Fusion F300SQ, F300S User Manual
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
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
Table Of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Indications of Note, Caution, Warning, and Danger . . . . . . . . . 12
Icon Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reflector and Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
P300M/P300MQ/P300MT . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RF Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shipping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Returned Material Authorization Number . . . . . . . . . . . . . . . . 22
General Packing Instructions . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Magnetrons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
UV Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
RF Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ultraviolet Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Microwave Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Personnel Effects of Microwave Radiation . . . . . . . . . . . . . . . . . . . 27
Radio Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ozone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation, Operation, and Maintenance Manual # 509252 Rev R 5
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
UV Curable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 2. Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Mechanical Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 31
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Supply Unit(s) Placement . . . . . . . . . . . . . . . . . . . . . . . . . 32
Irradiator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lamps Mounted in Opposing Configuration . . . . . . . . . . . . . . . . . . 34
UV Light Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RF Detector Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Remote Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Irradiator Exhaust Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Quartz Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 3. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical Installation/Setup Checklist . . . . . . . . . . . . . . . . . . . . . . 39
Accessory Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connection and Program Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installing the External Interlocks Control . . . . . . . . . . . . . . . . 40
User Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Supply Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Settings for Six-Position Switch S1 . . . . . . . . . . . . . . . . . . . . 41
Single Unit Programming and Connections . . . . . . . . . . . . . . . . . . 43
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Irradiator Cable H340 Connections . . . . . . . . . . . . . . . . . . . . 44
Input/Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remote Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Output Ports (J105B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Alternate Function for K5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Multiple-Unit Programming and Connections . . . . . . . . . . . . . . . . . 48
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 F300S/F300SQ Ultraviolet Lamp System
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 Resistor Assembly Installation . . . . . . . . . . . . . . 53
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
System Operation Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Lamp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Off/Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Initial Startup Procedure, Single Unit . . . . . . . . . . . . . . . . . . . . . . 56
Initial Startup Procedure, Multiple-Unit Systems . . . . . . . . . . . . . . 57
Master/Slave Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Operating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Resetting the System After a Fault . . . . . . . . . . . . . . . . . . . . 58
Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operation with Remote Controls . . . . . . . . . . . . . . . . . . . . . . 60
Quick Restart Option (QRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical Installation and Setup . . . . . . . . . . . . . . . . . . . . . . 63
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Basic Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Safety Interlock Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Unit Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fault Diagnosis Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Failure Diagnosis Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . 68
Chapter 6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
I300M Irradiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Installation, Operation, and Maintenance Manual # 509252 Rev R 7
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 . . . . . . . . . . . . . . . . . . . . 81
Reflector Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 82
I300M Irradiator Housing Removal/Replacement . . . . . . . . . . 86
Direct View Photoresistor Removal/Replacement . . . . . . . . . . . 87
Filament Transformer Removal/Replacement . . . . . . . . . . . . . 88
Magnetron Removal/Replacement . . . . . . . . . . . . . . . . . . . . . 89
Air Pressure Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Air Pressure Switch Replacement . . . . . . . . . . . . . . . . . . 91
I310M/I311M Irradiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Bulb, Screen, and Reflector Maintenance . . . . . . . . . . . . . . . . 91
Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Bulb Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Reflector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Screen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Screen Assembly Removal/Replacement . . . . . . . . . . . . . . . . 93
Lamp Bulb Removal/Replacement . . . . . . . . . . . . . . . . . . . . 93
Reflector Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 94
Replacing the RF Gasket Assembly . . . . . . . . . . . . . . . . . 99
I310M/I311M Irradiator Housing Removal/Replacement . . . . . 100
I310M/I311M Scatter View Photoresistor Removal/Replacement . .
100
Direct View Photoresistor Removal/Replacement . . . . . . . . . . 101
Filament Transformer Removal/Replacement . . . . . . . . . . . . 103
Magnetron Removal/Replacement . . . . . . . . . . . . . . . . . . . . 104
Air Pressure Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Air Pressure Switch Replacement . . . . . . . . . . . . . . . . . 105
P300M/P300MQ Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Test Point Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8 F300S/F300SQ Ultraviolet Lamp System
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Test Point Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Control Card Removal/Replacement . . . . . . . . . . . . . . . . . . . 113
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
High Voltage Transformer Removal/Replacement . . . . . . 116
K300 Modular Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 118
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Appendix A. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
RF Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
System Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . 125
Appendix B. Cables and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
System Connector Contact Kits . . . . . . . . . . . . . . . . . . . . . . 128
Appendix C. Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Appendix D. Lamp System Maintenance Log . . . . . . . . . . . . . . . . . . . . 139
Appendix E. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
I300M/I310M Irradiator Parts List . . . . . . . . . . . . . . . . . . . . . . . 142
Installation, Operation, and Maintenance Manual # 509252 Rev R 9
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 . . . . . . . . . . . . . . . . . . . . . . 150
Appendix G. Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10 F300S/F300SQ Ultraviolet Lamp System
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 or troubleshoot system equipment.
• Chapter 2, “Mechanical Installation,” gives unpacking instructions, and
instructions for equipment placement, mounting, shielding and exhaust venting.
• Chapter 3, “Electrical System,” explains the power supply software setup,
including single and multiple unit programming and connections. HV capacitor
frequency tapping instructions are also provided.
• Chapter 4, “Operation,” describes steps for initial startup for both single and
multiple unit systems, how to operate master/slave and remote systems, and how
to reset the system after a fault. It also contains setup and operations instructions
for the Quick Restart Option (QRO).
• Chapter 5, “Troubleshooting,” consists mainly of information in table form. There
is a reference table for faults and indications, tables describing unit and system
fault indications, and a fault diagnosis table. The fault diagnosis table provides
faults, causes, and corrective actions.
• Chapter 6, “Maintenance,” covers routine maintenance and removal/replacement
instructions for the irradiator, power supply and modular blower. There is a
maintenance procedure page locator at the front of the chapter.
• Appendix A, “Specifications,” outlines the various characteristics of major
components of the F300S/F300SQ Ultraviolet Lamp System. It also lists agency
approvals and certificates for the relevant systems and components.
• Appendix B, “Cables and Connectors,” provides information on the interconnect
cables and system connector contact kits used with the F300S/F300SQ Ultraviolet
Lamp System.
Installation, Operation, and Maintenance Manual # 509252 Rev R 11
• 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 Systems Irradiators.
• Appendix F, “Ignitor Bulb,” applies to lamps manufactured before July 1, 2002. It
describes the operation of the ignitor bulb that provides ignition to the main bulb.
• Appendix G, “Schematics,” contains figures that illustrate the various wiring
diagrams for Irradiator components.
Document Conventions
The products and components discussed in this document are designed and tested for
safe operation; however, they use technologies and resources that have inherent risks.
This section describes the conventions used throughout this manual when discussing
such technologies, so that users can plan and act accordingly when installing,
operating, or troubleshooting equipment.
Indications of Note, Caution, Warning, and Danger
Four categories of notice are indicated in this document; descriptions and examples of
their formatting are provided next.
NOTE: Notes serve to point out additional information about a subject or
process that is important, but not hazard-related.
CAUTION: Cautions generally indicate areas where a user should take
special care to avoid minor or moderate injury. It may also indicate
unsafe practices that could damage equipment or materials.
WARNING: Warnings indicate actions that can cause recoverable physical
harm; or destruction of equipment, data, or products.
12 F300S/F300SQ Ultraviolet Lamp System
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 the various
components.
Icon Definition
DANGER: Danger indications identify conditions where death or
permanent injury to personnel can occur if proper procedures and
precautions are not followed.
Table 1. Icons
CAUTION:
Exclamation Mark: This icon is used for other instances and
items for which a standard symbol does not exist.
CAUTION: Risk of Electric Shock
This icon identifies instances where dangerous or lethal
voltages might be present when working with various
components of the irradiator or site power.
CAUTION: Microwave Radiation
The Fusion UV Lamp System is powered by high
energy RF microwave power which can be dangerous if
misused or inadequately shielded. The lamp system
should never be turned on if the lamp housing and
screen are not intact, or if the microwave leak detector
and interlock are not functioning.
Installation, Operation, and Maintenance Manual # 509252 Rev R 13
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
personnel should
certified lenses.
should wear gloves and long sleeves to protect their hands
and arms, and ensure that their legs are covered.
CAUTION: Radio Interference
be required to wear goggles with UV
All personnel within ten feet of the lamp
Fusion lamps operate at a fundamental frequency of
2.45 GHz. The unit may cause interference with some
local area networks (LANs) that also operate at this
frequency. Please check with your LAN manufacturer
for compatibility. Ensure that the equipment is properly
maintained and shielded.
CAUTION: Ozone
High concentrations of ozone can cause discomfort, or at
sufficiently high levels be dangerous. Although Fusion lamp
systems make ozone at a level that could barely be detected
by odor and at a factor of five below the level of 0.1 parts per
million allowable for continuous exposure (American
Conference of Governmental Hygienists), all Fusion UV Lamp
Systems should be exhausted to the outdoors.
CAUTION: Hot Temperature, Do Not Touch
Surface temperatures of the lamp during normal
operation may exceed 120
the lamp will also be hot. Observe appropriate
precautions to avoid burns.
14 F300S/F300SQ Ultraviolet Lamp System
o
F. Metal components near
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 properly generated
and focused, and used in conjunction with specially formulated UV sensitive inks and
coatings, causes virtually instantaneous curing (drying) of the exposed materials.
The unique properties of the Fusion UV Lamp System are obtained by using
microwave radiation to energize the lamp. Microwave energy at 2450 MHZ is
generated by a power tube (magnetron) of the type widely available for commercial
microwave cooking ovens. The patented Fusion UV Systems lamp has no electrodes,
and consequently overcomes many of the basic limitations of conventional mercury
arc lamps.
Installation, Operation, and Maintenance Manual # 509252 Rev R 15
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 irradiated in the focal plane
53.3mm (2.1") below the lamp bottom, and at the juncture between the two lamps,
receives sufficient radiation from each 6" module to provide uniform curing over the
entire region.
Microwave energy from a single magnetron is directed into the cavity formed by an
aluminum reflector and a screen over the bottom of the reflector. The lamp bulb is
located inside this chamber. The screen keeps microwaves inside the chamber but
allows UV light to pass through onto the material to be cured.
16 F300S/F300SQ Ultraviolet Lamp System
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 must supply the following if not provided by Fusion UV Systems:
• Cooling for the irradiator, if no modular blower is provided. (See Appendix A,
“Specifications” and Appendix C, “Outline Drawings” for irradiator cooling
requirements.)
• Mechanical mounting of the lamp modules over a substrate, conveyor, or other
transport mechanism
Control
• Light shield surrounding the lamps
• Exhaust system for the light shield
• Any desired interlock mechanisms (see Chapter 3 on page 39)
• Electrical wiring of the power supply into the plant electrical system
The control system of the F300S/F300SQ provides precise control of high voltage and
filament voltage supplies. The control board also monitors cooling air pressure,
detection of RF, power levels, bulb ignition, and interlocks such as transformer
thermal switches. If a problem arises, the control system turns off all high voltage
power to the lamp and flashes a fault LED indicator on the power supply control panel.
Inputs for customer ON/OFF control are available. Outputs allow detection of
STANDBY or LAMP ON operation, or of interlock failures.
Installation, Operation, and Maintenance Manual # 509252 Rev R 17
Cooling
Irradiators
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 through the RF screen.
The I300M irradiator family is the heart of the UV system. For example, the model
I300M contains both the 15.2 cm (6") long electrodeless lamp bulb mounted in the
elliptical reflector and the magnetron which energizes the bulb. The reflector is
elliptical in cross-section and the lamp bulb is mounted at the focus of the ellipse,
producing an intense strip of light at the other focus of the reflector (53 mm [2.1"]
below the bottom rails of the lamp).
M3 screen retaining
screws (4) (2 per side)
RF screen
18 F300S/F300SQ Ultraviolet Lamp System
Cooling air holes
Lamp bulb
Cavity
Reflector
Figure 2. Reflector Assembly
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 Direct View I6 Front Connect Plenum
I311MP-D Direct View I6 Top Connect Plenum
I310MB-D Direct View I6 Modular Blower
Reflector and Cavity
The top of the reflector contains two rectangular slots which admit microwave energy
into the cavity. The slots are fed by one 1800 W, 2450 MHz magnetron located in the
top half of the lamp enclosure and connected to the cavity by a waveguide launcher.
Lamp Bulb
The lamp bulb (Figure 3) is made of quartz and has a tapered shape which optimizes
its UV, thermal, and microwave properties. The short quartz stubs at either end of the
15.3 cm (6") bulb provide mechanical support for quick mounting into spring-loaded
receptacles at the cavity ends. They are not electrodes and have no electrical function.
Figure 3. Lamp Bulb
Access to the cavity for changing the bulb or routine cleaning of the bulb and reflector
is easily accomplished by removing the screws which secure the screen assembly to
the bottom of the lamp. This procedure is explained in detail in Chapter 6,
“Maintenance”. The fine mesh screen must be intact and firmly secured to the lamp if
the system is to work properly and safely. The RF leakage interlock automatically
shuts the system off if excess microwave energy passes through the screen.
Installation, Operation, and Maintenance Manual # 509252 Rev R 19
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 fan.
The power supply is fully modular. Up to six units may be interconnected and
controlled from a single master unit. Any power supply may assume either Master or
Slave status in a multi-unit installation.
P300M/P300MQ/P300MT
The power supply high voltage circuit consists of a dual half-wave voltage doubler
circuit which supplies a regulated source of high voltage power (approximately
3900V, 700 mA DC) to the magnetron in the irradiator. The capacitors and diodes
provide regulation and rectification to the high voltage transformer outputs.
RF Detector
The system includes a detection device which shuts the system down if microwave
energy in excess of permissible levels is in danger of being released into the work
environment. This might be caused by a faulty RF screen or some other type of damage
to the lamp, or by inadequate or damaged shielding.
The power supply fault detection circuitry searches the system for a functioning RF
detector by means of the System Interconnections Bus. A multi-unit installation must
have at least one RF detector, which is usually connected to the master power supply.
Additional detectors may be connected to slave units.
During the startup sequence, each power supply will automatically perform a
functional test on any installed RF detector (if switch S1-5 is set to “YES”). The
operator may also verify detector operation by pushing a test button on the RF-1
module for 4 seconds. Complete information appears in Chapter 5, “Troubleshooting”.
System Interconnections
All electrical connections to the power supply are made through connectors at the rear.
Instructions for wiring are provided in Chapter 3, “Electrical System”. The power
supply does not require any routine maintenance other than occasional cleaning of the
interior with compressed air (depending on the environment).
20 F300S/F300SQ Ultraviolet Lamp System
Warranty Policy
Items manufactured by Fusion UV Systems Incorporated are warranted (under normal
and proper use) to be free from defects in material and workmanship. Fusion UV
Systems will repair or replace, at its option, any defective parts when returned to
Fusion by the purchaser, transportation paid. See the Terms & Conditions included
with your sales order for the length of the warranty period.
Equipment may not be returned, whether for warranty or other purposes, without prior
authorization and issuance of a Returned Material Authorization Number by Fusion
UV Systems. After inspection and acceptance, equipment returned for credit will be
subject to a handling and restocking charge.
Fusion UV Systems assumes no expense or liability for repairs made outside its plant
without written consent nor for any labor costs which are so incurred. For equipment
manufactured by others, Fusion UV Systems will pass along to the purchaser whatever
warranty it receives and will not be responsible for any incurred expense outside of
such warranty.
If repair of equipment is required but return of such equipment to Fusion UV Systems
is not feasible, then by mutual consent of Fusion and the purchaser, an authorized
Fusion UV service representative will be sent to the purchaser’s plant to effect
necessary repairs. The purchaser will be charged for the representative’s time and
expense.
Figure 4. P300M Front Panel
The two consumable items in a Fusion UV lamp system are the lamp bulb and the
microwave power tube (magnetron). The special warranties on these components are
detailed on the sales contract.
Installation, Operation, and Maintenance Manual # 509252 Rev R 21
NOTE: Any repairs or alterations, including the use of non-Fusion UV
Systems (Fusion) parts, made by the user of this product without Fusion
UV Systems’ prior written consent shall void all warranties provided by
Fusion UV Systems and such warranties shall cease to be in effect. No
allowance will be granted for such repairs or alterations. No person,
agent, representative, or distributor is authorized to give any warranties
on behalf of Fusion UV Systems, or to accept for Fusion UV Systems any
other liability in connection with any of Fusion UV Systems’ products.
Shipping Instructions
Read the following sections carefully to ensure compliance with the requirements and
recommendations for returning products or components, whether for credit,
replacement, or repairs.
Returned Material Authorization Number
Equipment may not be returned, whether for warranty or other purposes, without prior
authorization and issuance by Fusion UV Systems of a Returned Material
Authorization Number. After inspection and acceptance, equipment returned for credit
will be subject to a handling and restocking charge. Returned equipment must be
shipped prepaid.
General Packing Instructions
If possible, original packaging materials should be reused for return shipment to
Fusion UV Systems. If Fusion UV Systems’ packaging materials are not used,
equivalent packaging, as outlined in the following sections, is to be used.
Power Supply
Secure the chassis to the cover by M5 x 12 mm screws. (There are three on each side
of power supply for the P300M/P300MQ, two on each side of power supply for the
P300MT.)
Box: Bursting Test: 24 kg/cm
Gross Weight Limit: 70 kg (155 lbs.)
Fills: Rigid high density styrofoam or cardboard fills as required to
CAUTION: Packaging materials should not push against connectors or
controls.
22 F300S/F300SQ Ultraviolet Lamp System
2
(350 lbs./sq. in.)
ensure power supply does not shift in box during shipment.
Irradiators
Irradiators should be returned in their original packaging. If this is not available, lamps
must be double boxed, as follows:
The lamp is to be placed in an inner box, using cardboard fills to assure a snug fit. The
RF screen should be protected by taping a piece of cardboard over it. The inner box
should then be placed in an outer box that provides about a two-inch clearance on all
sides. High density styrofoam corner pads should be placed in the corners between the
outer and inner boxes to isolate the lamp from impact.
Box: Bursting test: 24 kg/cm
Gross Wt. Limit: 70 kg (155 lbs.)
Magnetrons
If available, use a special Fusion replacement magnetron shipping box. Otherwise,
magnetrons must be double boxed as described next.
Wrap magnetrons in three layers of plastic “bubble wrap” or equivalent. Place
magnetrons in the box and add loose styrofoam fill. Place this inner box in an outer
box and surround the inner box with loose styrofoam fill.
UV Bulbs
2
(350 lbs./sq. in.)
Place the bulb in a rigid tube (use Fusion UV Systems’ plastic lamp bulb replacement
shipping tube if available.) Secure ends to prevent impact against the tube and wrap
the tube in three layers of plastic “bubble wrap” or equivalent. Ship with loose
styrofoam fill in the box.
Control Cards
The integrated circuits in control board assemblies are susceptible to damage from
static electrical charges which may be transmitted by handling or packaging materials.
To guard against static, place control cards in anti-static bags, if available. If not, wrap
control cards in aluminum foil. Isolate the cards from impact with additional wrapping
of “bubble wrap” or equivalent.
RF Detectors
RF Detectors should be wrapped in two layers of “bubble wrap” or equivalent and
placed in a box with loose styrofoam fill.
Installation, Operation, and Maintenance Manual # 509252 Rev R 23
24 F300S/F300SQ Ultraviolet Lamp System
Chapter 1. Safety
Fusion UV Systems’ Ultraviolet (UV) Lamp Systems have been designed to operate
safely. Many systems are in production in a wide variety of industrial environments
without any problems of worker safety or health hazards. However, like most
industrial equipment, this equipment can present worker safety problems if care is not
taken to install, operate, and maintain it correctly.
The following pages provide information concerning various aspects of worker safety
with regard to this equipment. Because some features of the system may be new to
personnel using the equipment, an attempt has been made to provide a fairly extensive
background on these issues as well as references, where feasible, to further information
or U.S. Government Standards.
Care in installation and operation, coupled with adequate worker training, should
ensure that no unusual safety problems arise.
IMPORTANT: All personnel using the equipment
must become familiar with this safety information.
Installation, Operation, and Maintenance Manual # 509252 Rev R 25
Ultraviolet Radiation
Ultraviolet radiation which is emitted during normal operation of the
Fusion Ultraviolet Lamp System can be dangerous to the eyes and
skin of personnel. Adequate shielding around the system and the
region to be irradiated must be provided. If unsafe levels of light are
allowed to escape during operation, then all personnel in the vicinity
of the lamps should be required to wear goggles with UV certified
lenses. Protection is needed for indirect as well as direct eye
exposure; UV certified lenses are recommended. Discomfort from
excessive eye exposure to ultraviolet light typically occurs about six
hours after exposure. Personnel who experience eye pain after
possible exposure to direct rays from the UV lamp should see a
doctor. Furthermore, in the event that adequate shielding is not
possible, all personnel within ten feet of the lamp should wear gloves
and long-sleeved shirts to protect hands and arms.
There are no present U.S. government standards on worker exposure to ultraviolet
light. However, there is a NIOSH document, “Criteria for a Recommended
Standard...Occupational Exposure to Ultraviolet Radiation” (No. HSM 73-11009),
and several useful publications are available from the Bureau of Radiological Health
of the Food and Drug Administration.
Microwave Radiation
The Fusion UV Lamp System is powered by high energy RF
microwave power. This form of energy is identical to that used in
home microwave ovens and, as in the case of ovens, can be
dangerous if misused or inadequately shielded. In the Fusion UV
lamp, the shielding is adequate only as long as the lamp and the
screen on the bottom of the lamp are intact. Any rip or large hole in
the screen may lead to microwave radiation leakage in dangerous
amounts. The power to the lamp is interlocked to shut off if there is
excessive microwave radiation leakage. The lamp system should
never be turned on if the lamp housing and screen are not intact, or if
the microwave leak detector and interlock are not functioning.
Fusion UV equipment is interlocked to shut down if microwave leakage in excess of 5
mW/cm
26 F300S/F300SQ Ultraviolet Lamp System
2
(milliwatts per square centimeter) is detected.
Personnel Effects of Microwave Radiation
OSHA (U.S. Department of Labor, Occupational Safety, and Health Administration Standard 29CFR 1910.97) and ANSI (American National Standards Institute Standard C95.1-1999) are the only major national organizations with voluntary
guidelines for safe limits of occupational microwave radiation exposure.
The ANSI recommendation is the more stringent of the two guidelines. Conservatively
expressed, it states that a worker should not be exposed to microwave radiation levels
in excess of 8 mW/cm
exposure to much higher levels by stating that over a six-minute period the average
power density to which a worker is exposed to microwave radiation should not exceed
8 mW/cm
2
.
Microwave radiation is considered a non-ionizing electromagnetic radiation, which is
not known to produce genetic damage. The primary effect of this energy is to simply
raise the temperature of a body which absorbs it. For example, 5 mW/cm
cc of water 0.07
level continuously, he would absorb about 30 watts over his whole body. At rest, the
body dissipates about 100 watts. Therefore, this additional heat load is considered safe,
although we do not recommend continuous exposure to levels anywhere near 5
mW/cm
2
.
2
on a continuous basis at 2.45 GHz. It allows for short-term
o
C in one minute. If the average worker were exposed to this energy
2
will raise 1
Fusion UV Systems equipment normally produces low level leakage well below
8mW/cm
2
in the work environment. If a microwave survey meter is used, one should
read levels well below 1 mW/cm
exposed. When a lamp is started, leakage levels may increase by a factor of two or
three for the few seconds it takes to start and couple energy to the bulb. This is
considered safe due to the requirement to average under 8 mW/cm
period.
Radio Interference
Fusion lamps operate at a fundamental frequency of 2.45 GHz. The unit may cause
interference with some local area networks (LANs) that also operate at this frequency.
Please check with your LAN manufacturer for compatibility.
2
where personnel are likely to be continuously
2
over a six-minute
Fusion UV lamps are classified as non-consumer industrial, scientific
and medical equipment, as defined in Federal Communication
Commission (FCC) Rules and Regulations Volume 47, Part 18. As
required by these rules, Fusion UV Systems verifies that their systems
are capable of compliance with applicable technical standards
governing radiated emissions when the equipment is properly
maintained and is installed in an appropriate light shield.
Installation, Operation, and Maintenance Manual # 509252 Rev R 27
Ozone
The Fusion UV Lamp System makes less ozone than a conventional arc lamp. For
example, a pair of lamps running for twelve hours in a non-vented room resulted in a
steady state concentration of less than 0.02 parts per million. This was a level that
could barely be detected by odor and a factor of five below the level of 0.1 parts per
million allowable for continuous exposure (American Conference of Governmental
Hygienists).
All Fusion UV Lamp Systems should be exhausted to the outdoors.
Temperature
Ozone is a gaseous form of oxygen which is formed by ultraviolet light. It
has a characteristic pungent odor to which most people are quite sensitive
(people can typically detect concentrations of several parts per hundred
million). At high concentrations it can cause discomfort or at sufficiently
high levels be dangerous.
Surface temperatures of the lamp during normal operation may
exceed 120
Before attempting service procedures on the lamp, allow the unit
to operate in STANDBY so that the blower continues to run. The
bulb will cool completely in less than one minute. If the blower
is not allowed to run, the bulb will retain heat for several
minutes. Observe appropriate precautions to avoid burns.
Handle the bulb with cotton or surgical gloves or a lint-free towel at all times, as
fingerprints can be etched into the quartz.
o
F. Metal components near the lamp will also be hot.
28 F300S/F300SQ Ultraviolet Lamp System
High Voltage
Insulated electrical cables carry power at 3900 Volts from the power supply to the
lamp. These voltages can be dangerous, so some precautions should be taken in both
the location and protection of these lines. High voltages are exposed within the power
supply chassis, which should never be operated without its cover.
DANGER: Never touch the power supply/lamp cable
connections while the system is ON or in STANDBY. A faulty
magnetron may cause 7000 Volts DC to appear on connector
pins and may cause serious injury.
Do not touch power supply/irradiator harness plug P10 near the
contacts, and do not lay P10 down on any conductive material.
Never troubleshoot the power supply without first disconnecting
all external power and discharging the high voltage capacitors
with an insulated screwdriver.
A high quality cable, rated at 10,000 Volts, is used in all high voltage cables
manufactured by Fusion UV Systems, and can be supplied to users for any additional
connections that may be required.
UV Curable Materials
Please consult your UV materials supplier for recommended precautions regarding the
proper handling and use of these products.
Installation, Operation, and Maintenance Manual # 509252 Rev R 29
30 F300S/F300SQ Ultraviolet Lamp System
Loading...