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BlueWave LED DX-1000 VisiCure User Guide

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1. Shield the Source of the Light Any substrate that blocks Visible light can be used as a shield to protect workers from stray light The following materials can be used to create simple shielding structures Sheet Metal Aluminum steel stainless steel etc Sheet metal should be coated black or black anodized to minimize reflection of UV and visible light toward operators Rigid Plastic Film Transparent or translucent light blocking plastics typically polycarbonate or acrylic are commonly used to create shielding where some level of transparency is also desired Flexible Film Translucent light blocking flexible urethane films can be used to guickly 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 temp
2. The up arrow A increases the cycle exposure time in 0 1 second increments Note that holding the up arrow increases the rate of change of the digits The down arrow V decreases the cycle exposure time in 0 1 second increments 5 The output intensity can be adjusted from 1 to 100 in 196 increments using the light intensity up arrow A or down arrow V Press the Timed Manual Mode Button to place the unit in manual mode and then adjust the intensity using the Intensity Adjustment Buttons Output intensity cannot be adjusted in the timed mode Figure 10 Front Control Panel E Intensity Control Feature See Intensity Control Feature on page 8 CYCLE TIME SECONDS do Button Cycle Time wa Timed Manual Cycle Time Mode Button Adjustment Buttons Dymax BlueWave LED DX 1000 VisiCure User Guide Using Advanced and Optional Features Using the Optional Stand You can purchase an optional stand that enables convenient and efficient use of the BlueWave LED DX 1000 VisiCure on a bench top To assemble and use the stand follow these steps 1 Attach the Upright to the Stand Base Unit using the Bracket and M6 hardware supplied Figure 11 2 Attach the Irradiator Head unit to the Irradiator Head Support Arm using the two M5 x 10 mm Mounting Screws and the 3 mm hex wrench 3 Place the Stand Base Unit over the BlueWave LED DX 1000 Controller 4 Adjust the height of the Irradiator Head Support Arm us
3. ENVISION DELIVER amp DYMAX 2013 Dymax Corporation All rights reserved All trademarks in this guide except where noted are the property of or used under license by Dymax Corporation U S A Please note that most dispensing and curing system applications are unique Dymax does not warrant the fitness of the product for the intended application Any warranty applicable to the product its application and use is strictly limited to that contained in Dymax s standard Conditions of Sale Dymax recommends that any intended application be evaluated and tested by the user to 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 PN41061 MANO57 6 17 2013 Dymax Corporation Dymax Oligomers amp Coatings Dymax Europe GmbH Dymax UV Adhesives amp Dymax UV Adhesives amp Dymax Asia H K Dymax Korea LLC 860 482 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 co kr www dymax com cn www dymax com cn
4. FFF OR RR HR RO DA M UID D ni UIN GO RAF 12 Unpacking and Inspecting Your Shipment a nnns sna r LLE aiat ness s assess aane sanas 12 Parts Included in the BlueWave LED DX 1000 VisiCure Small Area LED Light Source 12 System COn iaClipgheu u T K 14 Operating the LED LIEDE Pr 15 Powering up the Controller rre u ek Yuri DEON Pran DNA VE PAS DARN Frau p ak VP SE rhv ODNA peg vEb eR PARE Pod DYNO YN PURI ON NN e ror pe AE Pes ur ANIAN bred besuis 15 Using Advanced and Optional Features 16 Using the Optional Ecos ao ERROR E 16 Osme eS RES RET ETT T T TER 17 System Cleaning RRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRREMMMMMMMMMMMMMMMMM AA 19 Error Codes and TroubleshootlHlg LLULLA E AGA SU NG N42 ARNAU WARD TNRY ANNA o PES 21 Spare Parts and AcceSs0Tie5 esu i SN NES YN ws ere 23 Option NEPBSEDEIBS u FT Lene cont ANH IYW ed estt ste EU EN tas ota RAN FFA FR HF 23 SOG eli ers Qu n a cata FF E TOO 25 Specifications r rara NFED RONYN RF FFY ERFYN EFFRO FFFYRYRN FRFWYN FFUFRYFTANYYY 25 MI ug pin EE OI 27 Dyma
5. Head Power Cable 36 91 44 cm 40583 Controller to irrddistor Head Power Cable 72 182 88 cm 40745 Controller to Irradiator Head Power Cable 120 304 80 cmi 40746 Benchtop Stand and Lightguide Adapter ACCU CAL 50 LED 2 Lens Optic 1 Work Platform Dymax BlueWave LED DX 1000 VisiCure User Guide Spare Replacement Parts Item Part Number Key System Components DX 1000 Controller 40599 DX 1000 Irradiator 40588 Fuses Fuses F2 0 amp 37236 Fan Filters Fan Filter and Holder Irradiator Head 5097 Fan Filter Media Irradiator Head 40008 Fan Filter and Holder Controller 40605 Fan Filter Media Controller 40705 Footswitch and AC Power Cords Footswitch 40402 Power Cord North American 35255 Power Cord no molded plug end 37008 Power Cord China 40542 User Manuals User Manual English 41061 Tools amp Hardware 2 mm Hex Wrench 38656 3 mm Hex Wrench 40720 4 mm Hex Wrench 40721 M5 x 8 mm Low Profile Socket Hex Screws 40578 M6 x 12 mm Hex Screws 40740 M5 x 12 mm Philips Pan Head Screws 39682 M5 x 10 mm Hex Screws 40741 Miscellaneous Silicone Pad for Benchtop Stand Base 40747 Benchtop Base Controller to Irradiator Head Power Cable Footswitch Dymax BlueWave LED DX 1000 VisiCure User Guide Specifications Specifications Property Part Numbers Flood Mode Package Spot Mode Package Lab Developer Package Intensity Output Output Frequency Power Requirements LED T
6. 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 DX 1000 VisiCure s Intensity Control Feature to allow for compensation of gradual decreases in light intensity The unit s intensity can be adjusted using the Intensity Control Feature Figure 3 on the Front Control Panel The intensity adjustment is software controlled and allows for control of output intensity The ten LED Power Level Bars correlate to 1096 increments of the total available power Pressing the up button A increases the light intensity in 1 increments Pressing the down button Y decreases the light intensity in 196 increments As the power level is adjusted the Cycle Time Display changes and displays the power level percentage Adjustment of the power setting is done while in manual mode and is not possible while running a timed exposure Dymax BlueWave LED DX 1000 VisiCure User Guide PW WE Use a Radiometer to correlate the percent power output to a reading in W cm The adjustment of power level and correlation to a light intensity value W cm enables precise control of light intensity during validation and operation Figure 3 Intensity Control Feature on the BlueWave LED DX 1000 VisiCure LED Power Level Bars Light Intensity Up Button Light Intensity Down Button Validation Tests should be cond
7. ones as specified in the Specifications Section Insert serviceable Fuses back into Fuse Tray Push the Fuse tray into the Power Receptacle Snap the Fuse Tray Cover back into the closed position Figure 16 Opening the Fuse Tray Cover left and Sliding Out the Fuse Tray right Fuse Tray Cover Fuse Tray Dymax BlueWave LED DX 1000 VisiCure User Guide Error Codes and Troubleshooting If your BlueWave LED DX 1000 VisiCure displays an error code Er01 for example you can determine the cause of the error by referring to Table 3 If your BlueWave is not responding as expected you can probably resolve the issue using the troubleshooting chart Table 4 Table 3 Error Codes Error Code Description ErO1 Power supply failure terminate current cure cycle and shut down ErO2 Fan failure in Irradiator Head Complete current cure cycle then shut down ErO3 LED Over Temp terminate current cure cycle and shut down Er04 Temp sensor open failed or unplugged terminate current cure cycle and shut down ErO5 Control box over temp terminate current cure cycle and shut down ErO6 LED over current terminate current cure cycle and shut down Er07 If Er06 occurs and current cannot be shut down alert beeper continuous to indicate unit needs to be powered down Er08 5V failure to LED Check connections and LED module Fltr Change Filter complete current cure cycle then shut down Dymax BlueWave LED DX 1000 VisiCure User Guide Tab
8. packages Base System For custom mounting and system integration mount supplied by user Flood Lamp Package Includes all parts necessary for using this system as a small area flood lamp Spot Lamp Package Includes all parts necessary for using this system as a spot lamp Lab Developer Package Includes all parts necessary for both spot and flood modes Figure 6 BlueWave LED DX 1000 VisiCure Components Dymax BlueWave LED DX 1000 VisiCure User Guide Table 1 Parts List Base System Flood Mode Spot Mode Lab Developer Package Package Package 41047 41051 41055 41048 41052 41056 H Part 41046 41049 41053 41057 1 Irradiator Head with Collimating Optic 41 v Zx yx Y 2 Controller Y v Y Y 3 Interface Cable Choice of 3 6 10 or 19 in length yx Interface Cable 19 in x x Y Interface Cable 3 in x 4 Footswitch yx v x yx 5 Power Cord yx yx yx Y 6 Filter Media Y v v Y 7 Hex Key yx yx yx yx 8 UV Protection Goggles Zx yx yx yx 9 3 PC Magnetic Flexible Shielding x yx yx yx 10 Benchtop Stand and Work Platform yx yx yx 11 Benchtop Base yx yx 12 Lightguide Adapter yx yx 13 Lightguide Mounting Stand yx yx 13 Lightguide 5 mm x 1M yx yx BlueWave LED DX 1000 VisiCure User Guide Y v yx yx Dependent on model ordered Some models do not include a power cord Dymax BlueWave LED DX 1000 VisiCure User Guide System Connections Figure 7 Installing Cables on the Back Panel of the Controller Power Cord Footswitch Jac
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10. 0096 power This activation can be either Footswitch Front Panel Button or Intensity In This is a PWM based signal to drive the LED It is a confirmation of operation for a given setting and as a relative indication of power level This Pin is active when any critical fault conditions are met and the LED operation is inhibited Dymax BlueWave LED DX 1000 VisiCure User Guide Figure 13 Pinout Diagram for 15 Pin D Subminiature Connector 24V PIN 1 COM PIN 2 PLC CONNECTOR PINOUT REAR VIEW SLEEP IN PIN 3 B 7 6 5 4 3 2 1 0000 000 0 INTERLOCK IN PIN 4 000000 0 15 14 13 12 11 10 9 ACTIVATE IN PIN 5 INTENSITY IN PWM PIN 6 LOCAL DISABLE IN PIN 7 POWER ON PIN 8 LAMP LIT OUT PIN 9 INTENSITY OUT PWM PIN 10 FAULT OUT PIN 11 A OUT PIN 12 B OUT PIN 13 C OUT PIN 14 D OUT PIN 15 42 1 i J2 2 J2 3 J2 4 J2 5 l gt es gt gt ET es l gt Dymax BlueWave LED DX 1000 VisiCure User Guide Cleaning and Maintenance System Cleaning Optic Lens Based on the cleanliness of your operating environment establish a schedule for cleaning the LED Light Source Lens When cleaning is reguired shut the unit down and allow it to cool Then clean the Lens surface Figure 14 with a clean lint free cloth and isopropyl alcohol Figure 14 Lens Assembly Lens Surface Replace Cooling Fan Filters One Cooling Fan Filter is located on the Irradiato
11. Dymax BlueWave LED DX 1000 VisiCure User Guide Small Area LED Light Source Instructions for Safe Use m Setup and Operation Maintenance m Ordering Spare Parts and Accessories NS 4uUe N ROF Vv Dymax BlueWave LED DX 1000 VisiCure User Guide About Dymax UV Visible light curable adhesives Systems for light curing fluid dispensing and fluid packaging Dymax manufactures industrial adhesives light curable adhesives epoxy resins cyanoacrylates and activator cured adhesives We also manufacture a complete line of manual fluid dispensing systems automatic fluid dispensing systems and light curing systems Light curing systems include LED light sources spot flood and conveyor systems designed for compatibility and high performance with Dymax adhesives Dymax adhesives and light curing systems optimize the speed of automated assembly allow for 10096 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 unigue 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 criter
12. a cure cycle duration gt 20 min the unit will terminate the current cure cycle and go into sleep mode Allows operation of the unit in the PLC mode only if this signal is present If a safety switch is used then a failure mode in the switch or cables will terminate the operation of the unit This Pin will work as the Run or Footswitch activation at the current intensity level will be used for simple remote control of the unit when there is no desire to vary intensity and place the unit in manual mode The PLC will dictate cycle duration The Cycle Time Display will indicate all dashes When this signal is terminated the unit will remain in manual mode This is a PWM input used to set the LED intensity and describe a running set point This input will work in conjunction with the Activate Input to enable operation The PWM base freguency shall be 1 KHz The duty cycle will dictate relative intensity When this Pin is asserted the Footswitch and Run triggers will still be operational but the Front Panel Controls will be locked out from the user Activation can be accomplished but no adjustment to the mode of operation set point of the LED intensity or the timer setting will be possible This will also prevent the ability to check system or LED operation hours Asserted when the unit has correct AC voltage supplied and the internal supplies are within limits Asserted when the LED is actively powered regardless of set point 0 1
13. described below WARNINGS Looking directly at the high intensity light emitted by the BlueWave LED DX 1000 VisiCure can result in eye injury To prevent eye injury never look directly at the high intensity light and always wear protective goggles provided Operating the light with the Lens Cover in place can result in overheating and equipment damage To prevent equipment damage never operate the unit with the Lens Cover in place Removing the cover from the BlueWave LED DX 1000 Controller can result in electrical shock To prevent electrical shock never remove the cover from the DX 1000 Controller If you block the air flow from the LED Irradiator Head or Controller Cooling Fans equipment damage and malfunction can result To prevent damage and malfunction ensure there is adequate space at the Cooling Fan Outlets to allow the free flow of air 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 Standard Dymax VisiCure systems have been designed to primarily emit visible light as shown in Figure 1 Although OSHA does not currently regulate visible or ultraviolet light exposure in the workplace the American Conference of Governmental Industrial Hygienists ACGIH does recommend Threshold Limit Values TLV s for ultraviolet light The strictes
14. erature rise in each application Dymax BlueWave LED DX 1000 VisiCure User Guide Bright Visible Light The bright visible light energy emitted by curing systems can cause eye strain if proper eye protection or shielding is not used The proper use of tinted eye protection and or opague tinted shielding can be utilized to reduce eye strain and address this concern Product Overview Description of the BlueWave LED DX 1000 VisiCure The BlueWave LED DX 1000 VisiCure is a high intensity light curing system used for curing adhesives coatings and potting materials You can mount and integrate the unit into automated manufacturing systems or using the optional stand conveniently mount and use the unit on a bench top The BlueWave LED DX 1000 VisiCure consists of two main components a Controller that contains the User Interface and Power Supply and an LED Irradiator Head A cable connects the two components Figure 2 The unit can be operated in timed or manual modes The output intensity level can be adjusted from O to 10096 to meet process and adhesive reguirements The BlueWave LED DX 1000 VisiCure is rated for continuous operation Fans in the Controller and Irradiator Head provide cooling and must not be covered or blocked Fan Filters must be maintained regularly to ensure reliable operation Thermal Sensors in the Controller and Irradiator Head shut the unit down to protect the components if the internal temperature exceeds max
15. ia are satisfied Dymax is willing to assist users in their performance testing and evaluation by offering eguipment 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 DX 1000 VisiCure User Guide Contents mH Odu Uon u Y EN ON EN GA t 4 introduction to the User Guide Y FO RYW GA Y WE YNAD 4 MTS L LTiA uu HF ae HR FA FI WU A AR NA EA EWE A Y EF FR 4 clin Me TT 4 Specillc Salety Copsiderarioh uu uuu YG in AY CY OG V Ta NAG EN COFGOLOFN OVV RFT DTE ERE CE UTE REN REIS 5 Dymax Light Curing System Safety Considerations n ness a HL LLEN Y nns 5 acie p Wa CYR 7 Description of the BlueWave LED DX 1000 VisiCure nnne nennen nnne nennen nnns 7 Special Features and Benefits of the BlueWave LED DX 1000 VisiCure System 8 intensity COLL OFF SEU Cm GREDU ARFOG IST NAD DAC GU GNAU CEP SI ONE EI KIT RISE GANAF PI I UN GAN UIT EDI LESE I UTI EGE 8 NU LL z ell ETT Torr 9 Font eo aun go iU Panel OIN 10 Back Panel FF FC NR FRAN TYNU YA AE RF NEN EFA YFC FAN FA NF FC 11 Assembly and SetuP
16. imer LED Activation Cooling Hour Meter Controller Dimensions W x D x H Irradiator Head Dimensions W x D x H Interface Cable Length standard I O Port Weight Unit Warranty Operating Environment Sound Level Recommended Accessories ACE Specification 41046 Basic System Power cord type and interface cable length selected separately 41047 No Power Cord 41048 Asian Version Type G power cord 41049 North American Version power cord with 120V plug 41051 No Power Cord 41052 Asian Version Type G power cord 41053 North American Version power cord with 120V plug 41055 No Power Cord 41056 Asian Version Type G power cord 41057 North American Version power cord with 120V plug 1 2 W cm at 1 2 54 cm as measured with an ACCU CAL 50 LED in flood mode See Figure 17 for further intensity information 405 nm see Figure 16 below 100 240 V 47 63 Hz auto ranging 0 1 to 999 9 seconds Footswitch Front Panel or PLC Forced air filtered fan Unit operation and exposure non resettable 6 5 x 9 0 x 2 25 16 51 cm x 22 86 cm x 5 72 cm 4 0 x 5 0 x 4 5 10 16 cm x 12 70 cm x 11 43 cm 19 48 26 cm custom lengths available 15 Pin D Sub Controller 1 5 lbs 0 68 kg Head 3 0 Ibs 1 36 kg 1 year from purchase date 5 40 C non condensing 65 decibels 12 30 48 cm distance at full power 40505 ACCU CAL 50 LED Radiometer For European customers the appropriate power co
17. imum limits Figure 2 Main Components of a BlueWave LED DX 1000 VisiCure lt Optional Stand with Mounting Post ordered separately LED Irradiator Head Light Source with Lens Cover Interface Cable Controller Oa Dymax BlueWave LED DX 1000 VisiCure User Guide Special Features and Benefits of the BlueWave LED DX 1000 VisiCure System The Dymax BlueWave LED DX 1000 VisiCure is engineered for precise performance and long service life Key features include Feature Curingareaupto1 x1 5 2 54 cm x 3 81 cm Flexible mounting options 10096 duty cycle capability No mechanical shutter Intensity output adjustment 1to 10096 405 nm LED Co optimized to cure with Dymax formulations Multiple energy delivery configurations Stable LED temperature LED Benefit 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 High photo initiator sensitivity Compatibility with many formulations Fewer re qualifications Direct emission Lightguide Multi lens optical stacks Optimizes cure time efficiency Increases LED life Superior LED cooling for consistent frequency output Longer LED life via reduced intensity degradation Intensity Control Feature The components used
18. ing light for the length of time displayed in the Cycle Time Display A second press will stop the cure cycle immediately In manual operation pressing and holding the Run Stop Button illuminates the curing light until the button is released The curing light illuminates until the cycle time is reached Timed Manual Button Pressing this button toggles between manual and automatic operation In timed operation pressing the Run Stop Button illuminates the curing light for the length of time displayed in the Cycle Time Display In manual operation the Cycle Time Display changes to a series of dashes and the curing light remains illuminated as long as the Run Stop Button is depressed Cycle Time Display This LED display indicates the current cycle time It also displays the light intensity percentage when light intensity is adjusted It also will display error codes if an operating error occurs Cycle Time Adjustment Buttons Pressing these buttons increases or decreases the cycle time Hold the button in to increase the speed at which the value changes Intensity Control Feature Enables manual control of the light intensity see ntensity Control Feature on page 8 Pressing the or button momentarily will change the display to show the current setting in 96 holding the button will increase or decrease the setting and the display will show the set level as it is adjusted Operating Time Log unit operation and exposure hour
19. ing the locking Height Adjustment handle on the Irradiator Head Support Arm Figure 12 Figure 11 Assembling the Optional Stand Back View Upright Bracket and M6 Screws Stand Base Unit Figure 12 Assembling the Optional Stand Upright Irradiator Head Support Arm Attachment Point for Irradiator Head Height Adjustment Handle Work Pad Stand Base Unit Using the PLC Interface Dymax BlueWave LED DX 1000 VisiCure User Guide The BlueWave LED DX 1000 VisiCure includes a 15 Pin D Subminiature Connector for communication with a PLC or similar process control eguipment The connector provides for input and output signals Table 2 Pinouts for 15 Pin D Subminiature Connector on BlueWave LED DX 1000 VisiCure Pin Number 10 11 12 13 14 15 Name 24V input Power supply and signal common Sleep input Interlock input Activate input Intensity input Local disable input Power on output Lamp lit output Intensity output Fault output Not used Not used Not used Not used Description If this input is not present ignore all PLC inputs and allow the outputs to run as usual Return for all signals on the on the PLC With 24V applied disables all functions on the Front Panel Footswitch and PLC Inputs Shuts down the Fan completely after cooling the LED Disables the LED Displays except for the Scrolling Display Panel to indicate sleep mode If this signal is initiated during
20. k and Connection Irradiator Head Interconnect Cable Figure 8 Attaching the Irradiator Head to the Optional Stand Irradiator Head Irradiator Head Support Arm Included with Optional Stand Irradiator Head Cable Connection Point Dymax BlueWave LED DX 1000 VisiCure User Guide Operating the LED Light WARNINGS Looking directly at the high intensity light emitted by the BlueWave LED DX 1000 VisiCure can result in eye injury To prevent eye injury never look directly at the high intensity light and always wear protective goggles provided Operating the light with the lens cover in place can result in overheating and eguipment damage To prevent eguipment damage never operate the unit with the lens cover in place Powering up the Controller Follow these steps to operate the BlueWave LED DX 1000 VisiCure system 1 Move the Power Switch on the Back Panel of the Controller to the On I position The Power Supply and Timer are now operational 2 Activate an exposure cycle by pressing the Footswitch or the Run Button on the Controller Front Panel Figure 10 3 In manual mode all timer digits will be dashes the exposure time is controlled directly from the Footswitch In timed mode operation is determined by the setting displayed on the Cycle Time Display 4 To adjust the exposure time push the Cycle Time Adjustment Buttons Figure 10 to enter the desired number of seconds the LED needs to be powered
21. le 4 Troubleshooting Chart for BlueWave LED DX 1000 VisiCure Problem BlueWave LED DX 1000 VisiCure does not power up BlueWave LED DX 1000 VisiCure powers up but LED does not produce light BlueWave LED DX 1000 VisiCure is operating normally and LED suddenly stops producing light LED light source provides only low intensity light Footswitch does not function Unit appears to run hot Possible Cause Power Cord not plugged in or damaged Onboard Fuse blown No electrical power at Receptacle LED intensity adjustment set to minimum Lens Cover is still in place Interface Cable connections loose or damaged Over temperature shutdown was triggered LED intensity adjustment set to minimum Contaminated dirty Lens optics Footswitch not connected Footswitch defective Cooling Fan Filter is dirty or blocked Insufficient clearance around the Controller Fan not operating Controller is contaminated with dust or debris Corrective Action Check Power Connection and condition Check Onboard Fuse Test Receptacle for power Increase LED intensity setting Remove Lens Cover Clean Output Window if necessary Check connections and condition of Interface Cable Check that the flow of cooling air into the Controller or Irradiator Head unit is not restricted Check that the Filter is clean If the LED does not illuminate after restarting contact Dymax Applications Engineering Increase LED inte
22. ly and Setup 12 Back Panel Controls 11 Cable Connections 14 Cleaning and Maintenance 19 Cleaning the Lens 19 Curing System Safety 5 Error Codes and Troubleshooting 21 Fan Filters 19 Features and Benefits 8 Filter Cleaning 19 Filter Replacement 19 Front Panel Controls 10 Fuse Replacement 20 Fuses 20 Help 4 Intensity Control Feature 8 Lens Cleaning 19 Maintenance 19 Operation 15 Optional Eguipment 23 PLC Interface 17 Powering up the Controller 15 Product Overview 7 Safety of UV Light Bright Visible Light 7 High Temperature Surfaces 6 UV Exposure 5 Spare Parts and Accessories 23 Specifications 25 Stand 16 Support 4 System Connections 14 Technical Description of BlueWave System 7 Troubleshooting 22 Using Advanced and Optional Features 16 Using the Optional Stand 16 Using the System 15 UV Exposure 5 UV Light Shielding 6 Validation 9 Warranty 27 In addition to our light curing eguipment Dymax also offers high performance oligomers adhesives and coatings DYMAX E as well as a variety of dispensing eguipment Our products are perfectly matched to work seamlessly with each EDG other providing design engineers with tools to dramatically improve manufacturing efficiency and reduce costs Dymax is committed to providing the best chemistry curing equipment and dispensing systems that offer customers complete manufacturing solutions for their challenging applications LISTEN
23. nsity setting Clean the surface of the Lens Connect Footswitch Activate unit using the Front Control Panel Replace the Footswitch if the unit operates from the Front Control Panel Replace Cooling Fan Filters Remove items that are blocking Filter and Air Inlet Ensure 1 2 54 cm inch of clearance is provided around the Controller and at least 6 15 24 cm inches of clearance are provided around the Cooling Fan Inlets Ensure Fan is operating Contact Dymax Applications Engineering Contact Dymax Applications Engineering Dymax BlueWave LED DX 1000 VisiCure User Guide Spare Parts and Accessories Options Accessories Item Part Number Personal Protection Eguipment Protective Goggles Green 35286 Protective Goggles Gray standard model included with unit 35285 Face Shield 35186 Flexible Amber Shielding with Magnetic Attachment Strip l 40719 Radiometer Dymax ACCU CAL 50 LED Radiometer spot 40505 Dymax ACCU CAL 50 LED Radiometer flood 40519 Stands Benchtop Stand and Work Platform Benchtop mini flood mode 40725 Benchtop Base and Lightguide Adapter 40755 Lenses amp Adapters 2 Lens Optic 1 40581 Lightguide Adapter 40743 Lightguides Liguid D Lightguide 5 mm x 1M 5720 Liguid D Lightguide 5 mm x 1 5 M 5721 Liquid D Two Pole Lightguide 3 mm x 1 M 38476 LED Interconnect Cable Assembly Controller to Irradiator Head Power Cable 19 48 26 cm 40744 Controller to Irradiator
24. r Head and one is located on the Controller The procedure for cleaning or replacing the Cooling Fan Filter is similar on both components One procedure is provided below Based on the cleanliness of your operating environment establish a schedule for cleaning the Cooling Fan Filter When the Cooling Fan Filter shows signs of wear from cleaning and use replace it with one of the spare Filters provided with your unit Follow these steps to wash or replace the Cooling Fan Filter 1 Unplug the unit Remove the Filter Cover by lifting it from the Irradiator Head Figure 15 Remove the Foam Filter from the Filter Cover If the Foam Filter is serviceable wash it with water and a mild detergent Allow it to dry If the Foam Filter is not serviceable replace the Foam Filter with a new one supplied with your unit Install a Foam Filter in the Filter Cover Install the Filter Cover on the Fan Dymax BlueWave LED DX 1000 VisiCure User Guide Figure 15 Cooling Fan Filter Replacement Fan Filter Cover Foam Fan Filter Cooling Fan Inspect and Replace Fuses The Controller uses two Fuses held in a Fuse Holder Follow these steps to inspect and replace the Fuses if indicated as a corrective action based on troubleshooting 1 Unplug the unit Remove the Fuse Tray Cover using a small screwdriver Figure 16 Slide out the Fuse Tray using a small screwdriver Remove and inspect the Fuses Replace blown Fuses with new
25. rd is added Dymax BlueWave LED DX 1000 VisiCure User Guide Figure 17 BlueWave LED DX 1000 Intensity by Distance and Delivery Mode Intensity mW cm 1400 Intensity by Distance and Delivery Mode 1200 1000 800 Inches Away 0 Beam Spread Inches Away 1 Inches Spot 2 Inches Spot 600 400 3 Inches Spot 1 Inches Flood 2 Inches Flood 200 3 Inches Flood 0 3 0 3 Beam Spread Inches Figure 18 BlueWave LED DX 1000 Spectral Output Intensity counts 3000 2000 1000 300 500 6010 Foo Wavelength nm 600 Warranty Dymax BlueWave LED DX 1000 VisiCure 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 eguipment 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 eguipment IMPORTANT NOTE DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES EXPRESSED OR IMPLIED DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON DYMAX EOUIPMENT WITHOUT WRITTEN AUTHORIZATION FROM DYMAX THOSE CORRECTIVE ACTIONS LISTED ABOVE ARE LIMITED TO THIS AUTHORIZATION Index Assemb
26. s non re settable This display is only visible when both the and time buttons are pressed and held simultaneously for 5 seconds The display will indicate in hours the accumulated run time of the LED first and then the Controller second Figure 4 Front Control Panel Run Stop Button Timed Manual Cycle Time amp Cycle Time Intensity Control Button Digital Intensity Adjustment Feature See Intensity Display Buttons Control Feature on page 8 Dymax BlueWave LED DX 1000 VisiCure User Guide Back Panel The Back Panel Figure 5 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 Controller Moving the switch to the O off position cuts power to the Controller Cooling Air Intake Cooling air enters the Rear Intake which includes a replaceable Filter NOTE The exhaust vents located on the side of the enclosure must not be blocked or the unit may overheat and shutdown Footswitch Jack Connection point for the Footswitch Pressing the Footswitch starts a curing cycle In timed operation pressing and releasing the Footswitch illuminates the Curing Light 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 Footswitch illuminates the Curing Light until the Foot
27. switch is released PLC Connector Connection point for a user supplied cable to connect the unit to a PLC for remote operation Connection is a standard 15 Pin D Style Connector Refer to page 19 for details on the connections to this port Irradiator Head Cable Connector Connection point for the Power Cable connecting the Controller to the Irradiator Head Figure 5 Back Panel Controls and Connections TO LAMP HEAD I O PORT Power Cord Receptacle Irradiator Head I O Switch Cable Connector On Off Power Footswitch Jack PLC Connector Dymax BlueWave LED DX 1000 VisiCure User Guide Assembly and Setup Unpacking and Inspecting Your Shipment When your BlueWave LED DX 1000 VisiCure arrives inspect any boxes for damage and notify the shipper of box damage immediately Open each box and check for eguipment 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 DX 1000 VisiCure Small Area LED Light Source The BlueWave LED DX 1000 VisiCure is available in four
28. t interpretation of the TLV over the UVA range for workers eyes and skin is 1 mW cm intensity continuous exposure Unless workers are placing bare hands into the curing area it is unusual to exceed these limits To put the 1 mW cm limit into perspective cloudless summer days in Connecticut regularly exceed 3 mW cm of UVA light which includes the more dangerous UVB light primarily responsible for sun tans sun burns and skin cancer MENTRE Dymax BlueWave LED DX 1000 VisiCure User Guide Figure 1 Light Spectrum Portion of the spectrum that DYMAX primarily emits dat Germicidal Sunburns M 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 660 660 700 Wavelength nm 2 001 nm 1 am 1000 nir 1mm 1m 1 km Wavelength nm Checking the Workstation A radiometer should be used to measure stray light to confirm the safety of a visible light curing process A workstation that continuously exposes an operator to more than 1 mW cm of UVA light should be redesigned Protecting Operators Light curing technology can be a regulatory compliant worker friendly manufacturing process when the proper safety eguipment 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
29. ucted 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 light intensity changes and take corrective action either adjusting the light intensity or performing maintenance Dymax BlueWave LED DX 1000 VisiCure User Guide Front Control Panel In addition to the Light Intensity Control Feature the Front Control Panel Figure 4 includes Run Stop Button Pressing this button starts a curing cycle In timed operation pressing and releasing the Run Stop Button illuminates the cur
30. visible light A WARNING Always observe safety requirements AN CAUTION Risk of electrical shock if cover is removed To use a BlueWave LED VisiCure system safely it must be set up and operated in accordance with the instructions given by Dymax Using the system in any other manner will impair the protection of the system Dymax assumes no liability for any changes that may impair the protection of the BlueWave LED VisiCure system Safety Recommendations m Use the goggles provided or an approved face shield for eye face protection Dymax BlueWave LED DX 1000 VisiCure User Guide m Long sleeved shirts or a lab coat are recommended for arm protection The use of opaque gloves will protect the hands NOTE The BlueWave LED VisiCure emits high intensity light Never look directly at the light emitting end of the lightguide while the unit power is on 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 reguested through the Dymax website Specific Safety Considerations The BlueWave LED DX 1000 VisiCure 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 unigue to LED curing systems as
31. x BlueWave LED DX 1000 VisiCure User Guide Introduction Introduction to the User Guide This guide describes how to assemble use and maintain the Dymax BlueWave LED DX 1000 VisiCure Small Area LED Light Source 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 Before continuing with the installation please read the following chapters of this manual for safety recommendations and installation operation and troubleshooting instructions A CAUTION Always wear protective goggles or face shield when working near the front of the unit which emits high intensity

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