MPS410F Power Supply with Unicableemanuals.enordson.com/uvsystems/Files/1074168A.pdf · completely...

MPS410F Power Supplywith Unicable

Customer Product ManualPart 1074168A01

Issued 6/07

NORDSON CORPORATION • AMHERST, OHIO • USA

To order parts call 866-885-1212.For technical support call 800-524-1322.

This document is available on the Internet at http://emanuals.nordson.com/finishing

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Part 1074168A01 � 2007 Nordson Corporation

Address all correspondence to:

North American Sales and Service

Nordson UV Systems Inc.

300 Nordson DriveAmherst, OH 44001

United States

Tel: (440) 985-4592(800) 717-4228

Fax: (440) 985-4593

Email: [email protected]

Website: www.nordson.com/uvcuring

Nordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2004. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

Nordson and the Nordson logo are registered trademarks of NordsonCorporation.

CoolWave is a trademark of Nordson Corporation.

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Table of Contents i

Part 1074168A01� 2007 Nordson Corporation

Table of Contents

Safety 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualified Personnel 1-2. . . . . . . . . . . . . . . . . . . . . . . . . Intended Use 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulations and Approvals 1-2. . . . . . . . . . . . . . . . . . Personal Safety 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . Ultraviolet Radiation 1-3. . . . . . . . . . . . . . . . . . . . . . . .

First Aid 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Microwave Radiation 1-4. . . . . . . . . . . . . . . . . . . . . . . Ozone Gas 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Temperature 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Bulbs (Lamps) 1-6. . . . . . . . . . . . . . . . . . . . . UV Curable Inks and Products 1-6. . . . . . . . . . . . . . . Fire Safety 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Action in the Event of a Malfunction 1-6. . . . . . . . . . . Safety Precautions While Servicing 1-7. . . . . . . . . . .

Control System Cleaning 1-7. . . . . . . . . . . . . . . . . High Voltage Connections 1-7. . . . . . . . . . . . . . . .

Cabinet Cooling 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving and Storage 1-7. . . . . . . . . . . . . . . . . . . . . . . . Safety Symbols 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is UV Curing? 2-1. . . . . . . . . . . . . . . . . . . . . . . .

The UV Curing System 2-1. . . . . . . . . . . . . . . . . . . How Does it Work? 2-1. . . . . . . . . . . . . . . . . . . . . . System Components 2-2. . . . . . . . . . . . . . . . . . . .

Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Packaging 3-1. . . . . . . . . . . . . . . . . . . Mounting Guidelines 3-1. . . . . . . . . . . . . . . . . . . . . . .

Power Supply 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . RF Detector 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lamphead Cooling 3-2. . . . . . . . . . . . . . . . . . . . . . . . . Electrical Installation Guidelines 3-3. . . . . . . . . . . . .

Power Line Connections 3-3. . . . . . . . . . . . . . . . . Input Power Configuration 3-3. . . . . . . . . . . . . . . . Power Source 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Operating Conditions 3-4. . . . . . .

Capacitor Configuration 3-4. . . . . . . . . . . . . . . . . . . . .

Network Connections 3-5. . . . . . . . . . . . . . . . . . . . . . . Network Connectors IN1 and OUT1 3-5. . . . . . . Output Connector TB1 3-7. . . . . . . . . . . . . . . . . . . Input Connector TB2 3-8. . . . . . . . . . . . . . . . . . . . .

Lamp Start-Up Timing Diagramfor Remote Input Contact Closures 3-9. . . . . .

Cable Connections 3-10. . . . . . . . . . . . . . . . . . . . . . . . . Lamphead 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF Detector 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Control Board Standard Configurations 3-11. . Control Board Dip Switches 3-12. . . . . . . . . . . . . . .

SW1 Control Board Dip Switches 3-12. . . . . . . SW1 Dip Switch Configurations 3-13. . . . . . . . . . .

SW3 Control Board Dip Switches 3-14. . . . . . . Power Supply Address Switch 3-14. . . . . . . . . . . .

Standalone Units 3-15. . . . . . . . . . . . . . . . . . . . . Networked Units 3-15. . . . . . . . . . . . . . . . . . . . . .

Remote Configuration of Main Control Board 3-16. . Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display and Controls 4-1. . . . . . . . . . . . . . . . . . . . . . . Display Messages 4-2. . . . . . . . . . . . . . . . . . . . . . . . . Fault Messages 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting a Fault 4-3. . . . . . . . . . . . . . . . . . . . . . . . Lamp Start-Up Timing Diagramfor Remote Input Contact Closures 4-4. . . . . . . . . . . Startup 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locally Operated Units 4-5. . . . . . . . . . . . . . . . . . . Remotely Operated Units 4-8. . . . . . . . . . . . . . . . .

Shutdown 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Repair 5-1. . . . . . . . . . . . . . . . . . . Maintenance and Replacement Schedule 5-1. . . . . Replacement Procedures 5-2. . . . . . . . . . . . . . . . . . .

Preparation 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Control Board 5-2. . . . . . . . . . . . . . . . . . . . . . Fuses 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Cleaning and Supply Cooling Fan 5-3.

Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . Parts 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 7-1. . . . . . . . . . . . Power Supply 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Drawings 8-1. . . . . . . . . . . . . . . . . . . . . . . . . .

UV Glossary 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contentsii


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Safety 1-1


Section 1Safety

IntroductionRead and follow these safety instructions. Task-and equipment-specific warnings, cautions, andinstructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, includingthese instructions, is accessible to all personsoperating or servicing equipment.

All equipment is designed and manufactured toInternational Safety Standards to ensure that thehealth and safety of the operator is protected at alltimes.

1500136A

Figure 1-1 Microwave UV Warning

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Safety1-2


Qualified PersonnelEquipment owners are responsible for making surethat Nordson equipment is installed, operated, andserviced by qualified personnel. Qualifiedpersonnel are those employees or contractors whoare trained to safely perform their assigned tasks.They are familiar with all relevant safety rules andregulations and are physically capable ofperforming their assigned tasks.

Intended UseNordson ultraviolet (UV) equipment is intendedspecifically for integration into other machines andshould NOT be operated as a standalone systemor without appropriate safety guarding, shielding,and interlocks. It is the responsibility of theintegrator and end user to ensure that the finalassembly fulfills all necessary legislation and iscompletely safe before operation.This equipment is designed for the acceleratedcuring of UV inks, adhesives, and coatings. Do notuse this equipment to cure alternative materialsunless approved by the material supplier.The equipment is not flame or explosion proof andis not designed for use in hazardous areas.Use of Nordson equipment in ways other thanthose described in the documentation supplied withthe equipment may result in injury to persons ordamage to property.Some examples of unintended use of equipmentinclude:

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards, shielding,or interlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximumratings

� using equipment in hazardous areas

Regulations andApprovalsMake sure all equipment is rated and approved forthe environment in which it is used. Any approvalsobtained for Nordson equipment will be voided ifinstructions for installation, operation, and serviceare not followed.

Currently there are two organizations that setrecommended guidelines for exposure tooccupational microwave radiation exposure, OSHA(U.S. Department of labor, Occupational Safety andHealth Administration - Directive 29cfr 1910.97)and ANSI (American National Standards Institute -Directive C95.1-1982). The ANSI directive, whichis more stringent and most commonly referred to,states that individuals should not be exposed tomicrowave radiation levels above 5 mW/cm2 at2.45 GHz on a continuous basis.

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Safety 1-3


Personal Safety To prevent injury follow these instructions.

� Do not operate or service equipment unless youare qualified.

� Do not operate equipment unless safetyguards, light shields, doors, and/or covers areintact and automatic interlocks are operatingproperly. Do not bypass or disarm any safetydevices.

� Keep clear of moving equipment. Beforeadjusting or servicing any moving equipment,shut off the power supply and wait until theequipment comes to a complete stop. Lock outpower and secure the equipment to preventunexpected movement.

� Obtain and read Material Safety Data Sheets(MSDS) for all materials used. Follow themanufacturer’s instructions for safe handlingand use of materials. Always userecommended personal protection devices.

� Make sure the UV area is adequatelyventilated.

� The UV equipment runs at extremely hightemperatures. Do not touch the UV lampheadface during operation or immediately aftershutting off the equipment.

� To prevent injury, be aware of less-obviousdangers in the workplace that often cannot becompletely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, andmoving parts that cannot be enclosed orotherwise guarded for practical reasons.

� Always wear safety glasses that offer UVprotection.

� Never expose any part of the body to direct orindirect UV light.

Ultraviolet RadiationWARNING: Ultraviolet light is a form ofelectromagnetic radiation and can beharmful if exposure exceeds recommendedlevels. Protect eyes and skin from directexposure to UV light. All equipment orareas where UV light is used must beadequately guarded, shielded, andinterlocked to prevent accidental exposure.

Ultraviolet light is not capable of penetrating intothe body and interacting with internal tissues andorgans.

The National Institute for Occupational Safety andHealth (NIOSH) document Criteria forRecommended Standard... Occupational Exposureto Ultraviolet Radiation (PB214 268) establishesguidelines for safe use.

See Figure 1-2. Ultraviolet light is divided intowavelength bands A, B, C, and V along withvacuum UV. Although values for wavelength bandswill vary depending on the source, the followingranges may be used as a guide.

� Vacuum UV (100-200 nanometers) - absorbedby air and poses no danger to humans.

� UV-A (315-400 nanometers) - represents thelargest portion of UV energy and is mostresponsible for human skin aging and increasedpigmentation. UV-A is at the lower limit ofsensitivity to the human eye. Referred to as farUV.

� UV-B (280-315 nanometers) - mostresponsible for reddening and burning of theskin and damage to the eyes.

� UV-C (200-280 nanometers) - filtered byozone. Referred to as near UV.

� UV-V (400-450 nanometers) – visible UV

Exposure to UV radiation can result in

� reddening of skin

� headaches

� sore eyes

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Safety1-4


1500021A

X RAYSULTRAVIOLET INFRA RED MICROWAVES RADIO WAVES

VISIBLE

VACUUM UV

FARUV

NEARUV

UVC UVAUVB

100 200 300 500 600 700 800 900400 1000 nanometers

UVV

Figure 1-2 Ultraviolet Light Wavelength Bands

It is very important that all precautions are taken toprevent all UV light, whether direct or indirect, fromescaping the curing area. Exposure to UV light canbe harmful to both eyes and skin. Use thefollowing table to determine the permissibleexposure time to UV light on unprotected eyes orskin.

Permissible Ultra Violet Exposures asRecommended by the American Conference

of Government and Industrial Hygienists

Duration ofExposure (Per Day)

Effective Irradiance(E Micro Watts/cm sq)

8 hours 0.1

4 hours 0.2

2 hours 0.4

1 hour 0.8

30 minutes 1.7

15 minutes 3.3

10 minutes 5.0

5 minutes 10

1 minute 50

30 seconds 100

10 seconds 300

1 second 3000

First Aid Store-bought creams, lotions, or aloe can beapplied to affected areas of the skin. Seekimmediate medical attention for skin burns anddirect UV exposure to the eyes.

Microwave Radiation The lamp system utilizes high powered RFmicrowave energy generated by amagnetron to provide power to the UVlamp. This technology is identical to that ofresidential microwave ovens and like theseovens can be dangerous if misused. Thelamp system is safe provided that the RFscreen and gasketing are intact. Anydamage such as rips or holes in the screenmay cause leakage of dangerous amountsof microwave radiation. The power to thelamp is interlocked to the RF detector andwill shut down if microwave leakage inexcess of 2 mW/cm2 is detected. Anyexcessive leakage will cause the system toshutdown and the RF Detector fault willilluminate on the front of the power supply.

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Safety 1-5


Ozone Gas Ozone (O3) is a colorless gas that is generated bythe reaction of short-wave UV light (around200-220 nanometers) with air, and it occurswhenever high-energy electrical discharge ispresent.

Ozone readily reverts to breathable oxygen whenmixed with atmospheric air. Ozone should beremoved from the UV source via a sealed duct anddischarged to atmosphere according to localregulations. The discharge location should beaway from pedestrian walkways and windowopenings and should be well above the averagehuman breathing height for the area.

Regular ozone checks should be carried out everythree months using an ozone meter.Recommended levels of ozone in the atmosphereof a factory should not exceed 0.1 parts permillion (PPM). This level is easily obtainable iffactory recommended exhaust rates are followed.

Ozone has a very distinct, strong odor even at lowlevels. Immediate ozone checks should be made ifan operator can smell ozone. Most people cansmell ozone at about one third the maximumallowable 0.1 PPM level.

Ozone exposure will cause headaches and fatigue.It will also irritate the mouth and throat.Overexposure can lead to respiratory infections.

If ozone is detected,

1. Shut down the UV system.

2. Check exhaust ducting for leaks.

3. Check the operator working area with an ozonemeter.

If a person is overcome by ozone,

� Move the individual to a warm uncontaminatedatmosphere and loosen tight clothing at theneck and waist.

� Keep the individual at rest.

� If the person has difficulty breathing, oxygenmay be administered provided that suitableapparatus and a trained operator are available.

� If breathing is weak or has ceased, artificialrespiration should be started.

� Seek medical assistance.

High Temperature

UV curing systems generally run atextremely high temperatures. A suddenshock from touching a high temperaturesurface might cause an operator to jump ortake his attention away from other potentialhazards.

When shutting down UV equipment formaintenance, allow the equipment to cool beforebeginning work, or wear protective gloves andclothing to prevent burns.

High Voltage The UV curing equipment operates at high voltagesup to 5000 Vdc. The system uses high-voltage,self-discharging capacitors. Once power to thepower supply is shut off, the capacitors need120 to 130 seconds to discharge.

If any electrical faults develop, the operator should:

1. Switch the equipment off immediately.

2. Make no attempt to service the equipment.

3. Call a qualified electrician, trained to servicethis type of equipment.

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Safety1-6


Mercury Bulbs (Lamps)The bulbs used in UV lamp systems containmercury under medium pressure. Mercury is atoxic substance and must not be ingested or comeinto direct contact with the skin. Under normal UVoperating conditions, mercury presents no hazardas it is completely contained in the sealed quartztube of the bulb; however, it is stronglyrecommended that protective gloves and eyeprotection be worn when handling UV bulbs.

These precautions should be followed whendisposing of UV bulbs:

� Place the bulb in a rigid protective carton.

� Dispose of used bulbs through a local mercuryrecycling center.

� Wash your hands if a bulb breaks: mercurycould come into contact with your skin.

� Do not store or handle bulbs near food orbeverages.

� Nordson Corporation will dispose of UV bulbsfree of charge provided the customer covers allshipping costs associated with returning thebulbs. For bulb disposal, please clearly markon the all bulb containers AND shippingpackages BULBS FOR DISPOSAL ONLY

Bulbs should be shipped to:

PrimarcBulb Disposal Department2 Danforth DriveEaston, Pennsylvania 18045

UV Curable Inks andProducts Some materials used in UV curable inks,adhesives, and varnishes are toxic. Beforehandling them, read the Material Safety DataSheets provided by the manufacturer, use therecommended personal safety equipment, andfollow the recommended procedures for safe useand disposal.

Fire Safety Under proper operating conditions, the surfacetemperature of the bulb is anywhere between700-900 �C (1300-1700 �F), and the vapor gasinside the bulb is several thousand degreesFahrenheit.

Any form of flammable material (such as paper, lint,powder, or dirt) trapped under the lamp, within thelamp housing or in the lamp’s vicinity, will result inan increased risk of fire.

To avoid a fire or explosion, follow theseinstructions.

� Know where emergency stop buttons, shut-offvalves, and fire extinguishers are located.

� Clean, maintain, test, and repair equipmentaccording to the instructions in this manual.

� Always keep a fire extinguisher approved forelectrical equipment near the unit.

Should a fire occur, the operator must:

1. Switch the equipment off immediately.

2. If possible, put out the fire with a fireextinguisher.

Action in the Event of aMalfunctionIf a system or any equipment in a systemmalfunctions, shut off the system immediately andperform the following steps:

1. Disconnect and lock out system electricalpower.

2. Identify the reason for the malfunction andcorrect it before restarting the system.

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Safety 1-7


Safety Precautions WhileServicing A qualified competent electrician must carry out allelectrical maintenance and servicing of thisequipment.

WARNING: This equipment operates athigh voltages up to 5000 volts dc and istherefore potentially dangerous. Theelectrician servicing this equipment musttake all precautions.

WARNING: Isolate the equipment at themain, disconnect or lockout beforeremoving any of the cover panels

Control System Cleaning Keep all contactors and relays clean and free fromdirt and dust. Check these regularly, particularly inextremely dusty or powder-charged working rooms.

High Voltage Connections Check the high-voltage connections within theequipment carefully to make sure that these do notbecome dirty or coated with powder or otherpossible conducting material. Clean them regularly,at least whenever the lamp is changed, possiblymore often where a particularly heavily pollutedatmosphere occurs.

Always make sure the unicable connectors aresecure and tight before applying power.

Cabinet Cooling Check the cabinet cooling fan at least weekly andkeep clear of any material that might clog or stop itsoperation. The power supplies run warm andkeeping them cool with proper ventilation willprolong their life.

DisposalDispose of equipment and materials used inoperation and servicing according to local codes.

Moving and Storage

Moving or storing of the Nordson UV curing systemmust comply with all applicable local and stateregulations. All electrical power and other servicesmust be disconnected and the lamp head must becool before moving or storing this equipment.Power supplies should be properly attached orfastened to an appropriate fixture such as a palletfor handling and storing. Due to the power supply’sweight, it is recommended a mechanical device beused for handling and they should be kept as low tothe floor as possible. It is recommended that thebulb be removed from the lamp head and stored orshipped in the original shipping tube. The lamphead and power supply should be shipped and orstored in the original container or an equivalent andkept dry and clean at all times.

Shipping of Nordson UV curing systems and theircomponent parts must be done in accordance withall applicable shipping regulations includingrequirements for shipping of magnetic materialsand mercury lamps.

Safety SymbolsThe following safety symbols are used in thismanual. The symbols are used along withwarnings to help you operate and maintain yourequipment safely. Pay attention to all warnings andfollow directions to avoid personal injury.

WARNING: Mechanical or combinedmechanical/electrical hazards.

WARNING: Electrical hazard

WARNING: Ultra violet light hazard

WARNING: Burn hazard

CAUTION: Equipment hazard

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Safety1-8


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Description 2-1


Section 2Description

Introduction

The MPS410F power supply is used with theNordson CoolWave ultraviolet microwave appliedcuring system with a CW410 lamphead.

The power supply unit provides the voltage supplyfor the lampheads and a control circuit to interlockthe lampheads with the curing machine.

Power Supply Versions Two versions of the power supply are available:

Part Number Usage

775784 50 Hz power, lampheads withoutinternal blowers

60 Hz power, lampheads with orwithout internal blowers

1075801 50 Hz power, lampheads withinternal blowers

This power supply features anintegrated motor speedcontroller, which ensures aninternal motor blower lampheadwill develop the correct coolingair flow for all 50 Hz powerinstallations. Refer to theInstallation for proper line powerconnection and input powerconfiguration.

What is UV Curing?

Ultraviolet curing is achieved by a chemicalreaction in special inks and coatings when intenseUV energy is focused on them. Curing efficiencydepends on UV power, coating weight, operationspeed, type of substrates, material chemistry, andother factors.

The UV Curing System The system is designed to cure UV inks,adhesives, and coatings for numerous industrialapplications.

The system consists of an individual 10-in.lamphead, a corresponding fixed output powersupply, and an RF detector. Additional lampheadscan be lined up end-to-end to form longer curingwidths.

Figure 2-1 and Table 2-1 illustrate and describe themajor components of a typical setup for aCoolWave ultraviolet microwave applied curingsystem. Your system may appear differentdepending on your application requirements.

How Does it Work? A microwave generator (magnetron) operating at2400 to 2500 MHz is used to excite a mediumpressure mercury bulb installed in a lamphead.Ultraviolet light between 220 and 470 nanometersis emitted.

Microwave energy from a magnetron is directedinto a cavity containing the UV bulb. A screenlocated at the opening of the cavity allows the UVlight to pass through while the microwave radiationis contained.

In addition to ultraviolet light, the high-energy bulbsradiate heat. Therefore, a cooling system isincorporated to take away the excess heat andmake sure that the bulbs and housings remain atan acceptable operating temperature.

The unit is fitted with interlocks and safety faultsthat prevent the operation of the system in anunsafe condition and indicate any faults that mightoccur on the front panel of the power supply.

Light shielding is required to ensure the stray UVlight and heat meet agreed safety criteria.

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Description2-2


System Components Refer to Table 2-1 and see Figure 2-1 for a description of the system components.

Table 2-1 System Components

Item Component Description

1 Lamphead withexternal blower

The lamphead consists of a bulb housing, UV bulb (4), wave guide,reflectors (3), light detector, starter bulb (5), and the magnetron (6)assembly. The patented wave guide couples RF energy to the bulband provides cooling for the bulb. The lamphead reflects the emittedUV light onto the substrate. 300 CFM @ 5 in. W.C. of cooling air froman external source is required at each lamphead.

NOTE: For more information on the lamphead, refer to the CW410Lamphead with Unicable manual.

2 Lamphead withinternal blower

This lamphead is the same as the external blower lamphead butcontains an internal blower to cool the UV bulb and magnetron. Theinternal blower is sized to provide a minimum of 300 CFM at 5 in. W.C.

NOTE: For more information on the lamphead, refer to the CW410Lamphead with Unicable manual.

7 External Blowersfor Cooling

External blowers are used to cool the UV bulb and magnetron on theexternal blower lamphead. The lamphead requires approximately300 CFM at 5 in. W.C. of cooling air per lamphead in order to functionproperly. The external blowers must be sized appropriately to provideadequate cooling air.NOTE: Lampheads with external blowers require a device to monitorthe air flow and static pressure. In the event of cooling air loss thedevice will shut the system down.

8 Power Supply The power supply is fully modular. One power supply must beprovided for each lamphead. The power supply can operate as astandalone system or part of a Master/Remote circuit. Refer to PowerSupply on page NO TAG for details.

9 RF Detector An RF detector monitors microwave energy levels. The system willshut down when RF levels above 2mW/cm2 are measured. Systemsoperated as standalone units require one RF detector per powersupply unit. If multiple systems are networked then the master powersupply unit must be connected to one RF detector. Refer to the RFDetector on page NO TAG for details.

NOTE: The CoolWave lamphead produces heatedair and ozone, which must be safely ventilatedaway from the work area. (Refer to page NO TAGfor more on ozone gas.) The minimum ventilationrequirement for each lamphead is 125% of thecooling air or 375 cfm @ 2-in. W.C. to properlyevacuate the heat and ozone from the lamphead.

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Description 2-3


1500125A

8

1

7

9

R

INTERNAL BLOWERLAMPHEAD

6

10

4

4

3

1

5

2

Figure 2-1 System Components (Typical UV Curing System Setup)

1. Lamphead with external blower2. Lamphead with internal blower3. Reflectors4. Ultraviolet bulb

5. Starter bulb6. Magnetrons7. Tubing to external blowers for

cooling Pressure switch8. Power supplies

9. RF detector10. Pressure switch

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Description2-4


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Installation 3-1


Section 3Installation

WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

Inspection and Packaging The Nordson CoolWave system has been carefullytested, inspected, and packaged prior to shipping.Upon receipt, inspect the shipping materials andcomponents for visible damage. Report anydamage immediately to the shipper and to theNordson UV systems engineering department.

NOTE: When opening the packaging, please takecare so that the packaging can be re-used to shipthe unit to the next destination. Keep all packagingmaterials together and in a location that they willnot get damaged.

Mounting Guidelines Power Supply

WARNING: Heavy equipment. Be carefulwhen moving the unit.

See Figure 3-1 for power supply dimensions andclearance requirements.

� The power supply can be mounted on anyhorizontal surface.

� Power supplies can be stacked up to five unitshigh but due to the weight of each unit(approximately 138 lb) it is recommended thatthey be stacked so they can be easily accessedfor service.

� Leave at least six inches of ventilationclearance on all four sides of the power supplyunit.

� Blowers are mounted on the front and the rearof the power supply and need to be free andclear of any obstructions.

1500114A

(25.75 in)

654.05 mm

(6 in)152 mm

(17.675 in)448.95 mm

(18.125 in)

460.37 mm

VentilationClearance

on all Four Sides

(8.25 in)

209.55 mm

Figure 3-1 Power Supply Dimensions

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Installation3-2


RF Detector See Figure 3-2.

� One RF detector is normally required for every16 networked units within one curing enclosure.However, some applications and systems mayrequire an RF detector on each unit. Contactyour Nordson representative for moreinformation.

� Mount the RF detector so that the antennafaces the lamphead screen and is between theoperator and the lampheads or the lampheadsand any opening (the major source for RFleakage).

� The minimum distance should be eight inchesto prevent excessive heat on the detectorsurface.

� Do not mount the RF detector directly below thelamphead.

� For RF detector connections, refer to RFDetector on page 3-11.

1500115A

(3.50 in)88.9 mm

(1.50 in)38.1 mm

(0.50 in)12.7 mm

(0.75 in)19.1 mm

(Ø0.28 in)Ø7.2 mm

(Ø0.16 in)Ø4.0 mm

(0.55 in)14.0 mm

(1.69 in)

42.8 mm

No RF Detec-tor

12 in

8 in

R

Figure 3-2 RF Detector

Lamphead Cooling Lamphead cooling is critical to the operation of thelamphead. There are two types of lampheadsavailable:

Internal Blower: requires no external coolingair.Remote Blower: requires an external sourceof cooling air ducted to each lamphead.

The following specifications must be maintained forall applications at all times regardless of which typeof lamphead is used:� cooling airflow through the lamphead is always

maintained and not restricted at the exit end ofthe lamp face

� a constant static pressure of 5-in. water columnfrom the inside of the lamphead to ambient orthe lamp face

� 300 CFM of airflow through the lamphead� 375 CFM of ventilation airflow

If you are using an exhaust box or any other type oflamp face attachment that can impede the airflowthrough the lamphead, you must monitor thepressure and CFM on the lamp face.

The specified cooling air, static pressure and CFMrequirements must be maintained. If not, the life ofthe lamphead will be greatly reduced with thepossibility of failure.

The CoolWave lamphead produces heated air andozone, which must be safely ventilated away fromthe work area. (Refer to page NO TAG for more onozone gas.) The minimum ventilation requirementfor each lamphead is 125% of the cooling air or375 cfm @ 2-in. W.C. to properly evacuate the heatand ozone from the lamphead.

For more information on lamphead cooling, contactyour Nordson UV representative.

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Installation 3-3


Electrical Installation Guidelines Power Line Connections Refer to Table 3-1 and see Figure 3-3. This unit isdesigned to accommodate a broad range of powerline voltages for both 50 and 60 Hz found aroundthe world. The power line input is three phase, andthe transformer taps must be changed to select theoperating voltage range. The power supplies aredesigned to operate at +/- 10% of the normalvoltage for a given tap setting. Only the taps on thetwo identical power transformers need to bechanged.

Table 3-1 Transformer Taps

NormalVoltage

VoltageRange

TransformerTap

240 +/- 10% 216-264 240

210 +/- 10% 189-231 210

200 +/- 10% 180-220 200

1500128A

Figure 3-3 Transformer Taps

Input Power Configuration Refer to Table 3-2. Current ratings indicate currentdemand during normal full-power operation. Sizesupply wiring and circuit breakers or fuses to allowfor heavy current draw during startup.

Table 3-2 Power Line Current

Line 60 Hz 50 Hz

Amps @200 Vac

Amps @210 Vac

Amps @ 240 Vac

Amps @200 Vac

Amps @210 Vac

Amps @240 Vac

L1 26 24 22 23 22 20

L2 16 15 14 15 14 13

L3 17 16 15 15 14 13

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Installation3-4


Power Source The customer power source must be wired inaccordance with either the National Electric Code,Part I or the Canadian Electrical Code, Part I, orlocal codes.Connector P1 on the power supply is forthree-phase input power. A 250 Vac, 30 Amp twistlock connector is supplied with the system for thepower input.Measure the incoming power source voltage fromthe main power supply. Make sure that the powersource voltage matches the transformer tapsettings.

Environmental OperatingConditions

Condition Specification

Altitude Up to 2000 meters (6561 ft)

Temperature 5-40 �C (41-104 �F)

Rh 80%

Capacitor Configuration The power supply can be configured to operate at50 Hz or 60 Hz. See Figures 3-4 and 3-5 to seehow the capacitors should be wired for eachconfiguration.

NOTE: There are two sets of capacitors and bothmust be set for the correct frequency, 50 or 60 Hz.

1500061A

Figure 3-4 50 Hz Capacitors

1500062A

Figure 3-5 60 Hz Capacitors

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Installation 3-5


Network Connections NOTE: Equipment must be connected inaccordance with the NEC and local wiring codes.

The power supply can be configured to form anetwork of up to 16 systems. The entire networkcan be operated either from the master control unitfront panel or from a remote source.

Network Connectors IN1 andOUT1 See Figure 3-6 and refer to Table 3-3. Use the IN1and OUT1 connectors (1) (shielded RJ45) toconnect multiple units in a Master/Remote fashion.The connection cable is commercially available andshould have a rating of CAT3 or higher. Repeatthis for each unit

Table 3-3 IN1 and OUT1 Network Connectors

Cable From To Length (ft) Part

Network OUT1 connectorof a unit

IN1 connector ofthe next unit

6 775031

Network OUT1 connectorof a unit

IN1 connector ofthe next unit

4 1071854

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Installation3-6


Network Connections (contd)

1500116A

4 3

2

2

2

5

1

6

DIS

PL O

R LE

DR

EM

CF

GF

RT

PN

L LOC

KR

F D

ET

FAU

LTR

EM

AN

ALG

R

R

R

LIGH

T D

ET

CA

N C

TR

LN

OT

US

ED

NO

T U

SE

DN

OT

US

ED

CA

N/485

8

7

7

7

DIGITAL OR ANALOGJUMPER D

ISP

L OR

LED

RE

M C

FG

FR

T P

NL LO

CK

RF

DE

TFA

ULT

RE

M A

NA

LG

LIGH

T D

ET

CA

N C

TR

LN

OT

US

ED

NO

T U

SE

DN

OT

US

ED

CA

N/485

DIS

PL O

R LE

DR

EM

CF

GF

RT

PN

L LOC

KR

F D

ET

FAU

LTR

EM

AN

ALG

LIGH

T D

ET

CA

N C

TR

LN

OT

US

ED

NO

T U

SE

DN

OT

US

ED

CA

N/485

NORDSON739034A

U6

0

71

9

10

12

3

4

6

OPENOPEN

12 3456123 456

9

9

9

10

10

10

Figure 3-6 Network Connections

1. Network connectors IN1 and OUT12. Power supply3. Input connector TB2

4. Output connector TB15. Power lines6. Main control board

7. DIP switches8. Rotary address switch9. Lamphead

10. Unicable

NOTE: Correct dip switch settings for the main control board are located in Tables 3-8 through 3-13.

NOTE: Refer to Figure 3-12 for a photograph of main control boards manufactured before August 2004.

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Installation 3-7


Output Connector TB1 Refer to Table 3-4 and see Figure 3-7.

All outputs from the TB1 output connector (4) areisolated normally open relay contacts and are ratedat 240 Vac, one amp maximum.

Table 3-4 Output Connector TB1 Pin Assignments

Pin Function Description

1, 2 High Voltage ON Contact closes when high voltage is applied to the magnetron.

3, 4 Lamp ON Contact closes when the light detector has detected light output from thelamphead.

5, 6 System Ready(network)

Contact closes after the power supply unit has been turned on and thelight detector senses light output.

In a networked system all power supply units that are turned on must besending Lamp On output to the master power supply for system ready togo closed on the master unit.

7, 8 Remote Blower This output contact closes when the lamphead is placed in Standby orOn and remains on for cooling after the lamphead is turned off.

9, 10 Fault Output Contact closes whenever there is a fault present on the system.

11, 12 Not Used

NOTE: Power supplies manufactured prior to September 2006 were configured to provide 240 Vacacross I/O terminals 11 and 12 of TB1 when the system requires lamphead cooling. This signal controlsan external blower in specialized applications. For applications not using this signal, a mating connectoris available to prevent accidental connection to pins 11 and 12. Contact your Nordson representative formore information.

1500157A

Figure 3-7 Output Connector TB1 and InputConnector TB2 - Located on the RearPanel of the Power Supply

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Installation3-8


Input Connector TB2 Refer to Table 3-5 and see Figure 3-7.

The inputs from the TB2 input connecter (3) aredesigned for contact closure or an open collectoroutput. With the exception of the 4-20 ma remoteanalog input, the input terminal voltage is 24 Vdcand will source about 8 ma.

Table 3-5 Input Connector TB2 Pin Assignments

Pin Function Remote Local Description

1 Common X X If this input is not interfaced to externalequipment, a jumper must be installed.Opening this input shuts down the power

2 Machine StopOpening this input shuts down the powersupply unit, sets the FAULT output, andcauses the F STOP fault message to appearon the display.

3 Common X NA Allows for remote control of the power supplyunit when operating in the Remote mode. Apulse or momentary contact closure to this

4 Remote Standbypulse or momentary contact closure to thisinput places the power supply unit in theStandby mode. (The Off/Reset contact mustbe closed)

5 Common X NA Allows for remote control of the power supplyunit when operating in the Remote mode.This contact must be closed for the lamphead

6 Remote Off/ResetThis contact must be closed for the lampheadto be turned on. Opening the contact will turnthe lamphead off and will clear a faultcondition.

7 Common X NA Allows for remote control of the power supplyunit when operating in the Remote mode. Apulse or momentary contact closure to thisinput turns the CoolWave lamphead to the on

8 Remote Lamp Oninput turns the CoolWave lamphead to the onstate. (The Off/Reset contact must beclosed). The Off/Reset contact must beopened to turn the lamphead off.

9 Common X X If this input is not interfaced to externalequipment, a jumper must be installed.Opening this input shuts down the power

10 External InterlockOpening this input shuts down the powersupply unit, sets the FAULT output, andcauses the F LOCK fault message to appearon the display.

11 Chassis Ground NA NA Not Used

12 Not used NA NA Not Used

13 Not Used

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Installation 3-9


Lamp Start-Up Timing Diagram forRemote Input Contact Closures See Figure 3-8. The Off/Reset contact must be held closed for the unit to go to Standby or On. Once thelamphead is put into the Standby or On mode the lamphead will remain in that mode until the Off/Resetcontact is opened.

1500003A

Lamp Off Lamp to Standby Lamp to ON Lamp Off

1

0

1

0

1

0

LAMP ON

STANDBY

OFF/RESET

>100 ms pulse

10 seconds to warm up

8 seconds to stabilize

>100 ms pulse

Figure 3-8 Lamp Start Up Timing Diagram for Remote Input Contact Closures

Rapid StartupUse if your system will sit idle in the Standby modebefore moving to the On mode.1. On the LAMP selector of the host machine (or

master control unit’s lamp selector), press theStandby button. There will be an approximate10 second warm-up time for the magnetronfilament.

2. After the 10 seconds the system will go intostandby and remain there indefintely.NOTE: Do not leave the power supply in thestandby mode for longer than 30 minutes inan eight-hour period or more than 15% ofthe total lamp-on time. Prolonged standbyperiods will shorten the magnetron life.

3. Press the On button to enable the UV light.The light will turn on instantly but will takeapproximately 8 seconds to stabilize. After the8 seconds, the system ready output contact(TB1) will close.

Standard Startup

Use to go directly through the warm-up to the Onmode.

1. On the LAMP selector of the host machine (ormaster control unit’s LAMP selector), press theLAMP On button.

2. During the next 10 seconds the unit will gothrough the warm up cycle before turning to On.

3. After approximately 8 more seconds the unithas stabilized and the system is ready to run.The system ready output contact (TB1) willclose.

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Installation3-10


Cable Connections See Figure 3-6.

CAUTION: It is important that the unicableconnectors be completely engaged andtightened before turning on the lampsystem. Failure to properly engage theseconnectors can result in damage to the UVsystem.

Before inserting plugs into receptacles check boththe plug and receptacle and ensure that the rubberinserts are in good condition and not torn. Makesure also that there is no evidence of arcing on thepins and sockets.

The plug is keyed and can only be inserted into thereceptacle when correctly oriented. Do not forcethe plug into the receptacle.

Push the plug into the receptacle as far as it will go,then start threading the screw ring onto thethreaded portion of the receptacle. Continue topush on the plug while tightening the screw ringuntil the plug is firmly seated into the receptacle.Do not use the screw ring to pull the plug into thereceptacle. In some cases, it might help to wigglethe plug slightly while pushing it into the receptacleto ensure that all the pins mate securely with thesockets.

All cables must be securely fastened. Be sure toturn screw-type connectors until they arecompletely tight against their mating receptacle.

See Figures 3-9 and 3-10. Each unicableconnector end features an indicator that identifieswhen the connector is fully mated. Tighten thescrew ring by hand. When fully mated, no redshould appear on the indicator locations and the isno movement between the plug and the receptacle.

Red Indicator - Partially Installed

Figure 3-9 Unicable connector partially installed

No Indicator - Fully Installed

Figure 3-10 Unicable connector fully installed

Lamphead

Table 3-6 Lamphead Cable Connections


Unicable Power supply unit Lamphead 12 775374pp yconnector

p

25 775023

50 775375

75 775377

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Installation 3-11


RF Detector Refer to Table 3-7

NOTE: Each network requires at least one RFdetector. If there are multiple light shieldingchambers at least one RF detector must be locatedin each chamber.

Table 3-7 RF Detector Connections


RF Detector CoolWave powerl

RF detector 12 1061134psupply 25 775029

50 775050

75 775051

100 775052

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Installation3-12


Main Control BoardStandard Configurations See Figures 3 -11 and 3-12.

The following information identifies the standardswitch configurations for the power supply unit.The systems may be configured to run asstandalone or interconnected to form a completenetworked system of up to 16 lamps.

NOTE: The main control board was changed inAugust 2004. Figure 3-12 illustrates the previouscontrol board.

1500117A3

1 2

DIS

PL O

R LE

D

RE

M C

FG

FR

T P

NL LO

CK

RF

DE

T

FAU

LT

RE

M A

NA

LG

2

OPEN

4

LIGH

T D

ET

CA

N C

TR

L

NO

T U

SE

D

NO

T U

SE

D

NO

T U

SE

D

CA

N/485

OPEN

5

SW1 SW3

Figure 3-11 Main Control Board

1. Main control board2. Dip switches

3. Power supply address switch4. Digital/Analog jumper (light

detector)

5. 4-20 ma/0-10 Vdc jumper

1500063B3

1 2

LAM

P 6“/10”

RE

M A

NA

LG E

N/D

IS

LOC

LKO

UT

/NO

RM

AL

FAU

LT A

LL/UN

IT

NO

NE

/RE

DE

T

SLA

VE

/MA

ST

ER

2

OPEN

4

Figure 3-12 Main Control Board Manufactured before August 2004

1. Main control board2. Dip switches

3. Power supply address switch 4. 4-2 ma/0-10 Vdc Jumper

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Installation 3-13


Control Board Dip Switches

There are two sets of dip switches (SW1 and SW3)that need to be set on the main board. Tables 3-8and 3-13 provide an explanation of each switch.

NOTE: Switches 5 and 6 were added to controlboards manufactured after 2002.

SW1 Control Board Dip Switches 1500126A

OPEN

DIS

PL O

R LE

D

RE

M C

FG

FR

T P

NL LO

CK

RF

DE

T

FAU

LT

RE

M A

NA

LG

Figure 3-13 SW1 Dip Switch Configurations

Table 3-8 SW1 Control Board Dip Switches

DipSwitch

Description Function

1 Closed/On = Remote analog On

OnOpen/Off = Remote analog Off

Configures the remote adjustable power input to onor off. (TB2)

2 Closed/On = Fault individual units

Open/Off = Fault all units

Configures the power supply (standalone ornetworked system) to shut down the individual lampor the entire network in the event of a fault.

3 Closed/On = RF Detector is used

Open/Off = RF Detector is not used

Configures the power supply unit to be operatedwith or without an RF detector. Standalone systemsor master units cannot operate without an RFdetector.

An RF detector can be installed at each powersupply when necessary.

Networked systems are typically configured for themaster unit to have one RF detector while itsremote units (up to 16 units) do not.

NOTE: Up to 16 units can be networked andoperate with one RF detector but it is recommendedthat every six units have one RF detector.

4 Closed/On = Front panel controls Off

Open/Off= Front panel controls On

Configures the front panel of an individual powersupply to be enabled or disabled. When disabled,all operational functions must be controlled by theinputs or the network master.

5 Closed/On = Front Panel configurationOn

Open/Off = Front Panel configurationOff

Allows power supply configuration to be completedat the front panel.

6 Closed/On = Front Panel Digital display

Open/Off = Front Panel has LEDs only

Configures the control board for an LED only frontpanel or a number display on the front panel.

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Installation3-14


SW1 Dip Switch Configurations Refer to Tables 3NO TAG through 3NO TAG forpossible configurations in which the dip switchescan be set.

OPEN = Off

CLOSED = On

1500156A

OPEN

DIS

PL O

R LE

D

RE

M C

FG

FR

T P

NL LO

CK

RF

DE

T

FAU

LT

RE

M A

NA

LG

Figure 3-14 SW1 Dip Switch Configurations

Table 3-9 Single System Operating Locally PowerSupply

SW1-1 SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 Suggested Settings

Standalone

(Set FrontPanel to:Local)

Rem Analog Open/OFF

FaultOpen/OFF

RF Detector Closed/ON

Fnt Pnl LockOpen/OFF

Rem CFGOpen/OFF =DisabledClosed/ON =Enabled

Display orLEDClosed/ON =Num

OPEN

Table 3-10 Single System Operating Remotely PowerSupply


Standalone

(Set FrontPanel to:Remote)

Rem Analog Open/OFF

FaultOpen/OFF


Fnt Pnl LockOpen/OFF =DisabledClosed/ON =Enabled



OPEN

Table 3-11 Networked System Operating Locally PowerSupply


Master


Rem Analog Open/OFF

FaultOpen/OFF





OPEN

Remote


Rem Analog Open/OFF

Fault Single =Closed/ONAll =Open/OFF

RF Detector Yes =Closed/ONNo =Open/OFF




OPEN

Table 3-12 Networked System Operating Remotely PowerSupply


Master

(Set FrontPanel to:Remote)

Rem Analog Open/OFF






OPEN

Remote

(Set FrontPanel to:Remote

Rem Analog Open/OFF


RF Detector Yes =Closed/ONNo =Open/OFF




OPEN

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Installation 3-15


SW3 Control Board Dip Switches

Table 3-13 SW3 Control Board Dip Switches

DipSwitch

Description Switch Settings

1 OFF

LIG

CA

NO

NO

NOC

2 OFFIG

HT

DE

T

CA

N C

TR

L

NO

T U

SE

D

NO

T U

SE

D

NO

T U

SE

D

CA

N/485

3 OFF Digital

4 OFFOPEN Analog

5 OFF

g

6 Closed/On = Digital light detector in thelamphead

Power Supply Address Switch See Figure 3-15

The rotary address switch is located on the mainboard right next to the DIP switch and has 0through 9 and A through F as locations. The switchis used to identify the electronic address of thepower supply if it is set up in a network.

When Remote Configuration (REM CFG) isEnabled or ON on the control board, the addressmust be set from the front panel.

When Remote Configuration (REM CFG) isdisabled or OFF on the control board, the addressmust be set properly on the board.

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Installation3-16


Standalone Units

When operating the power supply as a standaloneunit (single) the switch must be set in the 0position.

When Remote Configuration (REM CFG) isEnabled or ON on the control board, the addressmust be set from the front panel.

When Remote Configuration (REM CFG) isdisabled or OFF on the control board, the addressmust be set properly on the board.

Networked Units

When operating the power supplies in a networkedconfiguration (master/remote), you must set therotary power supply address switches as follows:

Unit Rotary Switch Setting

Master 0

Remote(s) any different value

Example: Set the master to 0, remote 1 to 1,remote 2 to 2, etc.

1500118A

NORDSON

739034A

U6

0

71

9

10

12

3

4

6

OPENOPEN

1 2 3 4 5 61 2 3 4 5 6

0

Figure 3-15 Power Supply Address Switch on Main Control Board

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Installation 3-17


Remote Configuration ofMain Control Board Remote configuration allows for easy user interfaceby using the front panel display and select buttonsto change the configuration settings of the maincontrol board. In order to begin the remoteconfiguration:

� Set SW1 switch position 5 in the Up/Onposition.

� If you will be controlling the output power of thelamphead (used on variable output powersupplies only), the jumper for the 4-20ma or0-10vdc should be set at this time.

1. Connect input power to the power supply.2. Place the front panel power switch to the ON

position. The system display will go through aPOWER UP TEST. Refer to Tables 3-14 and3-15 to configure the main control board.

3. Once the POWER UP TEST is complete, pressthe Magnetron 2 and Local buttonssimultaneously for 3-5 seconds. (The displayshould read ID 00 or ID 01, 02, 03,etc.). Usethe UP/DN button to set the configuration thenpress Set/Save to save the setting and advanceto the next field.

Table 3-14 Panel Display Function

Front Panel Button Description

Magnetron #2/Local Press simultaneously for3-5 seconds to enterconfiguration menu

Set/Save Set choice/Advance tonext field

Up/Down Allows field choiceselection

4. The display reads FLT A or FLT U. Use theUP/DN button to set the configuration thenpress Set/Save to save it and advance to thenext field.

5. The display reads RFD Y or RFD N. Use theUP/DN button to set the configuration thenpress Set/Save to save it and advance to nextfield.

6. The display reads NT 485 or NT CAN. Use theUP/DN button to set the configuration. PressSet/Save to save this configuration andadvance to next field.

7. The display reads ANA Y or ANA N. Use theUP/DN button to set the configuration thenpress Set/Save to save it and advance to nextfield.

8. The last display will read PWROFF. Turn thePower Supply power switch to OFF position.This will set the flash configuration memory.

9. The remote configuration of the main controlboard is complete. From this point forward, youwill not need to remove the power supply coverto configure the main control board.

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Installation3-18


Table 3-15 Configuration Options

Display Function Configuration 1 Configuration 2

ID 00..15 Sets master or slavepower supply identification

Master = ID 00 Remote = ID 01..15

FLT Sets Unit Fault to faultunits separately or alltogether

Fault U = Fault Unit Fault A = Fault All units

RFD Sets RF detector for eachpower supply

RFD = Y (yes)

(RFD is needed for masterunit.)

RFD = N (no)

NT Sets communicationnetwork for use withMaster/Remote units

NT 485 = 495 protocolcommunication network

NOTE: As of January2005, only the NT 485communication is active.

NT CAN = CAN BUScommunication network

ANA Sets remote input to powersupply via I/O boardconnection

ANA Y = Y (yes)

NOTE: If analog input isused to control thelamphead output, a jumperfor 4-20 ma or 0-10 Vdcmust be set on maincontrol board.

ANA N - N (no)

PWROFF Instruction to turn mainpower supply switch off

N/A N/A

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Operation 4-1


Section 4Operation


Introduction Startup procedures will vary depending on how thesystem was integrated into other equipment. As aresult, the startup procedures documented in thismanual are strictly for the UV equipment.

Display and Controls See Figure 4-1 and refer to Table 4-1.

1500119A

14

2

6

3 5

Figure 4-1 CoolWave System Displays and Controls

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Operation4-2


Display and Controls (contd)

Table 4-1 Displays and Controls

Item Control Description

1 Main Power Switch Turns the main power on and off to the CoolWave system.

2 SETUP Power supply configuration.

3 DISPLAY CURRENT Displays the current flowing to a magnetron. Press the buttonnext to the appropriate magnetron to display that magnetron’scurrent. To leave this display press the same button again.

4 LAMP Off: Turns the lamphead off.

Standby: Applies warm-up power to the magnetron filamentand the message WARMUP appears in the display whilewarming up. Once it is warm, STDBY appears.

On: Turns the lamphead on. LMPDLY displays as magnetronfilament warms up. LAMPON displays as the lampilluminates.

5 NETWORK Sets system operation from the Local or front panel mode to aRemote or external device or controller.

6 Digital Display Displays power levels, operation and fault messages.

Display Messages During operation, the system displays messagesthat indicate the system operating status. Table 4-2lists the display messages.

Table 4-2 Display Messages

Message Description

OFF The power is turned on to the power supply. The lamphead is in the Off mode.

WARMUP The magnetron filament is energized. This message will be present for onlythe filament warm-up time period, which is about 10 seconds.

STDBY The filament is warm and the unit is waiting for an On command.

LMPDLY Lamp ON has been enabled. The power contactor is closed, and high voltagehas been applied to the magnetrons. This message is present only for thelamphead warm-up period, which is about eight seconds.

LAMPON Lamp is On at the set power level.

L COOL Lamp was On and a Standby command has been received. The magnetronpower is shut off and the contactor is open. This message is present only forthe cool down period, which is about 30 seconds. The lamphead then goes toa standby state. The unit will not restart until the delay time expires.

C DELAY An Off command was received. The lamphead power is turned off. Themessage is present only for the cool down period, which is about 60 seconds.The unit will not restart until delay time expires.

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Operation 4-3


Fault Messages When a fault is detected, the unit shuts down thehigh voltage, turns on the FAULT relay output, anddisplays a fault message. Table 4-3 lists the faultmessages.

Table 4-3 Fault Messages

Message Fault Description

F PRSW Pressure Switch Insufficient or no air pressure in the lamphead.

F LOCK Interlock External interlock input is open.

F OTMP Over Temperature Transformer thermal switch(es) open. May be caused byinsufficient air flow through power supply cabinet.

F STOP STOP STOP interlock input is open.

F CABL Cable InterlockOpen

The high-voltage cable and/or the low-voltage cable from thepower supply to the lamphead is disconnected or open.

F RF RF Interlock RF detector is disconnected or has sensed high levels of RFfrom the lamphead.

F POWR Power Light output or magnetron current has been sensed when thepower supply is in the Off mode.

F LOUT Lamp Out There was insufficient output from the light detector when thepower supply energized the magnetrons in the Lamp Onmode.

F NETW Network The control board can no longer communicate with apreviously detected system.

F IBAL MagnetronCurrent Imbalance

The magnetrons are turned on (LAMPON) and the magnetroncurrents differ by more than 100 ma for a period exceedingabout 600 ms.

F OVER Magnetron OverCurrent

Either magnetron current exceeds 950 ma in the LAMPONmode.

F FUSE Open FilamentTransformerCircuit

There is no current detected on hte filament transformer cucuitwhen the power supply is turned on.

F MAG Short or ARC High current has been detected on high-voltage circuit.

F CFG Capacitor jumpersare not setproperly

The 50/60 Hz capacitor jumpers are not set for the correctfrequency.

FHDW Hardware andsoftwaremiscommunication

Miscommunication between control electronics and hardwaredue to incompatible software versions. Contact a Nordsonrepresentative.

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Operation4-4


Resetting a Fault Operating in the Local Mode: Press the Offbutton to clear a fault once it has been corrected.

Operating in the Remote Mode: Open and closethe off/reset contact to reset a fault once it hasbeen corrected.

NOTE: Once the fault has been corrected aremote unit can be reset by either the front panel ofthe master unit or a host controlling the master unit.

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Operation 4-5


Lamp Start-Up TimingDiagram for Remote InputContact Closures The Off/Reset contact must be closed for the unit togo to Standby or On. Once the lamphead is putinto the Standby or On mode the lamphead willremain in that mode until the Off/Reset contact isopened.

1500003A

Lamp Off Lamp to Standby Lamp to ON Lamp Off

1

0

1

0

1

0

LAMP ON

STANDBY

OFF/RESET

>100 ms pulse

10 seconds to warm up

8 seconds to stabilize

>100 ms pulse

Figure 4-2 Lamp Start Up Timing Diagram for Remote Input Contact Closures

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Operation4-6


Startup NOTE: Refer to the Troubleshooting section if thesystem fails during startup.

Locally Operated Units Table 4-4 Startup Procedures for Locally Operated Units

Step Single Unit Operated Locally

Multiple Units Networked to a Master UnitOperated Locally

1 Switch the electrical disconnect enclosure to ON.

2 Turn the main power switch on the front of the power supply unit to the on position. Thepower on message begins to scroll.

The power on message begins with the words UV CURING. Numbers will then scroll listingthe software version for the display board, phase board, main control board, light detectorinterface, and light detector board respectively.

3 Make sure that all interlocked access doors are closed and that the exhaust fan is running ifnot directly connected to the power supply blower contacts. If external interlocks are wiredand open, a fault message F LOCK will appear in the display.

4 On the NETWORK selector, press Local. Set the NETWORK configuration.

� On the master unit’s NETWORK selector,press Local.

� On the remote units’ NETWORKSelector, press Remote.

5 Enable the cooling fan by either an external/remote switch or a set of contacts from thepower supply. If the exhaust fan is wired to the normally open set of contacts on the powersupply they will close when the lamphead is put in STDBY or LAMPON mode. If there isinsufficient pressure (less than 5 in. W.C. static pressure) there will be a system fault and themessage F PRSW will appear in the display. (Check for proper pressure with theappropriate instrumentation.)

6 Start up the lampheads.

NOTE: If the LAMPON message does not appear, refer to the Troubleshooting section.

Rapid Startup

Use this procedure if your system will sit in an idle state in the STDBY mode beforemoving to the On mode.

1. On the LAMP selector (or master control unit’s LAMP selector) press the LAMPStandby button. There will be an approximate 10 second warm-up time for thefilament transformer. WARMUP will appear on the display.

2. After approximately 10 seconds the system will display STDBY until Lamp On ispressed.

3. Press the LAMP On button. It will take approximately eight seconds to stabilize.

Or

Standard Startup

Use this procedure to go directly through the warm-up to the On mode.

1. On the LAMP selector (or master control unit’s LAMP selector) press LAMP On.WARMUP will appear on the display.

2. After approximately 10 seconds the unit will display LMPDLY. It will take 10 secondsto stabilize as it goes through the warm up cycle before turning to On.

3. After approximately 10 more seconds and the unit(s) has stabilized at the set powerlevel, LAMPON will appear in the display and the system is ready to run.

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Operation 4-7


Remotely Operated Units Refer to Table 4-5.

NOTE: The system can be wired to initiatelamphead start from either the process machine orfrom the UV power supply control panel.

Table 4-5 Startup Procedures for Remotely Operated Units

Step Single Unit and Units Networked to a Master Unit Operated Remotely

1 Switch the electrical disconnect enclosure to ON.

2 Turn the main power switch on the front of the power supply unit to the on position. Thepower on message begins to scroll.

The power on message begins with the words UV CURING. Three numbers will then scrolllisting the software versions for the display board, main control board, and the phase boardrespectively.

3 Make sure that all interlocked access doors are closed and that the exhaust fan is running.If external interlocks are wired and open, a fault message F LOCK will appear in the display.

4 On the NETWORK selector, press Remote.

NOTE: For networked units, press Remote at each NETWORK selector.

5 Set the POWER SETTING. There are two ways of setting the POWER SETTING.

If the power level will be set at the control panel prior to turning on and off remotely (RemoteOperation), select the desired power level and save it while the unit is in Local mode. At theNetwork Selector then select Remote.

6 Enable the cooling fan by either an external/remote switch or a set of contacts from thepower supply. If the exhaust fan is wired to the normally open set of contacts on the powersupply they will close when the lamphead is put in STDBY or LAMPON mode. If there isinsufficient pressure (less than than 5 in. W.C. @ 300 cfm static pressure) there will be asystem fault and the message F PRSW will appear in the display. (Check for properpressure with the appropriate instrumentation.)

7 There are many ways that the system can be configured to operate Remotely. By utilizingthe power supply I/O the UV system can be controlled from a simple panel or fullyautomated to work in concert with a complete process. Contact a Nordson UV Curingrepresentative for details. Obs

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Operation4-8


Shutdown The system will stop if any of the followingconditions occur:

� LAMP STOP push button on UV operatorstation is pressed

� The power supply switch is turned to the offposition

� The LAMP On/Off switch is turned to Off

� Cooling air for the lamphead ceases or reachesan insufficient level

� Any of the safety interlocks wired into the UVequipment are interrupted. These includeexhaust fan, access panels, doors and processequipment

� Any fault condition occurs

Refer to Table 4-6 for shutdown procedures for theCoolWave UV system.

Table 4-6 Shutdown Procedures

Step Shutting Down Systems Locally Shutting Down Systems Remotely

1 Press the Lamp Off button. Press the Lamp Off button on the remote orhost machine.

2 Allow the lampheads five minutes of cooldown before shutting off the cooling air.

Allow the lampheads five minutes of cooldown before shutting off the cooling air.

CAUTION: Failure to do this cancause problems restarting the lampsas well as greatly reduce the life of thelamphead bulbs.

CAUTION: Failure to do this cancause problems restarting the lampsas well as greatly reduce the life of thelamphead bulbs.

NOTE: Typically the cooling fan will becontrolled by the remote or host machinethrough the I/O of the UV System.

3 Turn off the main power to all units.

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Maintenance and Repair 5-1


Section 5Maintenance and Repair


Maintenance andReplacement Schedule

Recommended maintenance to the power supplyconsists of cleaning or changing the cooling fanfilter material and removing dust from the powersupply.

Establish acceptable curing levels for your processand then develop a maintenance schedule that fitsyour needs. Radiometers can be used to measurerelative readings for spectral output as a means ofmonitoring spectral intensity.

The maintenance and replacement schedule forthe system will depend upon your:

� application process

� plant environment

� quality of cooling air passing through thesystem

� coating formulation

Table 5-1 Typical Maintenance and Replacement Schedule

Component Maintenance Guidelines Replacecomponent...

Filters

Remote blower

Filter material is designed to capture dust and contaminants fromthe plant before entering the UV equipment. These filters arelocated on the lampheads, remote blowers, and some power

Weeklyor as needed

cooling fanelectricalenclosure/

located on the lampheads, remote blowers, and some powersupplies (customer-supplied filters). Eventually, the filters willbecome loaded with matter and will start to impede the flow of air.A dirty filter also will release matter into the air stream that mayd i h b i d ll h b lb d fl

enclosure/lamphead

y ydeposit on the part being cured as well as the bulb and reflector.

Use soap and water to wash all filter material that provides coolingto any part of your UV system.

NOTE: Unmaintained or dirty filters can cause excessive heat, which will cause premature failure.

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Maintenance and Repair5-2


Replacement Procedures

Preparation 1. Turn off the UV system from the process

equipment controller or at the UV panel.

2. Allow the lamphead fan to complete its coolingcycle. If this has been prevented by prematureisolation of the control cabinet, always allowsufficient time for the bulb to cool beforeproceeding.

3. Turn off the main electrical disconnect. Followall relevant OSHA established lockoutprocedures.

Main Control Board 1. Remove the 10 M5 screws fastening the top

cover of the power supply. Remove the topcover.

2. Locate the main control board on the inner wallof the power supply and and disconnect all ofits connectors.

3. Using a #1 Phillips screwdriver, remove the sixM3 screws securing the main control board.

4. Carefully pull the main control board from thepower supply.

5. Using the old control board or the Installationsection as a guide, configure the new maincontrol board with the appropriate SW1 andSW3 dip switch settings, power supply addressswitch, remote analog jumper and digital/analoglight detector jumper.

6. Place the new control board in the properposition with the board’s part number located atthe top and secure the board to the powersupply’s inner wall with six M3 screws.

7. Secure the power supply’s top panel with the 10M5 screws.

8. Connect all the main control board connectorsremoved in step 2 of this procedure.

9. Restore power to the power supply and operateaccording to the procedures set up in thismanual.

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Maintenance and Repair 5-3


Fuses See Figure 5-1 to identify the four replaceablefuses on the main control board.

1500120A

Fuse

Fuse

NORDSON739034A

U6

0

71

9

10

12

3

4

6

OPENOPEN

1 2 3 4 5 61 2 3 4 5 6

Fuse

Fuse

F2 2A/250V

F1 160ma 250V

F3 3A/250V

F3 3A/250V

Figure 5-1 Main Control Board Fuses

Air Filter Cleaning and SupplyCooling Fan NOTE: Repeat the same procedure for all externalblowers.

NOTE: Some filter media can be washed andreused. Refer to the users’ manual for your blower.

1. Turn off the main electrical disconnect. Followall relevant OSHA-established lockoutprocedures.

2. Locate the cooling fan on the power supply. It islocated on the front side of the power supply.

3. Make sure the safety cover is clean and free ofany debris.

4. Examine fan blades for contamination. Cleanor replace if necessary.Obs

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Maintenance and Repair5-4


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Troubleshooting 6-1


Section 6Troubleshooting


Introduction This section contains troubleshooting procedures.These procedures cover only the most commonproblems that you may encounter. If you cannotsolve the problem with the information given here,contact your local Nordson representative for help.

General Troubleshooting NOTE: If your unit does not start up, disconnectpower to the unit then remove the cover and checkthe fuses. See Figure 7-1 for fuse locations.

Problem Possible Cause Corrective Action

1. Lamp Fault

Fault Message:F LOUT

The light detector outputs avoltage when the lamphead is inoperation: the voltage dropsbelow a minimum

Check the magnetron current, mainfuses, phase control board, and lightdetector.

Unicable at lamphead or powersupply is loose

Disconnect and reconnect the cable.

Bulb has failed Replace the bulb.

2. Pressure Fault

Fault Message:F PRSW

Cooling fan is not running Remote Blower: Check the motorstarter, fuses, and overloads. Resetor replace overloads and/or fuses ifnecessary.

Cooling fan is running in reverse Check the wires at the blower and atthe starter, check the fan rotation.

Filter on cooling fan is dirty Replace the filter on the blower.Wash the filter on the remote blowerwith soap and water.

Continued...

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Troubleshooting6-2


General Troubleshooting (contd)


2. Pressure Fault

Fault Message:F PRSW (contd)

Remote cooling fan is wiredimproperly

Switch two of the main input powerwires on the three-phase remoteblower. Air flow will be in the samedirection for all combinations;however, there will be greater air flowwhen the motor is spinning thecorrect direction. Follow the motorrotation diagram on the motor.

Pressure sensor has failed The pressure sensor is a normallyopen switch that closes with 5-in.W.C. static pressure. Make sure boththe external and internal port of theswitch are open and there are noobstructions. If there are noobstructions and the blower isoperating correctly, replace theswitch.

Pressure drop in remote blowerducting is too great

Ducting to the remote blower shouldbe large enough with minimum ofsharp bends to supply adequateventilation. If pressure faults haveconsistently been a problem, youmay want to consider mounting theremote blower closer to thelamphead, increasing the duct size orthe size of the blower.

3. Magnetron CurrentFault

(Normal magnetroncurrent is 720 ma � 25 mvdc @60 Hz, 660 ma � 25 mvdc @50 Hz

Fault Message:F POWR

The current in one or bothmagnetrons has dropped below200 ma for a duration of more than600 ms

Reset the lamphead and restart thesystem. If the problem still existsthere may be a magnetron failure.

Magnetron current is detectedwhen unit is off

Reset the lamphead and restart thesystem. If the problem still existsthere may be a magnetron failure.

4. Interlock Fault

Fault Message:F LOCK

Open external interlock Check all system interlocks.

Continued...

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Troubleshooting 6-3



5. Power SupplyOvertemp

Fault Message:F OTMP

Insufficient air flow to the powersupply

Clean the blower filters and makesure that there are no obstructions inthe blowers and the filters.

6. MagnetronOvercurrent Fault

Fault Message:F OVER

Magnetron current has exceeded950 ma

Check all the power supply tolamphead cables for damage orarcing. Check for signs of arcing inthe lamphead.

7. Network Fault

Fault Message:F NETW

A fault has been detectedsomewhere on the network; themaster shows F NETW and theproblem unit will display thespecific fault

Determine the unit with the fault andcorrect the fault. Clear the master orindividual control unit.

8. E-Stop system willnot start

Fault Message:F STOP

Pins 1 and 2 on the input are notjumpered

Add an E-Stop jumper between pins1 and 2.

E-Stop buttons are activated eitheron the power supply or externalequipment

Check and release all E-Stops.

9. Irradiator will not light

Fault Message:F CABL

Power supply to lampheadunicable is disconnected, faulty, ornot properly installed

Check the cable connections. Checkthe continuity of the cable. Refer topage 3-10 for proper unicableconnector installation.

10. RF Fault

Fault Message:F RF

RF detector switch is not setproperly on control board

Check the dip switch setting on themain control board.

RF detector is not properlyconnected

Check the connections.

RF cable is faulty Check the continuity of the cable.Replace the cable if necessary.

RF detector is detecting a highlevel of RF

Check the lamphead screen for holesand tears. Replace the lampheadscreen if necessary. Check to makesure the screen is securely fastened.

Continued...

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Troubleshooting6-4


General Troubleshooting (contd)


11. Magnetron currentimbalance

Fault Message:F IBAL

The current from magnetron 1 andmagnetron 2 has differed by morethan 200 ma for a time longer than600 ms

Magnetron current has fallenbelow 200 milliamps

Check the diode block five ohmfeedback resistor for short or open.

12. Open filamenttransformer circuit

Fault Message:F FUSE

Filament transformer fuse blown Check fuse on main circuit board.

Filament transformer bad Check output of filament transformer.

Filament in magnetron failed Replace the magnetron.

13. High current on thehigh voltage circuit

Fault Message:F MAG

Short in unicable Replace the unicable.

Short in the magnetron Replace the magnetron.

14. 50/60 Hz jumper arenot set correctly

Fault Message:F CFG

The jumpers that set the powersupply to run at 50 Hz or 60 Hzwere not set properly

Place the jumper on the capacitorlugs (refer to Figures 3-4 and 3-5).

15. Systemmiscommunication

Fault Message:F HDW

Miscommunication between thecontrol electronics and thehardware due to incompatiblesoftware versions.

Verify the software versions atsystem startup. Contact a Nordsonrepresentative.

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Parts 7-1


Section 7Parts

Introduction To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use thisfive-column parts list, and the accompanying illustration, to describe and locate parts correctly.

Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each partslist. The code NS (not shown) indicates that a listed part is not illustrated. A dash (—) is used when the partnumber applies to all parts in the illustration.

The number in the Part column is the Nordson Corporation part number. A series of dashes in this column(- - - - - -) means the part cannot be ordered separately.

The Description column gives the part name, as well as its dimensions and other characteristics whenappropriate. Indentions show the relationships between assemblies, subassemblies, and parts.

� If you order the assembly, items 1 and 2 will be included.

� If you order item 1, item 2 will be included.

� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit, assembly, or subassembly. The codeAR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list. Notes contain important informationabout usage and ordering. Special attention should be given to notes.

Item Part Description Quantity Note— 0000000 Assembly 11 000000 � Subassembly 2 A2 000000 � � Part 1

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Parts7-2


Power SupplySee Figure 7-1.

Item Part Description Quantity Note1 775784 50/60 HZ POWER SUPPLY, CoolWave 11 1075801 50 HZ POWER SUPPLY, internal blower,

CoolWave2 772225 � POWER TRANSFORMER, CoolWave 23 772241 � TRANSFORMER, step down, 480-240 14 772219 � 50/60 Hz CAPACITOR, 1.1 Mf, 2500 Volt,

CoolWave4

5 1053812 � FUSE, kit, CoolWave 1 A, B5a - - - - - - � � FUSE, 30 amp 3 B5b - - - - - - � � FUSE, 160 ma 250 volt 1 B5c - - - - - - � � FUSE, 2 amp, 250 volt 1 B5d 130200 � � FUSE, 3 amp, 250 volt 2 B6 775935 � FAN, cooling, CoolWave 2 A7 1054505 � PCB, CONTROL, CoolWave 18 320265 � PCB, DISPLAY, CoolWave 19 320475 � PCB, I/O, CoolWave 1 A10 772224 � MODULE, rectifier, CoolWave 211 - - - - - - � PAN HEAD SCREW, M5 x 10, with captive lock

washer, stainless steel10

12 775022 RF DETECTOR, CoolWave 6/10 1 ANS 772214 FAN, cooling, CoolWave ANS 1074169 MANUAL, CW410 lamphead

NOTE A: Recommended spare part. Keep this part in inventory to avoid unplanned downtime.

B: The fuse kit part, 1053812, contains three 30 amp, 500 volt main fuses; one 160 microamp, 250 voltcontrol board fuse; one two amp, 250 volt fuse for the filament transformer; and two three amp, 250 voltblower fuses.

NS: Not Shown Obsole

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Parts 7-3


1500121A

4

2 6

6

2 3

8

1

9

12

10

5c

5b

7

NORDSON739034A

U6

0

71

9

10

12

3

4

6

OPENOPEN

1 2 3 4 5 61 2 3 4 5 6

7

5

5a

5d

11

Figure 7-1 CoolWave Power Supply and RF Detector

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Parts7-4


Cables See Figure 7-2. Order the correct cable length foryour particular system.

Item Part Description Quantity Note13 775374 12-ft UNICABLE 113 775023 25-ft UNICABLE 113 775375 50-ft UNICABLE 113 775377 75-ft UNICABLE 114 1061134 12 ft CABLE, RF detector, 6/10 114 775029 25 ft CABLE, RF detector, 6/10 114 775050 50 ft CABLE, RF detector, 6/10 114 775051 75 ft CABLE, RF detector, 6/10 114 775052 100 ft CABLE, RF detector, 6/10 115 775031 NETWORK CABLE, 6 ft, 6/10 115 1071854 NETWORK CABLE, 4 ft, 6/10

NS: Not Shown

1500122A

1

R

R

15

1

14 12

13

13

Figure 7-2 Cables

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Specifications 8-1


Section 8Specifications

Power Supply

Table 8-1 Power Supply Specifications

Item Specification

Dimensions

length 654.05 mm (25.75 in.)

width 460.37 mm (18.125 in.)

height 209.55 mm (8.25 in.)

Weight 62 kg (138 lb)

Voltage 200/210/240 Vac, 3�, 50/60 Hz

Current Refer to Table 8-2

Ambient Temperature 5-40 �C (41-104 �F)

Relative Humidity up to 80%

Magnetron Current 720 mv dc at ± 5% mag1-mag2

Table 8-2 Power Line Current

Line 60 Hz 50 Hz

Amps @200 Vac

Amps @210 Vac

Amps @ 240 Vac

Amps @200 Vac

Amps @210 Vac

Amps @240 Vac

L1 26 24 22 23 22 20

L2 16 15 14 15 14 13

L3 17 16 15 15 14 13

System Drawings See Figures 8-1 through Figure 8-6 for the following system drawings.

Figure 8-1: UV Connector Board

Figure 8-2: IO Wiring

Figure 8-3: System Schematic - CW-410F

Figure 8-4: System Schematic - CW-410F, 50 Hz

Figure 8-5: Motor Control Wiring, MPS410 50 Hz

Figure 8-6: System Installation

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Specifications8-2


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Specifications 8-3


1500009A

NOT USED

Figure 8-1 UV Connector Board

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Specifications 8-4


1500135A

Figure 8-2 IO Wiring

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Specifications 8-5


Figure 8-3 System Schematic - CW-410F

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Specifications 8-6


Figure 8-4 System Schematic - CW-410F, 50Hz

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Specifications 8-7


Figure 8-5 Motor Control Wiring, MPS410 50 Hz

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Specifications 8-8


1500064B

UNICABLE

UNICABLE

DIS

PL O

R LE

DR

EM

CF

GF

RT

PN

L LOC

KR

F D

ET

FAU

LTR

EM

AN

ALG

LIGH

T D

ET

CA

N C

TR

LN

OT

US

ED

NO

T U

SE

DN

OT

US

ED

CA

N/485

DIS

PL O

R LE

DR

EM

CF

GF

RT

PN

L LOC

KR

F D

ET

FAU

LTR

EM

AN

ALG

LIGH

T D

ET

CA

N C

TR

LN

OT

US

ED

NO

T U

SE

DN

OT

US

ED

CA

N/485

R

268.00 mm(10.551 in)

312.00 mm(12.283 in)

200.50 mm(7.894 in)

280.00 mm(11.024 in)

374.00 mm(14.724 in)

654.00 mm(25.750 in)

R

268.00 mm(10.551 in)

312.00 mm(12.283 in)

200.50 mm(7.894 in)

280.00 mm(11.024 in)

374.00 mm(14.724 in)

654.00 mm(25.750 in)

NOTE: Refer to the Installation section for correct main board settings.

NOTE: THIS BOARD MANUFACTURED PRIOR TO AUG 2004

LAM

P 6“/10”

RE

M A

NA

LG E

N/D

ISLO

C LK

OU

T/N

OR

MA

LFA

ULT

ALL/U

NIT

NO

NE

/RE

DE

TS

LAV

E/M

AS

TE

R

Figure 8-6 System Installation

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UV Glossary 9-1


Section 9UV Glossary

absorption Not reflecting. The partial loss in energy that results when light passesthrough or reflects off a medium.

actinic UV Low-powered UV in the UVC band. Usually powered with several100-watt power supplies or less instead of several 1000-watt powersupplies. Nordson’s UV Star and CoolWave product lines are muchhigher in irradiance and energy density than actinic UV products.

additive bulb A mercury bulb that contains metal additives such as iron, gallium,indium, or others. These bulbs produce variations in spectral outputas compared to mercury only bulbs.

adhesion The state in which two surfaces are stuck together.

arc length The distance measured between the electrodes in a quartz bulb. AlsoRefer to effective cure length.

ASTM spec D3359-95a Refer to tape test.

ballast An inductive transformer device that stabilizes the amount of currentflowing through the bulb so that the power output remains constant.

black light UV Low powered UV composed of wavelengths in the UVA band. Usuallypowered with several 100-watt power supplies or less instead ofseveral 1000-watt power supplies. Nordson’s UV Star and CoolWaveproduct lines are much higher in irradiance and energy density thanblack light UV products.

bulb A sealed quartz tube that contains a mixture of inert gas and mercuryunder medium pressure. Electrode bulbs are fitted with electricalconnections at the ends of the bulb. Microwave bulbs contain noelectrical connections. The mercury and inert gas are energized(vaporized) by either a voltage arc or microwave energy. Thevaporized plasma gas emits UV light.

burn-in period The second stage of the startup process of an electrode UV bulb. Thetotal time that it takes the current and voltage inside the bulb tostabilize during startup.

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UV Glossary9-2


capacitor Corrects the power factor in the main power supply to reduce currentlevels in the UV system.

cold mirror A reflector that is coated with a dichroic material that absorbs orpasses wavelengths in the infrared range while reflecting those in theUV range. Refer to dichroic.

cover The upper half of the lamp head assembly or the sheet metal top ofthe power supply. In the lamp head, the cover contains openings andbaffles through which cooling air passes.

cradle Supports the UV bulb and reflector inside an electrode lamp headhousing.

cross hatch test Refer to tape test.

cure A UV drying process that occurs through a chemical reaction betweena UV ink or coating and UV light.

cure length Refer to effective cure length.

dichroic A coating designed to pass certain wavelengths and reflect otherwavelengths. In UV lamp heads, dichroics are used on reflectors topass or absorb infrared energy and reflect UV energy.

devitrification The act of making quartz glass opaque and porous through prolongedheating and UV exposure.

doped bulb Refer to additive bulb.

dose (dosage) Refer to energy density.

dose rate (dosage rate) Refer to irradiance.

Dual Concentrated Focus(DCF)

An electrode system where two bulbs and two angled reflectors arepositioned within one cradle. The UV light in a DCF system isconcentrated into a single band of energy.

dynamic exposure Exposure to a varying irradiance. It occurs when a lamp head passesover a substrate without pausing or when a substrate passes under alamp head without pausing.

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UV Glossary 9-3


dynamic range The span between the minimum irradiance and the maximumirradiance to which a radiometer will accurately respond. Measured injoules/cm5.

effective cure length The length of a bulb that delivers optimal UV output. For electrodebulbs, the effective cure length is always less than the arc length. Formicrowave bulbs, the effective cure length is the length of the bulb.

electrode The electrical fitting on the inside of an arc bulb. The electrodeconsists of a tungsten pin surrounded by a tungsten coil and is used tomaintain a voltage arc across the bulb. Electrode is also used to referto the style of bulb or system when differentiating between microwaveand electrode bulbs and microwave and electrode systems.

electrodeless A microwave-powered UV system.

electromagnetic spectrum The full wavelength range of electromagnetic radiation, includingmicrowave, ultraviolet, visible, and infrared energy.

energy density The total amount of UV energy delivered to a particular area,measured in joules/cm2. Also referred to as total energy. Improperlyreferred to as dose.

erythermal UV Low-powered UV in the UVC band. Usually powered with several100-watt power supplies or less instead of several 1000-watt powersupplies. Nordson’s UV Star and CoolWave product lines are muchhigher in irradiance and energy density than erythermal UV products.

flood An unfocused band of UV light that is more evenly and diffuselydistributed across the width of the reflector.

flux The flow of photons, measured in einsteins/second.

focal distance (length) The perpendicular distance from the edge of the lamp head to thepoint where the UV light emitting from the bulb converges. This is thelocation of maximum UV concentration.

focus The band where the UV energy reflected from the lamp head is at thehighest concentration.

frequency The number of times a periodic wavelength cycle occurs in onesecond, measured in Hertz (Hz).

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UV Glossary9-4


gallium A bluish-white metallic element used in additive mercury bulbs. Thegallium additive provides a yellowish tint to an unenergized UV bulband a violet coloration to the UV output. Gallium bulbs have a spectralpeak around 417 nm and a spectral concentration between 400 and450 nm. They are often used when deeper cure is required or withwhite coatings containing titanium oxides. In some industries,microwave gallium bulbs are referred to as V bulbs.

germicidal UV Low-powered UV in the UVC band. Usually powered with several100-watt power supplies or less instead of several 1000-watt powersupplies. Nordson’s UV Star and CoolWave product lines are muchhigher in irradiance and energy density than germicidal UV products.

housing The lower half of the lamp head assembly. Its function is to support thecradle.

igniter Refer to starter.

indium A silver-white metallic element used in additive mercury bulbs. Theindium additive provides a yellowish tint to an unenergized UV bulband a violet coloration to the UV output. Indium is used to shift thespectral output past 400 nm. In some industries, indium bulbs arereferred to as Q bulbs.

infrared energy Energy having wavelengths between 1 and 100 µm.

integral cooling fan(blower)

The bulb-cooling fan when it is mounted to the lamp head.

integral shutter A shutter assembly that is built into the lamp head. Common designsinclude a pneumatically actuated clam shell that blocks the light whenclosed and acts as a reflector when open and a pneumatic slidemechanism that moves the lamp head behind an internal louver whenshuttered. Shutters are typically associated with electrode systems.

intensity The amount of UV energy delivered to a particular area per unit time,measured in joules/cm2/sec or watts/cm2/sec. Also referred to as wattdensity. Improperly referred to as dose rate.

iron A white metallic element used in additive mercury bulbs. The ironprovides a reddish tint to an unenergized UV bulb and a bluishcoloration to the UV output. Iron is used to concentrate the spectraloutput between 350 and 400 nanometers. In some industries, ironbulbs are referred to as D bulbs.

irradiance Radiant power arriving at a surface from all forward angles per unitarea, measured in watts/cm2.

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UV Glossary 9-5


irradiator Refer to lamp head.

joule Metric unit for measuring work or energy. One joule is equivalent tothe work done by a force of one Newton acting through a distance ofone meter. (1 KW-hour equals 3.6 x 106 joules).

lamp Refer to bulb.

lamp head Assembly containing a sheet metal housing and cover and integral orremote cooling fan. An electrode system also contains cradles and amicrowave system contains magnetrons, a cavity, and a screen.

light detector A photocell inside a microwave lamp head that confirms UV output.

long UV Refer to UVA.

louver A part of a UV shutter system or shielding section that blocks the UVlight while allowing cooling air to pass through.

magnetron Assembly contained inside a microwave lamp head that convertshigh-voltage electrical input into RF energy.

mercury A silver-white metallic element that is liquid at room temperature and isused to create a vaporized, UV-emitting gas plasma inside a quartztube when it is energized through the use of either a voltage arc ormicrowave energy. When energized the bulb produces a bright whiteUV output. Mercury bulbs have a peak spectral output around 365 nmand a concentration around 254 nm. In some industries, mercurybulbs are referred to as H bulbs.

mercury plus (H+) Microwave bulbs that contain additional mercury. Mercury plus bulbsare only available in microwave systems as it is difficult to vaporize theadditional mercury in an electrode bulb.

mercury arc An electric discharge passed between two electrodes and through amercury vapor medium inside a quartz tube.

metal halide bulb Refer to additive bulb.

micrometer (�m) Unit of length equivalent to one millionth of a meter.

microwave That part of the electromagnetic spectrum associated with the largerinfrared waves and the shorter radio waves.

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UV Glossary9-6


monomers A molecule of relatively low molecular weight and simple structurecapable of combining with itself or other similar molecules to formpolymers.

nanometer (nm) Unit of length equivalent to one billionth of a meter.

negative cooling When the cooling air for the lamp head is drawn from the areasurrounding the substrate being cured and through the lamp head.Negative cooling provides exhaust for the UV system if it is ducted toatmosphere. Negative cooling is most often supplied through aremote cooling fan.

nitrogen blanketing Refer to nitrogen inerting.

nitrogen inerting When the coating or ink is flooded with a nitrogen blanket to preventthe coating or ink from oxidizing before cure. Nitrogen inertionreduces oxygen inhibition.

oligomers A low molecular weight resin or polymer used in a radiation curablecoating.

out-of-focus When a lamp head is located further away from the substrate or closerto the substrate than the focal distance.

oxidizing When the coating or ink reacts with oxygen and slows thepolymerization process of the cure.

oxygen inhibition Oxygen slows the cure response of UV curable coatings. The higherthe ratio of exposed surface area to coating mass, the greater theimpact oxygen has on the coating.

ozone (O3) An unstable, colorless gas with a penetrating odor that is generated bythe reaction of short-wave UV light (≈184 nanometers) with air.

ozone-inhibiting(ozone-free) bulbs

Bulbs where the quartz is manufactured with an additive that preventsthe transmission of UV beneath 200 nm in wavelength. It is thereaction of short-wave UV light (≈184 nanometers) with air thatproduces ozone.

Parts Per Million (PPM) The units of the Threshold Limit Value (TLV) when referring to themaximum level of a substance that a person should inhale over an8-hour shift during a 40-hour week without producing an ill effect. Alsorefer to Threshold Limit Value.

peak irradiance (peakpower density)

The maximum irradiance measured over a sample period, measuredin joules/cm2/sec or watts/cm2.

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UV Glossary 9-7


photoinitiator A molecule which when exposed to a specific wavelength of energyforms a reaction that begins the cure process.

photopolymerization Turning a liquid (wet) into a solid (dry) through exposure to UV light.

planar shutter A shutter assembly that is attached to the outside of a lamp head.The louvered shutter moves perpendicular to the emitted UV light.

polymer A macromolecule consisting of a large number of monomer units.

positive cooling When the cooling air for the lamp head is blown through the lamphead and onto the substrate being cured. Positive cooling can besupplied through either an integral or remote cooling fan. Withpositive cooling, an additional exhaust system is required to removeheat and ozone.

post cure The continuation of chemical reactions in the ink or coating afterexposure to UV has ceased.

power density Refer to irradiance.

quartz plate Plates that allow UV energy to penetrate with minimal loss in intensityand are mounted in front of the lamp head. The plates are used toprevent positive cooling air and airborne contaminants from contactingthe substrate, negative cooling air from contaminating the bulb andreflectors, or to remove some of the infrared that is radiated from theUV bulb. If the goal is to reduce the amount of heat contacting thesubstrate, additional cooling air must be blown across the quartz. Ifadditional air is not used, the quartz will eventually heat up and beginradiating heat onto the substrate. To further reduce heat, the quartzcan be coated with a material that passes UV light and absorbsinfrared energy.

quartz tube (1) A sealed tube made from a silicate material that is filled with aprecise mixture of mercury and various inert gases and sometimesfitted with electrical connections. The vapor emits light when it isenergized through the use of either a voltage arc or microwave energy.Often used to refer to the bulb.

(2) An open tube made from a silicate material through which asubstrate can pass. The tube is often placed in front of a UV lamphead and flooded internally with Nitrogen. Parts traveling through thetube are then safeguarded from exposure to the oxygen and ozone inthe lamp head cooling air.

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UV Glossary9-8


reflector Reflect and concentrate the UV light onto the substrate. Rolled fromhighly polished aluminum sheet metal or formed from borosilicate intoelliptical or parabolic profiles. Elliptical profiles optimize theconcentration of UV energy that is reflected by guiding the radiationinto a tightly focused UV band while parabolic reflectors result in aflood of UV light. Holes or slots in the reflector allow cooling air topass through. The holes or slots are engineered for size and locationto provide both optimal and balanced airflow across the length of thebulb.

remote cooling fan (blower) The cooling fan when it is mounted separate from the lamp head andducted in to the lamp head.

RF Radio Frequency. Any frequency between normally audible soundwaves and the infrared light portion of the spectrum lying between10 KHz and 1,000,000 MHz.

RF detector Monitors RF levels in the vicinity of the UV system and signals thepower supply to shut off the UV if RF levels exceed allowable limits.

screen A wire mesh assembly attached to a microwave lamp head that allowsUV to pass through but prevents RF from leaking from the unit.

short UV Refer to UVC.

single An electrode lamphead assembly with a cradle that supports only onebulb and one reflector.

shutter An assembly designed to block UV light while passing cooling air.

solarization The effect of the UV light on the quartz bulb. Over time, UV light andheat will cause the quartz to devitrify or revert back to a crystalline andporous state.

spectral output The various wavelengths of light emitted from a UV bulb.

spectral output efficiencygraph

A graph or chart showing the relative concentration of UV at variouswavelengths for a particular bulb type. Typically, the concentration isprovided as a normalized percentage where the energy is integratedover 10-nanometer bands to reduce the difficulty of quantifying theeffects of line emission spectra.

starter Used in electrode, ballast-based systems to vaporize the mercury.The starter puts a 3,000-4,000 volt potential across the bulb duringstart up and has an internal circuit that discontinues the potential whencurrent is established.

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UV Glossary 9-9


starter bulb Used in the start up of microwave systems to ignite the mercury vaporin the bulb.

static exposure Exposure to a constant irradiance for a controlled period of time.

striking The initial phase of the startup process where the mercury in the bulbis vaporized.

surface cure When the UV material is cured only on the surface exposed to the UV.

tape test for measuringadhesion

When an X-cut or lattice pattern of 6 or 11 cuts are scratched throughthe UV cured material to the substrate. Pressure-sensitive tape isthen applied over the cuts and removed. Pulling the tape away fromthe substrate will reveal the degree of adhesion. If any materialbetween the lines is pulled off with the tape, the adhesion is poor. Ifthe material remains, the adhesion is good. The recommendedguidelines for testing and evaluation are documented in the ASTMspec D3359-95a under Methods A and B. Method A employs theX-cut and is used for coatings that are 5 mils or greater. Method Bcalls for lattice cuts and is recommended for coatings with 0-5 mils ofthickness.

through cure When the UV material is cured down to and including the material /substrate interface.

Threshold Limit Value(TLV)

The maximum exposure a person should receive over an 8-hour shiftduring a 40-hour week without producing an ill effect. Often reportedin (mg / m3) or ppm.

Time-Weighed Average(TWA)

Refer to Threshold Limit Value (TLV).

total energy Refer to energy density.

transmittance The ratio of the radiant energy passed through a body to the totalradiant energy received by the body.

ultraviolet light Radiant energy in the wavelength band of 100 to 400 nanometers.

UVA (315-400 nanometers) The portion of the electromagnetic spectrum ranging between 315 and400 nm. UVA represents the largest portion of UV energy and iscommonly referred to as long UV. UVA is most responsible for skinaging and increased skin pigmentation. UVA is at the lower limit ofsensitivity to the human eye.

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UV Glossary9-10


UVB (280-315 nanometers) The portion of the electromagnetic spectrum ranging between 280 and315 nm. UVB is most responsible for reddening and burning of theskin and damage to the eyes.

UVC (200-280 nanometers)

The portion of the electromagnetic spectrum ranging between 200 and280 nm. UVC is typically referred to as short UV.

UVV (400-445 nanometers)

The portion of the electromagnetic spectrum ranging between 400 and445 nm. The V stands for visible UV.

vacuum UV (100-200 nanometers)

The portion of the electromagnetic spectrum ranging between 100 and200 nm. UVV does not transmit in air.

viscocity The state or quality of having a cohesive and sticky fluid consistency.

vitrification The act of changing pure opaque quartz into clear non-porous quartzthrough a fusion process.

watt One joule per second.

watt density Refer to irradiance.

waveguide Directs microwaves toward the bulb in microwave UV systems.

wavelength The measured cycle length of a wave in the direction of propagation.

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DECLARATION of CONFORMITY

PRODUCT:

CoolWave CW--410

APPLICABLE DIRECTIVES:

73/23/EEC (Low Voltage Directive)

89/336/EEC (Electromagnetic Compatibility Directive)

STANDARDS USED TO VERIFY COMPLIANCE:

EN61010--1:2001 EN55011 EN61000--4--4

EN61000--6--4 EN61000--4--2 EN61000--4--5

EN61000--6--2 EN61000--4--3 EN61000--4--6

PRINCIPLES:

The product specified conforms to the directives and standards described above.

This product has been designed and manufactured to general and safety requirements:

CAN/CSA--C22.2 NO. 61010.1, 2nd Edition 7/12/04

UL61010A--1, 2nd Edition Revised 7/12/04

Date: 23 May 2007

James W. SchmitkonsPrincipal Engineer, UVGroup

Nordson Corporation S Westlake, Ohio DOC15002A

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