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F300S/F300SQ
Ultraviolet Lamp System
Installation, Operation, and Maintenance
Manual No. 509252 Rev R 3/04
FUSION UV SYSTEMS, INC.
910 Clopper Road
Gaithersburg, MD 20878-1357 USA
(301) 527-2660 • FAX (301) 527-2661
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F300S/F300SQ Ultraviolet Lamp System Installation, Operation, and Maintenance Manual No. 509252 Rev R 3/04 Applies to systems using P300M/P300MQ/P300MT power supplies, and I300M/I310M series irradiators Serial Numbers 1001 and later. (C) Copyright 2004 Fusion UV Systems, Inc. All Rights Reserved. The products covered herein conform to EC standards. See Appendix A for details. FUSION UV SYSTEMS, INC. 910 Clopper Road Gaithersburg, MD 20878-1357 USA (301) 527-2660 • FAX (301) 527-2661
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Table Of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Indications of Note, Caution, Warning, and Danger . . . . . . . . . 12 Icon Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 System Components . . . . . .
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Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 UV Curable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Chapter 2. Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Mechanical Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 31 Unpacking and Inspection . . . .
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Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 System Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Frequency Tapping of HV Capacitors . . . . . . . . . . . . . . . . . . . 51 QRO HV Capacitors (For QRO only) . . . . . . . . . . . . . . . . . . . . 51 High Voltage Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . 51 QRO Transformer Taps (FOR QRO only) . . . . . . . . . . . . . . . . . 52 F300S Relay Coil Resi
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Bulb, Screen, and Reflector Maintenance . . . . . . . . . . . . . . . . 79 Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Bulb Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Reflector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Screen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 I300M Screen Assembly Removal/Replacement . . . . . . . . . . . 80 Lamp Bulb Removal/Replacement . . .
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Control Card Removal/Replacement . . . . . . . . . . . . . . . 107 Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 High Voltage Transformer Removal/Replacement . . . . . . 110 P300MT Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Safety Procedures . . . . . . . . . . . .
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P300M/P300MT Power Supply Parts List . . . . . . . . . . . . . . . . . . . 144 P300MQ Quick Restart Option Parts List . . . . . . . . . . . . . . . . . . . 146 K300 Blower Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . 147 Appendix F. Ignitor Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Ignitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Ignitor Bulb Removal/Replacement . . . . . . . . . .
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Introduction This manual is designed to be used, not set aside until problems occur. The following list of chapters and appendixes describes where to find information in this manual. • This Introduction provides a brief description of the total system, and system components. It also contains the Fusion UV Systems warranty policy and shipping instructions for returning equipment. • Chapter 1, “Safety,” contains important information! This chapter should be read by all persons who will operate
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• Appendix C, “Outline Drawings,” contains drawings that provide overview details for general reference for Fusion UV Systems products. These drawings are not to be used in designing an installation; contact Fusion directly for current specifications. • Appendix D, “Lamp System Maintenance Log,” contains an example of a Fusion UV Systems form to use for tracking lamp system maintenance. • Appendix E, “Replacement Parts,” lists the various accessory replacement parts available for Fusion UV
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DANGER: Danger indications identify conditions where death or permanent injury to personnel can occur if proper procedures and precautions are not followed. Icon Usage Several icons are used throughout the documentation to identify the types of hazardous resources or technologies used when working with a particular aspect of the system. Table 1, “Icons,” lists these and their definitions. Exercise extreme care by reading the material thoroughly and following all procedures when working with
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Table 1. Icons (continued) Icon Definition CAUTION: Ultraviolet Radiation This icon identifies instances where damaging levels of ultraviolet radiation may be present. Adequate shielding around the equipment and region must be provided, and be required to wear goggles with UV personnel should certified lenses. All personnel within ten feet of the lamp should wear gloves and long sleeves to protect their hands and arms, and ensure that their legs are covered. CAUTION: Radio Interference Fu
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Table 1. Icons (continued) Icon Definition Protective Conductor Terminal Earth (ground) Terminal Three Phase Alternating Current System Description The Fusion Ultraviolet Lamp System has been designed specifically for applications involving the industrial curing of inks and coatings and may be used effectively for a wide variety of applications. An ultraviolet (UV) lamp system for industrial curing must generate extremely intense radiation in the 200-400 nanometer region. Such radiation, when
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Figure 1. F300S/F300SQ Lamp System The F300S/F300SQ Fusion UV Lamp System (Figure 1) is modular, consisting of independent 6-inch (15.2 cm) lamp units and corresponding modular power supplies. Two lamps can be placed end-to-end to form a 12-inch (30.5 cm) lamp system or can be placed in a continuous array to form lamps of 18-inch (45.7 cm), etc. This is possible because the illumination of the lamp is a full 6". When two 6" lamps are placed end-to-end forming a 12" lamp, material being irra
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Electrical inputs to the lamp module are provided by a high voltage/control cable with a quick-connect fitting which supplies power for the magnetron, filament transformer and the interlock circuitry. System Components The basic F300S/F300SQ system consists of the following items: • A P300M/P300MQ/P300MT power supply • An HV Cable H340 (no modular blower) • An HV Cable H341 (with modular blower) • An I300 series irradiator • An RF detector cable H790 • An RF-1 detector In addition, the user mu
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Cooling Proper operation of the lamp requires adequate cooling of the magnetron and the bulb. (See Appendix C, page 129, for irradiator cooling requirements.) Cooling air from a blower goes through the magnetron cooling fins and into the lamp housing. At this point, the airflow splits into two paths: one path exhausts through the irradiator housing vent holes, and the rest of the air flows into the cavity through cooling holes in the reflector. This airflow cools the bulb and exhausts throu
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The following table lists the various irradiator models manufactured by Fusion UV Systems, and describes their high-level differences. Table 2. Irradiator Models Irradiator Model Photoresistor Assembly RF Gasket Air Delivery I300M Direct View Standard Front Connect Plenum I301M Direct View Standard Top Connect Plenum I300MB Direct View Standard Modular Blower I310MP Scatter View I6 Front Connect Plenum I311MP Scatter View I6 Top Connect Plenum I310MB Scatter View I6 Modular Blower I310MP-D Dire
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Mounting The lamps can be mounted over a moving substrate or web, supported by the bottom rails. The lamps should be mounted so that the rails sit 53 mm (2.1") above the surface to be cured. This allows the elliptical reflector to focus the most intense strip of light very near the substrate. Power Supply Each lamp system has its own power supply to house the high voltage circuits necessary to energize the magnetron, as well as all control and interlock electronics, and the built-in cooling
