm and RediCure 365 nm Only one LED flood array can be connected to the power supply at a time via the interconnect cable The power supply is designed to identify the type of LED array that is connected so the power supply can be used with any of the three LED flood arrays The unit can be operated in timed or manual modes and features 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 Fans in the LED flood power supply and array provide cooling and
25. for communication with a PLC or similar process control equipment The Fa A HEAD 0000c6006 connector provides for input and output signals ITA Typical connections to a PLC should be made according to Figure 24 2 Cha TE gt 2 J co ee gt e e ee 2 o o Coo CS eee Pa nte Figure 24 Typical Connections to a PLC 24VDC Oo gt 0 O Sa MAR SRO 00 ee 333 Typical PLC with Isolation gs O O wr x 8 S e A TO wi gt Q Vv AN a va gt a da 3 e oc 24VDC POWER si am O SUPPLY D E T gt gt O O O a NI AT N gt lt gJ v O l am a m O n 4 3 cc 5 2 Z Y o_ gt ba v 3 O A B 3 gt o O 2 _ AT O o Z 4 oO i O La Ga a 24VDC RETURN SIGNAL COMMON Dymax BlueWave LED Flood System User Guide Input Signal Definition Note Asserting an input signal means connecting the input pin to return Approximately 3mA will flow out of the pin The current is supplied from the 24VDC Supply Un asserting an input signal means that less than 1 microampere of current is drawn from the pin NOTE All Input signals are ignored
26. hutter Intensity output adjustment by keypad or PLC 10 to 100 Co optimized to cure with Dymax formulations Stable LED temperature LED Front Control Panel Benefit Large area cure capability with LED Adaptable to a variety of process and fixture scenarios Highest throughput exposure cycles at the speed of light Instant on Instant off exposures Superior accuracy over closed loop feedback or auto adjusting units Optimum process control Compatibility with many formulations Fewer re qualifications Optimizes cure time efficiency Increases LED life Superior LED cooling for consistent frequency output Longer LED life via reduced intensity degradation The LED flood system has a simple easy to use front interface The front control panel is located on the right side of the power supply and is used to make all manual adjustments Up Button Navigates the selector up one position m Down Button 4 Navigates the selector down one position Right Button Navigates the selector right one position m Left Button Navigates the selector left one position m Set Button Located in the center of the arrow buttons This button selects the option highlighted on the screen Run Button ET This button is used to activate the LED flood array when in manual mode Figure 2 Front Control Panel A Bluellave LED Flood Dymax BlueWave LED Flood System User Guide B
27. intensity control method Note The PLC Screen will always show the current LFA intensity no matter which method is used to control intensity This signal provides a means for the PLC to directly control LFA intensity The PLC output must be a contact closure to signal common switching at 2KHZ with a duty cycle of 0 to 100 Note Instructing the PLC to leave contact open all of the time is a command to have the LFA operate at 100 of rated intensity Note Instructing the PLC to leave the contact fully closed is a command to have the LFA operate at minimum intensity The minimum intensity varies with LFA part number Note to simplify interfacing and to reduce troubleshooting time the state of all PLC signals and the Intensity of the LFA are reported on the screen of the LCD Dymax BlueWave LED Flood System User Guide Output Signal Definition NOTE Output signals which are asserted can sink up to 2 5 milliamperes with 5V maximum between signal output pin and 24VDC Return Signal Common The current flows through the output signal pin to the 24VDC Return Signal Common pin Output signals which are not asserted may draw 5 microamperes of current at 24 VDC 10 Table 2 Outputs Signals from the Flood Unit on the PLC Interface Name Pin Number Definition and Notes When this signal is asserted the controller is functioning properly and the System Health 15 PLC outputs are valid If this signal is not asserted the PLC outputs
28. ion point for the interconnection cable connecting the power supply to the array Figure 3 Back Panel 0000000000000000000000000 00000600000000000000000e 000000000000000000000000e 000000000000 000000000000 000000000000 00000000 000000000000 000000000000 000000000000 00000000000 cove 0 ooo e o DOG OY eoe x c oo el ih At a DL RAR AAA A TA aR AA access FOOT le gt 120A 250 VAC 100 240 VAC 5060 Hr 12 A H al 7 p Intensity Control Feature The components used in all light curing systems degrade with use Therefore the maximum intensity decreases as exposure hours accumulate Setting process intensity requirements lower than the maximum enables the BlueWave LED Flood s intensity control feature to allow for compensation of gradual decreases in light intensity The unit s intensity can be adjusted using the intensity adjustment on the front control panel as a percentage of full scale intensity Dymax BlueWave LED Flood System User Guide Use a radiometer to correlate the power output setting to a reading in W cm The adjustment of power level and correlation to an intensity value W cm enables precise control of light intensity during validation and operation Operation Modes The power supply allows the user to select between manual activation mode timer mode or PLC mode The manual mode allows the user to active the LED array via a foot switch or by pressing the run
29. ist 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 Flood System User Guide Contents BEA ENC PERERA NN sive viv nc ates veins ony env eve A T T A A 5 Introduction to the User OUI ila 5 MTV GETE I apenas ea an E tt ne 5 Sole Se A ee Se ee 5 General Salety COMSIG SL ALIGNS sense ccneene cons discodees area ai 6 Specific Safety CONSIGErAto0 scia 6 ESE RR EEE EE EI 7 Dymax Light Curing System Safety Considerations 7 PFOGUCCONCNVIM ll 9 Description of the BlueWave LED Flood System sise 9 Special Features and Benefits of the BlueWave LED Flood System 10 Font contol PAR se aa de ue a 10 Back Panel RARO EI a 11 Ihntensity ControLFeatile a alcalina 11 Operation Modes cccccccsssscccccesceccsesccccceeseceeseueeceeseeneceesaeeeeeeeeseeeeeaeaseeesseaeeeseeaeeeeeseasecessuaseceesueasceesauaseessuaaeceesaganess 12 WI aio 12 ASSEMDINana SetU Dica 12 Safety S curit cccccccccccccccccccececeeeeceeeeeeeceeceeeeeeeeeeeeeeeeeeeeeeceeeeeeeeeeeeecececececeeeeeeeeeeeeeeeecececeeeeeeseeeeeceeeeeeeeeeececeeeeeeeeeeeeeees 12 Unpacking and Inspecting Your SHIPMENL cccssscccccssecccceseccccseseccecaeeceeseaseceeseueseceeseaeeesseasecessueeecessauaeceesauaeeeesages 13 Parts Included in the BlueWave LED Flood
30. l if the screen below appears Figure 14 Select Mode Menu Figure 15 PLC Mode Menu TIMER MODE PLC MODE MANUAL MODE CANCEL fein gn LED ARRAY COMMAND OFF LED ARRAY INTENSITY 100 LED INTENSITY CONTROL PLC PRESS AV TO SELECT PRESS SET TO ENTER PrimeCure fa Dymax BlueWave LED Flood System User Guide Selecting Timer or Manual Modes from the PLC Mode 1 Press the PLC Access Switch on the back of the unit Figure 16 NOTE The padlock will disappear from the PLC Mode screen after you press the PLC Access Switch 2 Pressthe button The Options Menu should appear Figure 17 NOTE If the screens do not change after you press the button then go back to step 1 Figure 16 PLC Access Switch Figure 17 Options Menu SELECT MODE ADJUST TIMER ADJUST INTENSITY CANCEL accese FOOT le F120A 250 VAC 100 240 VAC 50 60 Hz 12 A PRESS AV TO SELECT PRESS SET TO ENTER 3 Usethe and amp buttons so that the SELECT MODE option is flashing and press the button to open the Select Mode Menu Figure 18 4 Using the and amp buttons highlight TIMER MODE or MANUAL MODE and press the button Figure 18 Select Mode Menu TIMER MODE MANUAL MODE CANCEL PRESS AV TO SELECT PRESS SET TO ENTER Dymax BlueWave LED Flood System User Guide Operating in Manual Mode Manual Mode Description Manual Mode means that the LED activates whenever the foot switch or the run butt
31. le 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 may rise in temperature The intensity distance exposure time cooling fans and composition of the surface can all affect the rise 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 Bright Visible Light The bright visible light energy emitted by curing systems can cause eye strain if proper eye protection or shielding is not us
32. mendations Recommander de S curit m Use the goggles provided or an approved face shield for eye face protection Long sleeved shirts or a lab coat are recommended for arm protection The use of opaque gloves will protect the hands a Utiliser les lunettes de protection fournies ou une protection pour le visage approuv pour la protection des yeux et du visage a Il est recommand d utiliser un chandail avec des longues manches ou un manteau de laboratoire pour la protection des bras L utilisation de gants opaques prot ge les mains Specific Safety Considerations The BlueWave LED Flood System is designed to maximize operator safety and minimize exposure to light curing energy To use 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 LED curing systems as described below WARNINGS Looking directly at the high intensity light emitted by the BlueWave Large Area LED 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 BlueWave LED Flood System User Guide AVERTISSEMENT Vous pouvez blesser vos yeux si vous regardez directement la lumi re de haute intensit mise par le syst me BlueWave LED Flood Pour la pr vention de blessure aux yeux veuillez ne jamais regarder directement dans la direction de l
33. nd LFA ID2 are asserted NOTE If no array is connected the unit will report a system fault and LFA ID2 and LFA ID1 are asserted This signal output provides a means for the PLC to monitor intensity It is a pulse width modulated contact closure to 24VDC Signal Common When the contact is always closed the LFA is operating at 100 of rated intensity Intensity Status 21 When the closed 50 of the time the LFA is operating at 50 of rated intensity The contact closure frequency pulse width modulation frequency is 2 0 KHz Dymax BlueWave LED Flood System User Guide Troubleshooting the PLC Interface In PLC Mode the LCD screen gives the status of all inputs to the Flood Unit NOTE The LCD screen also indicates the set point intensity emitted by the LED Head which may be different from the intensity commanded by the PLC if the Intensity Control Method is via the front panel keyboard Testing Fixtures in PLC Mode When the unit is in PLC Mode and the Inhibit LFA signal is not present pressing the run button will turn on the LED This is useful for fixture troubleshooting and process verification Cleaning amp Maintenance Inspect and Replace Fuses The LED Flood Power Supply has two Fuse Holders located on the rear panel Figure 25 Follow these steps to inspect and replace the fuses if indicated as a corrective action based on troubleshooting 1 Unplug the unit 2 Remove the Fuse Holders using a screwdriver Figure 26
34. on on the front panel is pressed The LED remains active only as long as the foot switch or run button is pressed When the foot pedal and run button are released the LED shuts off Procedure 1 Ensure the BlueWave LED Flood is in Manual Mode Figure 19 If the system is not in Manual Mode follow Figure 19 Manual Mode the instructions in Choosing an Operating Mode Activated Screen 2 Verify that the LED Head is connected properly to the MAN UAL M O D E Power supply via the Interconnect Cable 3 Press and hold the Footswitch or the Button on the front panel to activate the LED INTENSITY 100 RUN 4 To stop exposure release the Footswitch or the Button on the front panel LED PrimeCure ON NOTE The LED ON text will only appear when the footswitch or run button is pressed Operating in Timer Mode Timer Mode Description Timer Mode means that the LED is active for a specific time period each time the foot switch or run button is pressed You must set the specific time by adjusting the timer s value on the screen Momentarily pressing the foot switch or run button starts the timer and activates the LED When the timer counts down to zero the shutter closes and the timer resets to the value that you set and is ready for another exposure cycle The activation can be cancelled at any time during the exposure cycle by pressing the foot switch or run button NOTE A timed exposure can be interrupted wi
35. otify 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 Flood System m LED Flood Power Supply 1 PN 41276 a LED Flood Array 2 VisiCure PN 41211 PrimeCure PN 41210 or RediCure PN 41212 model Power Cord 3 Dependent on model ordered Available options listed below o Standard North American Power Cord PN 41274 o Type G Power Cord for Asia PN 41275 o No Power Cord Note For European customers the appropriate power cord will be added Foot Switch 4 PN 40402 m Safety Glasses 5 PN 35285 m Interconnect Cable 6 PN 41228 Connects the power supply to the array m BlueWave LED Flood System User Guide 7 PN 41264 Figure 4 BlueWave LED Flood System Components 2 LED Flood Array 3 Power Cord lt lt 1 LED Flood Power Supply 4 Foot Switch sS 5 Safety Glasses i 7 User Guide 6 Interconnect Cable Dymax BlueWave LED Flood System User Guide System Connections WARNING Make sure the unit is turned off and unplugged before you make any connections to
36. ow 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 7 Options Menu Figure 8 Adjust Intensity Menu Mantes ADJUST INTENSITY ADJUST INTENSITY O CANCEL 1 00 o PRESS lt D TO SELECT DIGIT PRESS AV TO SELECT PRESS AV TO ADJUST DIGIT PRESS SET TO ENTER PRESS SET TO ENTER Operating Modes There are three basic operating modes Manual Mode Timer Mode and PLC Mode Manual Mode The LED activates whenever the foot switch or the run button on the front panel is pressed The LED remains active only as long as the foot switch or run button is pressed When the foot switch and run button are released the LED shuts off NOTE PLC outputs are always active in manual and timer mode Timer Mode The LED is active for a specific time period each time the foot switch or run button is pressed You must set the specific time by adjusting the timer s value on the screen Momentarily pressing the foot switch or run button starts the timer and activates the LED Once the timer counts down to zero the shutter closes and the timer resets to the value that you set and is ready for another exposure cycle The activation can be cancelled at any time during the exposure cycle by pressing the foot switch or run button NOTE PLC outputs
37. ssembling and operating a Dymax BlueWave LED Flood System AVERTISSEMENT Si vous utilisez le syst me de s chage sans lire le mode d emploi et comprendre les informations offertes des s rieuses blessures peuvent de produire suite l exposition la lumi re de haute intensit Pour r duire les risques de blessures veuillez lire et comprendre les informations du mode d emploi avant l assamblage et l utilisation du syst me Dymax Blue Wave LED Flood The BlueWave LED Flood System is not a stand alone unit and is intended to be incorporated into a larger system This integrated system should provide adequate mechanical and electrical safeguards with sufficient light shielding and protection for safe operator use Final installation must not block vents To use a BlueWave LED Flood System safely it must be set up and operated in accordance with the instructions given by Dymax Using the flood 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 curing system Le syst me BlueWave LED Flood n est pas un syst me con u pour l utilisation simple mais pour tre incorpor e dans un plus grand syst me Ce syst me int gr doit offrir des mesures de s curit ad quate pour GY Dymax BlueWave LED Flood System User Guide le syst me m canique et lectrique obstruer totalement la lumi re et prot ger l op rateur pour une utilisation s
38. t 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 Intensity 14 Assembly and Setup 13 Back Panel Controls 11 Cleaning and Maintenance 26 Curing System Safety 7 Features and Benefits 10 Front Panel Controls 10 Fuse Replacement 26 Fuses 26 Help 5 Intensity Adjustment 14 Intensity Control Feature 12 Maintenance 26 Manual Mode 19 Operating Modes 12 Operation 14 Manual Mode 19 PLC Mode 21 Timer Mode 20 Optional Equipment 29 PLC Mode 21 Product Overview 9 Safety 5 Safety Symbol Index 6 Safety of UV Light Bright Visible Light 8 High Temperature Surfaces 8 UV Exposure 7 S curit 5 Spare Parts and Accessories 29 Specifications 31 Support 5 Timer Mode 20 Troubleshooting 27 UV Exposure 7 UV Light Shielding 8 Validation 12 Warranty 33 In addition to our light curing equipment Dymax also offers high performance oligomers adhesives and coatings DYMAXEDGE as well as a variety of dispensing equipment Our products are perfectly
39. th the foot switch or the button on the front panel Adjusting the Timer 1 Ensure the BlueWave LED Flood is in Timer Mode Figure 20 If the BlueWave LED Flood is not in Timer Mode follow the instructions in Choosing an Operating Mode 2 Ifthe time on the screen is correct skip to Step 6 Otherwise you need to adjust the Timer to the correct value by following the next steps Dymax BlueWave LED Flood System User Guide 3 Press and release the O Button to enter the Options Menu Figure 21 4 Use or Arrows so that ADJUST TIMER is flashing and press the O Button 5 The Adjust Timer Screen Figure 22 will display Use the Directional Keys to adjust the Timer to the correct value The Timer can be adjusted from 0000 0 seconds to 9999 9 seconds Press and release the Button when you have entered the desired activation time Figure 20 Time Mode Figure 21 Options Menu Figure 22 Adjust Timer Main Screen Screen TIMER MODE SELECT MODE ADJUST TIMER ADJUST TIMER 0000 0 dit er UE 0000 0 INTENSITY 100 PRESS lt I gt TO SELECT DIGIT PRESS AV TO SELECT PRESS AV TO ADJUST DIGIT PRESS SET TO ENTER PRESS SET TO ENTER PrimeCure 6 Press the Foot Switch or the Button on the front panel to start the Timer An exposure cycle can be cancelled at any time by momentarily pressing the Button or Foot Switch Operating in PLC Mode PLC Mode Description CAUTION Always wear protective goggles or a face shield when
40. udes the more dangerous UVB light primarily responsible for suntans sunburns and skin cancer Figure 1 Light Spectrum Portion of the spectrum that DYMAX primarily emits Germicidal Sunburns n i UVA 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 2 001 nm nm 1000 nr 1mm 1m 1km Wavelength nm Dymax BlueWave LED Flood System User Guide Checking the Workstation A radiometer should be used to measure stray light to confirm the safety of a light curing process A workstation that continuously exposes an operator to more than 1mW cm of UVA light 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 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 The BlueWave LED Flood System needs to be used with sufficient light shielding in order to be operated safely The LED Flood Array and Power Supply are not designed to be used as a stand alone unit Any substrate that blocks light can be used as a shield to protect workers from stray light The following materials can be used to create simp
41. until the Flood Unit is placed in PLC mode Table 1 Input Signals to the Flood Unit on the PLC Interface Name Pin Number 24 VDC input 1 24 VDC Return 5 Signal Common PLC Interface Enable 3 LED Activation A Request Inhibit LFA 5 Intensity Selection 6 Intensity Control 20 Definition and Notes Provide 24VDC 10 to this pin Return for all signals on the on the PLC This signal is optically isolated from any AC power and Protective Earth The PLC should assert this signal after all other signal outputs by the PLC program are valid The unit will not respond to PLC control if this signal is not asserted The PLC should assert this signal to command the LED to turn on When asserted this signal will prevent the LED from turning on when the system is in PLC mode no matter what the state of other PLC input signals are Also the LED will not turn on if the front panel Run key is pressed in PLC Mode This signal is used to tell the Flood Unit to set the intensity using the entry in the front key panel or to set intensity using the Intensity Control signal below When asserted or wired to signal common the intensity will be controlled by the PLC If left unconnected the intensity will be controlled by the entry on the front key panel Note It is more useful to keep this signal disconnected from the PLC and use it as a fixed connection to Signal Common or disconnected from all other signals depending upon on the desired
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