BlueWave LED DX-1000 User Guide
Contents
1. 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 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 frequency shall be 1 KHz The duty cycle will dictate relat2. 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 2 Remove the Fuse Tray Cover using a small screwdriver Figure 16 3 Slide out the Fuse Tray using a small screwdriver 4 Remove and inspect the Fuses 5 Replace blown Fuses with new ones as specified in the Specifications Section 6 Insert serviceable Fuses back into Fuse Tray 7 Push the Fuse tray into the Power Receptacle 8 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 User Guide Error Codes and Troubleshooting Ifyour BlueWave LED DX 1000 displays an error code Er01 for example you can determine the cause of the error by referring to Table 2 If your BlueWave is not responding as expected you can probably resolve the issue using the troubleshooting chart Table 3 Table 2 Error Codes Error Code Er01 Er02 Er03 Er04 Er05 Er06 Er07 Er08 Fltr Description Power supply failure terminate current cure cycle and shut down Fan failure in Irradiator Head Complete current cure cycle then shut down LED Over Temp terminate
3. Wiesbaden Germany Cangsong Building Terra 6th Road Phone 49 0 611 962 7900 Futian District Shenzhen Fax 49 0 611 962 9440 China 518040 www dymax de Phone 86 755 83485759 Fax 86 755 83485760 www dymax com cn DYMAX BlueWave LED DX 1000 User Guide Safety WARNING If you use this LED light source 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 assembling and operating the DYMAX LED light source General Safety Considerations All users of DYMAX LED light sources should read and understand this user guide before assembling and using the system To learn about the safe handling and use of light curable formulations obtain and read the MSDS for each product DYMAX includes an MSDS with each adhesive sold In addition fluid product MSDS are available on our website Specific Safety Considerations The BlueWave LED DX 1000 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 LED DX 1000 can result in eye
4. ACGIH does recommend Threshold Limit Values TLVs for ultraviolet light The strictest interpretation of the TLV over the UVA range for workers eyes and skin allows continuous exposure up to 1 mW cm intensity Unless you are placing bare hands into the curing area it is unusual to exceed these limits To put 1 mW cm limit into perspective a cloudless summer day will typically exceed 3 mW cm of UVA light and also include the more dangerous UVB light primarily responsible for sun tans sun burns and skin cancer as well Figure 1 UV Spectrum Portion of the spectrum that DYMAX primarily emits Germicidal Sunburns UVC UVB K UVA s m gt 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 Wavelength nm 2 001 nm 1am 1000 nr 1mm im 1km Wavelength nm Checking the Workstation The human eye cannot detect pure UV light only visible light A radiometer should be used to measure stray UV light to confirm the safety of a UV light curing process A workstation that exposes an operator to more than 1 mW cm of UVA continuously should be redesigned DYMAX BlueWave LED DX 1000 User Guide Protecting Operators Light curing technology can be a regulatory compliant worker friendly manufacturing process when the proper safety equipment and operator training is utilized There are two ways to protect operators from UV exposure shield the
5. t DYMAX BlueWave LED DX 1000 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 required 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 Irradiator 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 2 Remove the Filter Cover by lifting it from the Irradiator Head Figure 15 3 Remove the Foam Filter from the Filter Cover 4 Ifthe Foam Filter is serviceable wash it with water and a mild detergent Allow it to dry Ifthe Foam Filter is not serviceable replace the Foam Filter with a new one supplied with your unit 5 Installa Foam Filter in the Filter Cover 6 Install the Filter Cover on the Fan DYMAX BlueWave LED DX 1000 User Guide
6. 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 User Guide Specifications Specifications Property Part Numbers Intensity Output Output Frequency Power Requirements LED Timer LED Activation Cooling Hour Meter Controller Dimensions WxDxH Irradiator Head Dimensions WxDxH Interface Cable Length standard I O Port Weight Unit Warranty Operating Environment Sound Level Recommended Accessories Specification 40560 Basic Unit Includes Irradiator Head Controller 19 Inter Connect Cable Footswitch 3 pc magnetic flexible Shielding gray safety eyewear 2 Lens Optic and User Guide 1 4 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 385 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 Ibs 0 68 kg Head 3 0 Ibs 1 36 kg 3 years from purchase date 5 40 C non condensing lt 65 decibels 12 30 48 cm distance at full power 40505 ACCU CAL 50 LED Ra
7. AUTHORIZATION Index Assembly and Setup 13 Back Panel Controls 12 Cable Connections 14 Cleaning and Maintenance 20 Cleaning the Lens 20 Contact Information 4 Curing System Safety 6 DYMAX Contact Information 4 Error Codes and Troubleshooting 22 Fan Filters 20 Features and Benefits 9 Filter Cleaning 20 Filter Replacement 20 Front Panel Controls 11 Fuse Replacement 21 Fuses 21 Help 4 Intensity Control Feature 9 Lens Cleaning 20 Maintenance 20 Operation 15 Optional Equipment 24 Parts Included 13 DYMAX BlueWave LED DX 1000 User Guide PLC Interface 18 Powering up the Controller 15 Product Overview 8 Safety 5 Safety of UV Light Bright Visible Light 7 High Temperature Surfaces 7 UV Exposure 6 Spare Parts and Accessories 24 Specifications 26 Stand 16 Support 4 System Connections 14 Technical Description of BlueWave System 8 Technical Support 4 Troubleshooting 23 Using Advanced and Optional Features 16 Using the Optional Stand 16 Using the System 15 UV Exposure 6 UV Light Shielding 7 Validation 10 Warranty 28 2011 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 applica
8. D DX 1000 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 curing 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 m 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 m 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 m Intensity Control Feature Enables manual control of the light intensity see Intensi
9. DYMAX BlueWave LED DX 1000 User Guide Small Area LED Light Source Instructions for Safe Use Setup and Operation Maintenance Ordering Spare Parts and Accessories DYMAX BlueWave LED DX 1000 User Guide About DYMAX UV Visible light curable adhesives Systems for light curing fluid dispensing and fluid packaging DYMAX manufactures industrial adhesives light curable adhesives epoxy resins cyanoacrylates and activator cured adhesives We also manufacture a complete line of manual fluid dispensing systems automatic fluid dispensing systems and light curing systems Light curing systems include LED light sources spot flood and conveyor systems designed for compatibility and high performance with DYMAX adhesives DYMAX adhesives and light curing systems optimize the speed of automated assembly allow for 100 in line inspection and increase throughput System designs enable stand alone configuration or integration into your existing assembly line Please note that most dispensing and curing system applications are unique DYMAX does not warrant the fitness of the product for the intended application Any warranty applicable to the product its application and use is strictly limited to that contained in the DYMAX standard Conditions of Sale DYMAX recommends that any intended application be evaluated and tested by the user to insure that desired performance criteria are satisfied DYMAX is willing to assist users in the
10. 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 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 Y decreases the cycle exposure time in 0 1 second increments 5 The output intensity can be adjusted from 1 to 100 in 1 increments using the light intensity up arrow A or down arrow Y 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 Intensity Control Feature See Intensity Control Feature on page 9 z CYCLE TIME SECONDS Run Stop Button Cycle Time Display Timed Manual Cycle Time Mode Button Adjustment Buttons DYMAX BlueWave LED DX 1000 User Guide Using Advanced and Optional Features Using the Optional Stand You can purchase an op
11. ble to the product its application and use is strictly limited to that contained in the DYMAX standard Conditions of Sale DYMAX recommends that any intended application be evaluated and tested by the user to insure that desired performance criteria 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 MAN019 PN 40598 8 30 2011 DYMAX Corporation DYMAX Europe GmbH DYMAX UV Adhesives amp DYMAX Asia DYMAX Korea LLC 860 482 1010 49 0 611 962 7900 Equipment Shenzhen Co Ltd Hong Kong Ltd 82 2 784 3434 info dymax com info_de dymax com 86 755 83485759 852 2460 7038 info dymax kr A TYRIA X www dymax com www dymax de dymaxasia dymax com dymaxasia dymax com www dymax co kr www dymax com cn www dymax com cn
12. cceesscceceeeececsesecesseeseceeaeeeeceeeueeceesaeeeeeeeseeeseesaeeeeessaaseeeesuaseceesuaseeessuaaeceesageeseesages 18 Cleaning and Maintenance 20 sy oj IO NN ul ulna eee ne a av sw le nv eins etna vee eve la env eee ncn ev neo de 20 Error COGES and Iroubleshno00ti Ruu uuu l l u SQ aaa a Suay asawa aN 22 Spare Parts and Accessories 24 Options ACCESSOTIES sscsceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeceeeeeeeeeeeeeeceeeceeeeeeeeeeeeeceeeeeeeeeececeeeeeeeeeeeeeees 24 Spale Beplaceme i Paypuuuu l l a lli ER ETA E EAE ER ENEA E EOE ON ER EE AE EE 25 Sp cIfieati Suyu u uya EAEN 26 SPCCITICATIONS accsscseocnwassdecawansbecrinassoteawassaneamadsdesawwaneeahdseneavedeoanseedsdesawwas satambassteaewdsvenweuasdeniavdsobiwaddsseniendabiavandssaanewwseaneas 26 WY AUP Qn y cess uu Duis EEEE Aaa 28 DYMAX BlueWave LED DX 1000 User Guide Introduction Introduction to the User Guide This guide describes how to use the DYMAX BlueWave LED DX 1000 PN 40560 Small Area LED Light Source Sections in this guide describe how to assemble use and maintain the light source safely and etfficiently Intended Audience DYMAX prepared this user guide for experienced process
13. current cure cycle and shut down Temp sensor open failed or unplugged terminate current cure cycle and shut down Control box over temp terminate current cure cycle and shut down LED over current terminate current cure cycle and shut down If Er06 occurs and current cannot be shut down alert beeper continuous to indicate unit needs to be powered down 5V failure to LED Check connections and LED module Change Filter complete current cure cycle then shut down DYMAX BlueWave LED DX 1000 User Guide Table 3 Troubleshooting Chart for BlueWave LED DX 1000 Problem BlueWave LED DX 1000 does not power up BlueWave LED DX 1000 powers up but LED does not produce light BlueWave LED DX 1000 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 C
14. diometer DYMAX BlueWave LED DX 1000 User Guide Figure 17 BlueWave LED DX 1000 Intensity by Distance and Delivery Mode Intensity mW cm2 1600 1400 1200 1000 800 600 400 200 0 Beam Spread f Distance o Target 0 50 0 25 0 00 0 25 Cure Width Inches _ Distance from Target 0 5 Lightguide 5mm 1 Direct Flood 2 Direct Flood 3 Direct Flood x 1 Lightguide 5mm 2 Lightguide Smm Figure 18 BlueWave LED DX 1000 Spectral Output Relative Intensity 0 30 0 25 0 20 0 15 4 0 10 4 0 05 4 0 00 300 320 340 360 380 400 Wavelength nm 420 440 460 480 500 DYMAX BlueWave LED DX 1000 User Guide Warranty From date of purchase DYMAX Corporation offers a three 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 equipment may void your warranty benefits The use of aftermarket replacement parts not supplied or approved by DYMAX Corporation will void any effective warranties and may result in damage to the equipment IMPORTANT NOTE DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANIIES 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
15. eWave LED DX 1000 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 maximum limits Figure 2 Main Components of a BlueWave LED DX 1000 LED Irradiator Head Light Source with Lens Cover Interface Cable Optional Stand with Mounting Post ordered separately Controller DYMAX BlueWave LED DX 1000 User Guide FPW aaa Special Features and Benefits of the BlueWave LED DX 1000 System The DYMAX BlueWave LED DX 1000 is engineered for precise performance and long service life Key features include Feature Curing area up to 1 x 1 5 2 54 cm x 3 81 cm Flexible mounting options 100 duty cycle capability No mechanical shutter Intensity output adjustment 1 to 100 385 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 Compatib
16. engineers technicians and manufacturing personnel If you are new to high intensity LED light sources and do not understand the instructions contact DYMAX Applications 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 Applications Engineering teams available by phone and email DYMAX adhesive product data sheets on our website a Material safety data sheets MSDS sheets provided with shipments of DYMAX adhesives DYMAX Contact Information You can contact DYMAX Customer Support and Applications Engineering in the United States Monday through Friday from 8 00 a m to 5 00 p m Eastern Standard Time You can also email DYMAX at info dymax com DYMAX Global Locations DYMAX Corporation DYMAX Asia H K Ltd DYMAX Korea LLC 318 Industrial Lane Flat B 9 F Yeung Yiu Chung No 8 903 CCMM B D Torrington CT 06790 USA Ind Bldg No 20 Wang Hoi Road 12 Yeoido Dong Phone 860 482 1010 Kowloon Bay Kowloon Hong Kong Youngdung Po Gu Fax 860 496 0608 Phone 852 2460 7038 Seoul Korea 150 869 www dymax com Fax 852 2460 7017 Phone 82 2 784 3434 www dymax com cn Fax 82 2 784 5775 www dymax co kr DYMAX Europe GmbH DYMAX UV Adhesives amp Kasteler Strasse 45 Equipment S Z Co Ltd Building G 359 65203 Room 617 amp 618 South Tower
17. ility with many formulations Fewer requalifications 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 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 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 10 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 1 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 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
18. 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 UU DYMAx Bluewave LED DX 1000 User Guide DYMAX UV Light Curing System Safety Considerations Operators must understand these three concepts to use the LED light source safely m UV exposure a High temperature surfaces a Bright visible light Each is described below UV Exposure Standard DYMAX UV light curing systems have been designed primarily to emit UVA energy Figure 1 The energy emitted from the DYMAX BlueWave LED DX 1000 system is in the upper end of the UV portion of the spectrum UVA energy is generally considered the safest of the three UV ranges UVA UVB and UVC Although OSHA does not currently regulate UV light exposure in the workplace the American Conference of Governmental Industrial Hygienists
19. ir 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 DX 1000 User Guide Contents BEACON a u oe sing wives eu we eae seeps sive viv nc ais veins E A E A A A N 4 introduction to the User GUJE ercer erii EE EEEREN EEEE EEE EEEE IEEE EAEE 4 Who s L P u E E u a a 2 unu z Zn 4 DYMAX Contact InforiWati a IIIa siqa aqusaakawasaqakaqqawqakawau sqan asqa qa NEANS EE EENEN SR EN ARSE 4 SANS OY un nus S SD nA SS sn Nn nun ss SA ss sS 5 General Safety Considerations a U Ta aaaaaas sasa ssssasasssssasasssasaskaasssssasisssasksssass asas sssasss S aen esaa 5 Specie Sarely CoOnsIderatiosu u uuu ei Eae ea A aAA ai aar ESAE RENSE aai 5 DYMAX UV Light Curing System Safety Considerations r 6 Prodnct COVE ON uuu u E n scan come valve nan n nn anon h 8 Description of the BlueWave LED DX 1000 rr rrrrssssssrrrssssssrrssssssssrsssssssssrrsssssssssssss 8 Special Features and Benefits of the BlueWave LED DX 1000 System rr rr rrrssssssssa 9 intensity Control Feature uuu R a u aS E ii AEA awe savasdausaatbeacsdlaucdcectabenxcoreiuccas 9 Validation ara ar rrr
20. ive 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 0 100 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 User Guide Figure 13 Pinout Diagram for 15 Pin D Subminiature Connector 24V PINT I gt COMPIN2 PLC CONNECTOR PINOUT REAR VIEW SLEEPINPIN3 10K 8 7 6 5 4 3 2 1 00000000 INTERLOCK IN PIN4 w z v 15 14 13 12 11 10 9 ACTIVATE IN PINS I fi INTENSITY IN PWM PING An LOCAL DISABLE IN PIN7 ww po POWER ON PIN8 pE LAMP LIT OUT PIN9 I pE INTENSITY OUT PWM PIN 10 Ie pE FAULT OUT PIN 11 e AOUTPIN12 JE B OUT PIN 13 b met C OUT PIN 14 t DOUTPIN15 l
21. operator and or shield the source Shield the Operator UV Blocking Eye Protection UV blocking eye protection is recommended when operating UV light curing systems Both clear and tinted UV blocking eye protection is available from DYMAX UV Blocking Skin Protection Where the potential exists for UV exposure upon skin opaque UV blocking clothing gloves and full face shields are recommended Shield the Source of UV Any substrate that blocks UV light can be used as a shield to protect workers from stray UV light The following materials can be used to create simple shielding structures Rigid Plastic Film Transparent or translucent UV blocking plastics typically polycarbonate or acrylic are commonly used to create shielding where some level of transparency is also desired Flexible Film Translucent UV blocking flexible urethane films can be used to quickly create workstation shielding This UV blocking flexible urethane film is available from DYMAX call for assistance NOTE The BlueWave LED DX 1000 includes UV blocking flexible film that is affixed with a magnetic strip that can be used to attach it to the LED Head and trimmed to suit your application 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
22. ork Platform Benchtop mini flood mode 40725 Benchtop Base and Lightguide Adapter 40755 Lenses amp Adapters 2 Lens Optic 1 40581 Lightguide Adapter 40743 Lightguides Liquid D Lightguide 5 mm x1 M 5720 Liquid 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 Head Power Cable 36 91 44 cm 40583 Controller to Irradiator Head Power Cable 72 182 88 cm 40745 Controller to Irradiator Head Power Cable 120 304 80 cm 40746 Benchtop Stand and Lightguide Adapter ACCU CAL 50 LED 2 Lens Optic 1 Work Platform DYMAX BlueWave LED DX 1000 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 40598 Tools amp Hardware 2 mm Hex Wrench 38656 3 mm Hex Wrench 40720 4 mm Hex Wrench 40721 M5 x 8 mm Lov Profile Socket Hex Screws 40578 M6 x 12 mm Hex Screws 40740 M5 x 12 mm Philips Pan Head Screws 39682 M5
23. orrective 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 intensity 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 User Guide Spare Parts and Accessories Options Accessories Item Part Number Personal Protection Equipment Protective Goggles Green 35286 Protective Goggles Gray standard model included with unit 35285 Face Shield 35186 Flexible Amber Shielding with Magnetic Attachment Strip 40719 Radiometer DYMAX ACCU CAL 50 LED Radiometer spot 40505 Stands Benchtop Stand and W
24. pport to resolve the problem Parts Included in the BlueWave LED DX 1000 Small Area LED Light Source a Irradiator Head 1 a Control Enclosure 2 m Interface Cable 3 Footswitch 4 Power Cord 5 a Filter Media 6 amp 7 m Hex Key 8 a UV Protection Goggles 9 m Using DYMAX BlueWave LED DX 1000 User Guide Figure 6 BlueWave LED DX 1000 PN 40560 Components DYMAX BlueWave LED DX 1000 User Guide System Connections Figure 7 Installing Cables on the Back Panel of the Controller Power Cord Footswitch Jack 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 User Guide Operating the LED Light WARNINGS Looking directly at the high intensity light emitted by the BlueWave LED DX 1000 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 Powering up the Controller Follow these steps to operate the BlueWave LED Dx 1000 system 1 Move the Power Switch on the Back Panel of the Controller to the On I position
25. precise control of light intensity during validation and operation DYMAX BlueWave LED DX 1000 User Guide Figure 3 Intensity Control Feature on the BlueWave LED DX 1000 LED Power Level Bars Light Intensity Up Button Light Intensity Down Button 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 insure 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 LE
26. 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 used The proper use of tinted eye protection and or opaque tinted shielding can be utilized to reduce eye strain and address this concern UU DYMAx Bluewave LED DX 1000 User Guide Product Overview Description of the BlueWave LED DX 1000 The BlueWave LED DX 1000 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 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 0 to 100 to meet process and adhesive requirements The Blu
27. ring 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 Footswitch 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 1 0 PORT Irradiator Head Power Cord Cable Connector PLC Connector Receptacle I O Switch Footswitch Jack On Off Power DYMAX BlueWave LED DX 1000 User Guide Assembly and Setup Unpacking and Inspecting Your Shipment Your BlueWave LED DX 1000 arrived in one or two boxes Inspect the boxes for damage and notify the shipper of box damage immediately Open each box and check for equipment damage If parts are damaged notify the shipper and submit a claim for the damaged parts Contact DYMAX so that new parts can be shipped to you immediately Check that the parts included in your order match those listed below If parts are missing contact your local DYMAX representative or DYMAX Customer Su
28. sssrrssssrrsssssrsssssrsssssrsssssrsssssssssssrrssssrsssssrrsssssrsssssrsssssrsssssrsssssrsssssissss 10 I I OH COT ECON NO cas aie uuu aE E E E EEEN AE T AARE 11 Back Panel iccancsosnsincsrinsaiatudavessuyeasadntedanessuysaxaiodsdaxscntvbansiedesasrasuysussintedesnussinsseiadenoavssnyounuiabedenusdvbauuiabedpaesanneinaiateteuencs poised 12 Assembly ANG SCCUD vcccecccececacesstacacacscccscncrecsscassencesscennsdcesseanuatecexsennensedecvtaenessecanesiceeueanacveseacentsusendeeseeeceeaGanests 13 Unpacking and Inspecting Your Shipment a rr rnnrrrsssrrsssssssssssssss 13 Parts Included in the BlueWave LED DX 1000 Small Area LED Light Source 13 SES Rel EES 10 avai I A E uuu 5 unn rer rr re 14 Operating the LED Light J uu aasuasasuqssaskusaswasaasqapaskanaspaspayqaskapassapasqausqassakusqasssssusasyskaswsasyaasskaysassyasssasapaqs 15 Powering up the Controller ssossnneoseennessennssseesssseersssreressrrressrrressreressreressrrresssrressserressereessreressrtresseeressreresseeressneresseerene 15 Using Advanced and Optional Features 16 Using the Optional SISRBQR 2 u L ua u a uasawkakiqusskayasawkukakuaykukaqkaykapaposskakyakaykupqqunapakaqsuykupuqpawkukkasawkskuqoschayqozykupazanika 16 Using the PLC Interface ccccccccsssscc
29. tional stand that enables convenient and efficient use of the BlueWave LED DX 1000 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 using 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 DYMAX BlueWave LED DX 1000 User Guide Figure 12 Assembling the Optional Stand Upright Irradiator Head Support Arm Attachment Point for Irradiator Head Height Adjustment Handle Work Pad Stand Base Unit DYMAX BlueWave LED DX 1000 User Guide Using the PLC Interface The BlueWave LED DX 1000 includes a 15 Pin D Subminiature Connector for communication with a PLC or similar process control equipment The connector provides for input and output signals Table 1 Pinouts for 15 Pin D Subminiature Connector on the BlueWave LED DX 1000 Pin Number 10 11 12 13 14 15 Name 24V input Power supply and signal common Sleep input Interlock input Activate input Intensity input
30. ty Control FeatureError Reference source not found on page 9 Pressing the or button momentarily will change the display to show the current setting in holding the button will increase or decrease the setting and the display will show the set level as it is adjusted a Operating Time Log unit operation and exposure hours 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 9 DYMAX BlueWave LED DX 1000 User Guide Back Panel The Back Panel Figure 5 includes these components and connection points Power Cord Receptacle Connection point for the Power Cord a W 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 m Cooling Air Intake Cooling air enters the Intake which includes a replaceable Filter NOTE The vents located on the side of the enclosure must not be blocked or the unit may overheat and shutdown a Footswitch Jack Connection point for the Footswitch Pressing the Footswitch starts a cu
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