Fusion F300SQ, F300S User Manual

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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

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.

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

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

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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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 . . . . . . . . . . . . . . . . . . . . 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

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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 . . . . . . . . . . . . . . . . . . . . . . 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.

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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 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

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

(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

(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

(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

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

on a continuous basis at 2.45 GHz. It allows for short-term

C in one minute. If the average worker were exposed to this energy

will raise 1

Fusion UV Systems equipment normally produces low level leakage well below 8mW/cm

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.

where personnel are likely to be continuously

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.

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

Chapter 2. Mechanical Installation

Mechanical Installation Checklist

Before operating the ultraviolet lamp system for the first time, be sure the following procedures have been completed.

Table 3. Mechanical Installation Checklist

Item Chapter

 Review safety procedures Chapter 1, “Safety”

 Light shields in place “UV Light Shielding” on page 34

 RF detector positioned correctly “RF Detector Mounting” on page 35

 Fan connection for exhaust of light shield “Remote Blowers” on page 36

 RF screen and lamp bulb inspected Introduction, page 11

This chapter describes the physical installation of the F300S/F300SQ Fusion UV Lamp System. Directions regarding mounting and shielding of the system are somewhat general because they will vary depending upon the details of each individual installation.

Unpacking and Inspection

This Fusion UV lamp system has been thoroughly tested inspected, and packed prior to shipment. Before unpacking, examine all shipping containers for damage. After unpacking, examine the equipment for damage. Any damage should be reported immediately to the shipper and to Fusion UV Systems Incorporated. A delay of more than 10 days may invalidate future claims for damages.

CAUTION: Irradiators are particularly vulnerable to dust, dirt, metal chips, and RF screen damage. They are shipped with a protective covering over the screen. The covering should not be removed until just prior to installation.

When unpacking, identify and compare each item with the packing list enclosed. Remember to examine each component for damage. Appendix E, “Replacement Parts” details the items included with the system which will be required to complete the installation.

Installation, Operation, and Maintenance Manual # 509252 Rev R 31

Preliminary unpacking and inspection should be completed immediately on receipt of equipment to allow time for repair or replacement if necessary prior to installing the equipment.

The P300M/P300MQ power supplies are shipped with six large Phillips head screws holding the cover to the chassis. There are three screws located on each side. The P300MT power supply is shipped with four large Phillips head screws holding the cover to the chassis. There are two screws located on each side of the P300MT.

The four or six cover screws must be in place before operation to maintain continuity of the power supply enclosure ground circuit.

After the inspection is completed, all components must be carefully re-packed and stored until actual installation. Save the packing materials. They will be valuable if any component must be returned to Fusion UV Systems for service. See “Shipping

Instructions” on page 22 for more information.

Power Supply Unit(s) Placement

The mechanical installation of a power supply unit is almost entirely at the user’s convenience. It can be placed on a sturdy shelf or in a cabinet provided that approximately 30 cm (12 inches) of space is left behind the power supply for cooling air to escape, and so that the cable harnesses can be run to the other components. See

Appendix C, page 129 for restricted space clearance minimums.

The P300M/P300MQ power supplies can function in any position, although standard horizontal mounting is recommended. Mounting the power supply so that the control panel is facing upward is not recommended because this allows dirt and dust to settle into the unit. In this position, the horizontal surface that is provided by the inlet finger guard also can be easily blocked by papers, notebooks, or other flat materials that will cause thermal overload and system shutdown.

Power supplies are stackable up to three (3) units high. However, a power supply can weigh up to 40.3 kg (88.6 lbs.), so units should not be stacked to, or installed at, a height that makes access of chassis removal difficult.

32 F300S/F300SQ Ultraviolet Lamp System

Irradiator Mounting

The irradiator mounting structure must also provide UV shielding and adequate venting for the cooling air. This is described on the following pages. Each user will normally design the mounting structure to suit the particular application, and the user is responsible for providing the required shielding and ventilation. (Irradiator dimensions are shown in Appendix C, “Outline Drawings” and detailed in the

Appendix A, “Specifications”.

The easiest and most common mounting position is with the irradiator vertical and the screen at the bottom 53 mm (2.1 in.) above the substrate. Simply rest the module on a pair of angle irons oriented in the same direction as the lamp bulb. One common mounting scheme is shown in Figure 5.

Vertical mounting requires that no part of the support can push against the irradiator screen, causing it to tear. Provisions may be made for raising or lowering the support structure with respect to the substrate to be irradiated. This allows the user to optimize the curing by working in focus or somewhat out of focus.

Figure 5. Vertical Mounting Design for Irradiators

Installation, Operation, and Maintenance Manual # 509252 Rev R 33

Lamps Mounted in Opposing Configuration

IMPORTANT: If two lamps are to be mounted

opposing each other (as shown in Figure 6 on

page 34), lamp performance and operation

may be impaired. Contact Fusion UV Systems Technical service department for consultation.

Figure 6. Lamps in Opposing Configuration

UV Light Shielding

Adequate light shielding must be provided for each irradiator in the system. If shielding is not used, or if UV light escapes around the irradiator support, the operator must wear a welder’s helmet or UV blocking eye wear. Long sleeved clothing is required to protect the skin from the effects of UV light.

34 F300S/F300SQ Ultraviolet Lamp System

The louvers which allow the flow of cooling air away from the irradiator must be of a light shielding design.

(For more information on safety considerations, see Chapter 1, “Safety.”)

RF Detector Mounting

Figure 7 illustrates the proper mounting of the RF Detector.

Figure 7. Fusion UV Systems RF Detector RF-1

One RF detection device must be installed for each light shield. The antenna should point toward the irradiator screen, which is the potential source of RF leakage. However, to protect the antenna from heat and UV light, it should be placed outside the light shield. It may “look” into the light shield through an existing opening, or one made for this purpose. The tip of the sensing cone should be at least two inches from the opening of the light shield.

The presence of metal surfaces near the detector may cause false readings; allow a maximum open area around the device.

The connection of the cable from the RF detector to the power supply is explained in

Chapter 3, “Electrical System”.

Installation, Operation, and Maintenance Manual # 509252 Rev R 35

Remote Blowers

An optional remote blower package is available from Fusion UV Systems. The package includes an air distribution plenum (for multi-lamp systems), inlet filter box, and flexible hoses or ducts for cooling the system. The blower delivers 2.8 m (100 cfm) of air to each irradiator inlet at 695 Pa (2.8" H

“Maintenance” for information on the measurement procedure.

Irradiator Exhaust Venting

Fusion UV Systems recommends that 3.6 m3/min (130 cfm) of air be exhausted from each irradiator. The air flow must be vented below the irradiator to prevent back pressure buildup, which would reduce the flow of cooling air. An exhaust fan is recommended to draw hot air and ozone away from the UV lamp and discharges them to the outside. The fan must remove at least 30% more air than is supplied to the irradiator inlets so a negative pressure will exist under the lamps. The makeup air enters through the UV shielding louvers or any other vents in the light shielding enclosure.

Light shielding louvers are recommended. At least 142 cm area is recommended for each irradiator to allow free flow of make-up air. If the exhaust air is not vented outside the building care should be taken to prevent it from recirculating into the inlet of the blower(s).

Quartz Plates

O). See Chapter 6,

(22 sq. in.) of louvered

/min

To protect the material being cured, quartz plates may be mounted below the UV lamp to block the air carrying heat away from the bulb. A typical mounting design is shown in Figure 8 on page 37. Details of the mounting structure depend upon the position and location of the irradiator and UV shielding.

Clearance C prevents the substrate from striking and breaking the quartz plate but varies with the application. Distance D should be at least one inch and as large as practical to provide maximum area for the escape of cooling air (see Figure 8 on page

37).

36 F300S/F300SQ Ultraviolet Lamp System

)

(

Irradiator

53.3mm (2.10)

Quartz plate (pair) P/N 300291

152.4 mm x 152 .4 mm x 2.29 mm (6.00 in x 6.00 in. x 0.90 in.)

Removal access

for cleaning

Figure 8. Quartz Plates - Example Mounting Design

Irradiator

cooling air flow

Quartz plate

mounting structure

(

Substrate

to be cured

Irradiator

mounting

structure

support

)

Installation, Operation, and Maintenance Manual # 509252 Rev R 37

38 F300S/F300SQ Ultraviolet Lamp System

Chapter 3. Electrical System

This chapter discusses the electrical installation and electrical setup aspects of the F300S/F300SQ Ultraviolet Lamp System.

Electrical Installation/Setup Checklist

Before operating the ultraviolet lamp system for the first time, be sure the following items have been reviewed and/or tested.

Table 4. Electrical Installation and Setup Checklist

Item Chapter

 AC input voltage matches equipment label and

connected correctly

 Power supply HV capacitors tapped for AC line

frequency

 Power supply HV transformers correctly tapped for AC

input voltage

Chapter 3, “Electrical System”

Chapter 3, “Electrical System”, page 51

 Programming correct for each unit Chapter 3, “Electrical System”,

page 43, page 44

 Interconnection cables secure Chapter 3, “Electrical System”,

page 44, page 49

 RF cable secure Chapter 3, “Electrical System”,

page 45, page 49

 User inputs (EXTERNAL INTERLOCK, SYSTEM

BLOWER) connected if wanted

 Remote inputs (RESET, LAMP ON) connected if

wanted

 User outputs (FILAMENT ON, HV ON, FUTURE USE,

LAMP ON, and PRESS ENABLE) connected if wanted

Chapter 3, “Electrical System”, page 40

Chapter 3, “Electrical System”, page 45

Chapter 3, “Electrical System”, page 46

 Review normal operating procedures Chapter 4., Operation, on page 55

Accessory Parts List

The Accessory Parts List is located in Appendix E, “Replacement Parts,” and should be reviewed when setting up your system.

Installation, Operation, and Maintenance Manual # 509252 Rev R 39

Interconnect Cables

The F300S/F300SQ interconnect cables and connector contact kits are listed in

Appendix B, “Cables and Connectors”. See this list for the available varieties and

lengths.

Connection and Program Log

To facilitate operation and maintenance, it is advisable to keep a record of the input/output connections and programming used on each unit. A blank log form is included in Appendix D, “Lamp System Maintenance Log” of this manual.

Installing the External Interlocks Control

An input has been made available for use as an external interlock control. When activated, this circuit will cause the system to shut down. (See Chapter 5,

“Troubleshooting” for details.)

User Connections

Pin removal and crimping tools are required to complete the optional user input/output connections to P105A and P106. Make these connections as described next.

J105A

INTERLOCKS

J105B J107

(K1-K5)

J106

BUS INPUT

BUS OUTPUTRELAYS

Figure 9. P300M/P300MQ Power Supply Rear Panel

40 F300S/F300SQ Ultraviolet Lamp System

J101

DISC ONNECT POW ER BEFORE SERVICI NG

J103

HIGH V OLTAGE CABLE

J104

IRRADIATOR

BLOWER CABLE

1. Disassemble the strain relief housing by removing the retaining screws and unscrewing the housing from the connector body.

2. To connect EXT INTLK or SYS BLWR inputs, remove jumper wires and the attached pins as indicated in Table 5, Table 6, and Table 7 in this chapter.

3. With a crimping tool, attach wires from user devices to new pins (supplied with system) and insert the pins in the proper locations.

4. Reassemble the strain relief housing.

Power Supply Programming

P300M/P300MQ/P300MT power supplies may be interconnected to form a complete system of up to six lamps. Through use of the System Interconnections Bus control functions, the entire system may be operated by the lamp control switch of one master power supply, or by a switch on an external control panel.

See Figure 10 on page 42 for the location of programming switch S1. To access S1, remove the six screws on the side of the power supply cover. For programming switch S1 settings, see the table illustration in Figure 11 on page 43.

Settings for Six-Position Switch S1

Positions 1, 2, and 3 of S1 (see Figure 10) must be set to determine whether a power supply is a master or a slave.

Position 4 determines whether a unit fault will turn off all power supplies or only the unit where the fault occurs.

Position 5 indicates to the system bus whether a power supply (either the master or a slave) has an RF Detector connected to it. (There must be at least one RF Detector connected to a system.)

Installation, Operation, and Maintenance Manual # 509252 Rev R 41

TP2

TP1

DS1

JP2

J14

J15

J16

OFF/RST MASTER

ON MASTER

HI / LO MASTER

UNIT TO SYS

RF MASTER

QRO

ASSY P/N 32755X

J11

Figure 10. Location of Programming Switch S1 on PWB

J10

F3q0008

42 F300S/F300SQ Ultraviolet Lamp System

Switch Position 1, 2, and 3

POS6POS5POS4

Figure 11. Table A: Programming Switch S1

Single Unit Programming and Connections

The programming and connections necessary to operate a single-unit F300S/F300SQ system are summarized in Figure 12.

Installation, Operation, and Maintenance Manual # 509252 Rev R 43

Figure 12. F300/F300SQ Single-unit Installation

Programming

Select one unit as the Master. Set S1-1, 1-2, 1-3, and 1-5 of this unit to “YES.” For programming switch S1 setting definitions, see Figure 11.

Irradiator Cable H340 Connections

Non-blower version cable H340 connects to J103 and J104 on the power supply; and to J10 on the irradiator. All connectors are labeled, and keyed so they cannot be inadvertently interchanged.

Blower version cable H341 connects to J103 and J104 on the power supply, and to J10 and J11 on the irradiator. All connectors are labeled, and keyed so they cannot be inadvertently interchanged.

44 F300S/F300SQ Ultraviolet Lamp System

Input/Output Connections

The P300M/P300MQ/P300MT has three customer use interlock inputs. A fault condition on any of these inputs will cause the system to shut down; the fault must be corrected before the system can be restarted.

There must be one RF detector per system. The remaining interlock inputs are optional. The system blower and external interlock inputs in the P105A connector must be jumpered if these inputs are not used.

NOTE: All external switches must have gold contacts or be designed for use with logic-level signals to ensure reliable operation.

Table 5. J105A Inputs

Interlock Pins

RF Detector (Master)

RF Detector (Slave)

SYS Blower 11,12 OPEN

External Interlock

1,2,3,4 RF trip or

3,4 OPEN

9,10 OPEN

Fault

Condition

no detector present

CIRCUIT

Remote Inputs

One switch is required for remote operation of an F300S/F300SQ (to control the STANDBY/LAMP ON functions). Connections are made through the P106 connector. Single or Master/Slave systems may be operated remotely.

(Customer Use Interlocks)

Contact Ratings

12mA @12 VDC Single lamp: One detector per system

Multiple lamps: RF Master must have RF detector.

12mA @12 VDC Single lamp: N/A

Multiple lamps: Typically jumpered. User should remove jumper to install additional RF detectors and set S1-5 to ON (Yes)

12mA @12 VDC Typically jumpered. User may remove

jumper to install N.O. pressure switch. Multiple switches should be wired in series.

12mA @12 VDC Typically jumpered. User may remove

jumper to install N.O. interlock switch. Multiple switches should be wired in series.

Application Comments

Installation, Operation, and Maintenance Manual # 509252 Rev R 45

NOTE: A dry contact (such as a relay contact or a PLC containing a relay contact) with gold contact material should be used to drive the remote inputs. The cable length to the dry contact should be no more than 6 meters. Shielded cable should be used to minimize possible electrical interference.

In a multi-lamp system, connections are made to the Master power supply.

If there is a requirement for clearing faults remotely, a Remote Reset switch must be used.

Table 6. J106 Inputs (Remote Operation)

Signal Pins

REMOTE LAMP ON

REMOTE RESET

CABLE SHIELD

Active

Condition

4,5 Closed circuit 12mA @12 VDC Set switch S1-2 of Master

1,2 Closed circuit 12mA @12 VDC Set switch S1-1 of Master

8 N/A N/A Keep cable length to a

Contact Ratings

Output Ports (J105B)

There are five relay outputs available on the P300M/P300MQ/P300MT through J105B. These outputs may be used to synchronize customer equipment with the system. In a multi-lamp system, connections are made to the Master power supply.

Table 7. J105B Outputs (Customer Interface)

J105B

Filament ON (K1) 3, 4 Closed 1 A @120 VAC

HV ON (K2) 5, 6 Closed 1 A @120 VAC

QRO 7, 8 Closed 1 A @120 VAC

Asserted

State

Circuit Ratings Comments

(10mA minimum)

Application Comments

to NO. Leave S1-1 and S1-5 set to YES.

to NO.

minimum.

K1 contacts close when filament voltage is applied (STANDBY).

K2 contacts close when high voltage is applied to lamp.

K3 contacts close when QRO is active.

46 F300S/F300SQ Ultraviolet Lamp System

Table 7. J105B Outputs (Customer Interface) (continued)

J105B

LAMP ON (K4) 9, 10 Closed 1 A @120 VAC

PRESS ENABLE (K5)

11, 12 Closed 1 A @120 VAC

Asserted

State

Circuit Ratings Comments

(10mA minimum)

NOTE: When using circuit currents for K1-K5 below 10mA, contact Fusion UV Systems Customer Service.

Alternate Function for K5

An alternate K5 function may be selected by installing a jumper onto JP2 on the control card. The STANDBY-READY function is asserted (K5 closed) when the power supply completes the transition from the STANDBY-WAIT (flashing yellow) to the STANDBY-READY state (steady yellow). K5 remains closed for the LAMP ON state (flashing or steady green), the QRO state (alternate flashing of yellow and green), and the return to the STANDBY-READY state (steady yellow). K5 opens during the OFF/RESET state and the STANDBY-WAIT state (flashing yellow) from either the LAMP ON state or from the OFF/RESET state.

K4 contacts close when photocell is satisfied. Note: If using K4 for press control, wait 6-8 seconds for lamp output to stabilize.

K5 contacts remain closed when no unit or system error exists.

STANDBY READY (K5 alt.)

Table 8. Alternate Function for K5

J105B Asserted State Circuit Ratings Comments

11, 12 Closed 1 A @120 VAC

(10mA minimum)

Installation, Operation, and Maintenance Manual # 509252 Rev R 47

K5 contacts close once STANDBY-READY state is achieved, and for any higher state.

Multiple-Unit Programming and Connections

Programming and connections for multiple-unit systems are summarized in Figure 13. Typically, one unit will operate as the MASTER and all others as slaves to the ON/OFF commands of this Master unit. Refer to detailed descriptions in Chapter 4,

“Operation” of this manual.

RF DETECTOR EXT. INTERLOCK (JUMPERED) SYSTEM BLOWER (JUMPERED)

Figure 13. F300S/F300SQ Multiple Unit Programming & Connections

48 F300S/F300SQ Ultraviolet Lamp System

RF DETECTOR (JUMPERED) EXT. INTERLOCK (JUMPERED) SYSTEM BLOWER (JUMPERED)

F3q0011

Programming

Refer to Figure 11 for programming switch S1 settings and set programming switches of each power supply as follows:

1. Select one unit as the Master. Set S1-1, 1-2, 1-3 and 1-5 of this unit to YES.

2. Set S1-1, 1-2, 1-3, and 1-5 of all slaves to NO.

3. To shut down all units in case of a single-unit fault, set S1-4 on all units to YES

Connections

The following procedure describes how to connect multiple power supplies (master/slave) within a system.

1. For proper operation, including fault detection, connect each power supply to the

2. Install input/output plugs P105A (with jumpers - provided with system) in

3. The Master power supply must have an RF Detector connected to J105A;

(For a detailed explanation of unit faults, see Chapter 4, “Operation.”)

next using the H760 interconnect cables supplied with the system. Cables run from J107 of one unit to J106 of the next.

J105A of slave units.

additional RF detectors may be plugged into J105A of the Slave power supplies by replacing the jumpered plug with the RF detector cable connector.

4. Make interlock connections to the Master using the P105A plug on RF detector cable harness as indicated in “Input/Output Connections” on page 45 in this chapter.

NOTES: When installing additional RF detectors on slave power supplies, be sure to set S1-5 to YES on those power supplies.

If additional RF detectors are used, an RF fault in a slave will automatically be interpreted as a system fault; this will shut down the entire system.

Additional interlocks such as RF, Remote Blower, and External Interlock may be connected to a SLAVE unit through P105A. Remove any factory-installed jumpers.

Installation, Operation, and Maintenance Manual # 509252 Rev R 49

Power Source

NOTE: If a line voltage greater than 230V and a frequency of 50 Hz is used, see the “F300S Relay Coil Resistor Assembly Installation” on page 53 at the end of this chapter.

System Power Connections

CAUTION: Measure the main single-phase voltage of your plant facilities to ensure that it conforms to the factory-wired operating voltage specified on the equipment label (rear panel of power supply). Available line voltage should be within 10% of the nominal operating voltage.

Fusion UV equipment must be connected in accordance with local wiring codes. Use applicable standards for wire sizes, fuse sizes, and disconnect box locations. Each power supply requires a separate, fused single-phase circuit with a line disconnect.

Figure 14. Power Supply Front Panel

Listed current ratings indicate current demands during normal full-power operation. Your customer-supplied wiring and circuit breaker or fuses should be sized to allow for heavier current draw at startup. Current ratings are the same for 50 Hz or 60 Hz systems. The recommended power cord to wire to P101 is:

50 F300S/F300SQ Ultraviolet Lamp System

F3q0004

North American Applications: 3x12 AWG UL listed

International Applications: 3x2.5 mm

Both cable types should have minimum ratings of 16A, 300V, 0-60 °C.

Refer to Table 11 on page 57 in Chapter 4, “Operation,” for the leg currents for each power supply/voltage combination.

Frequency Tapping of HV Capacitors

If it becomes necessary to configure the system for a line frequency other than that delivered, the following steps should be followed:

1. Turn the unit POWER switch OFF and unplug the power cord.

2. Remove the power supply cover (six screws).

3. Locate the HV capacitors C101 and C102 (refer to Figure 15 on page 54).

4. Discharge the capacitor by shorting the capacitor terminals with an insulated screwdriver.

5. Locate the jumper connected to the T terminal of each capacitor.

6. Disconnect the opposite end of this jumper from the capacitor terminal to which it is connected, and reconnect it to the appropriate terminal for the desired line frequency (50 for 50 Hz, 60 for 60 Hz).

Harmonized, VDE

QRO HV Capacitors (For QRO only)

When the Quick Restart Option is installed, one element of the retrofit is the replacement of the HV capacitors. These HV capacitors are a different value than the standard HV capacitors, but the frequency tapping procedure is exactly the same.

High Voltage Transformer Taps

Standard high voltage transformers have labeled taps. Power supplies are shipped with transformers tapped according to customer power specifications. If a unit is relocated or a transformer must be replaced, connections should be installed as shown in the following table.

Table 9. High Voltage Transformer Taps

Power

Installation, Operation, and Maintenance Manual # 509252 Rev R 51

HV Plate

Transformer

Primary Tap

Table 9. High Voltage Transformer Taps (continued)

50 Hz

60 Hz

Power

200

208

220

240

200

208

220

240 220, 240

Transformer

200

220, 240

200

QRO Transformer Taps (FOR QRO only)

When the Quick Restart Option is installed, the QRO transformers must be tapped according to the frequency and voltage specifications of the customer. Should these specifications change, or if a transformer is replaced, the transformer should be tapped as follows:

Table 10. QRO Transformer Taps (Optional)

QRO Transformer

Power

Primary Front Tap

HV Plate

Primary and

Secondary Rear Taps

200

50 Hz

60 Hz

52 F300S/F300SQ Ultraviolet Lamp System

208

220

240

200

208

220

240

200V

50 Hz

240V

200V

60 Hz

240V

F300S Relay Coil Resistor Assembly Installation

The relay coil resistor assembly must be used if the line voltage and frequency used with a P300M/P300MQ/P300MT power supply is 230-240 VAC at 50 Hz (nominal voltage). These resistor assemblies prevent the premature failure of the relay coils in high line voltage environments. There are two coil resistor assemblies available in a retrofit kit (See Appendix E, “Replacement Parts”). One assembly is placed in series with each of the coils of K101 and K102 in the power supply. These resistors should also be used when it becomes necessary to configure the system for a line voltage and frequency of greater than 230 VAC at 50 Hz (nominal voltage.)

Installation Instructions

1. Turn off the power and disconnect power from the power supply.

2. Remove the six cover screws and cover from the P300M/P300MQ power supply. (Remove the four cover screws and cover from the P300MT power supply.)

3. Locate relays K101 and K102. K101 is closer to the rear of the power supply and K102 is closer to the front (refer to Figure 15 on page 54).

4. On K102, locate tab 0. A black wire with a pink-insulated terminal will be connected to it.

5. Disconnect the black wire and press the pink-insulated female terminal of one resistor assembly onto K102 relay tab 0.

6. Connect the black wire with the red-insulated terminal to the red male terminal of the resistor assembly. The leads of the resistor assembly should be bent to form a U shape to make this connection easier.

7. On K101, locate tab 1. Two black wires with pink-insulated terminals will be connected to it.

8. Disconnect the black wire with the fully insulated right-angle terminal and leave the double terminal with the pink insulation connected. Press the female terminal of the remaining resistor assembly onto the exposed tab of the double terminal.

9. Connect the right-angle terminal to the male terminal of the resistor assembly. The leads of the resistor assembly should be bent to form a Z shape to make this connection easier.

Installation, Operation, and Maintenance Manual # 509252 Rev R 53

CB1A CB1B

L101

C102

C101

Front

S1 S2

B101

T103

T102 T101

C103

DB1DB2

K102

Top V i e w

Side View

TB1

K102

Rear

J101

K101

K103

K101

Rear

Figure 15. K101 and K102 on P300M/P300MQ

54 F300S/F300SQ Ultraviolet Lamp System

Chapter 4. Operation

WARNING: Before operating the system, the operator must become familiar with the operating safety information presented in Chapter 1, “Safety”.

System Operation Controls

The lamp system is operated from the controls on the front of the power supply.

NOTE: Ambient system operating temperature is 0 to 45°C.

Lamp Control

At STANDBY, power (115 VAC) is applied to the magnetron filaments without energizing the bulb. All interlocks and controls will continue to operate in STANDBY. An external blower can be triggered through a connection to output relay K1.

Pressing the LAMP ON button energizes the lamp to its full power level after a STANDBY delay and an additional “full power” delay. If after 8 seconds in the ON position the bulb has not successfully ignited, the lamp will shut down. Check the LED display on the power supply; it will indicate the probable source of the problem.

A “LAMP OUT” is a result of many different causes. The following are some reasons that may be a source of this fault condition:

• Successive short cycles

• Operation at improper air pressure

• Operation at continuous reduced power level with improper air pressure

• Improper initial ignition of the system

• Poor distribution of the fill material inside the bulb as a result of shipping and handling

Installation, Operation, and Maintenance Manual # 509252 Rev R 55

• Bulb producing insufficient output to activate the photocell

For proper initial ignition, the recommended “MINIMUM LAMP ON” time required for this system is “ten (10) seconds” at normal air pressure (3.5 inches w.c.) and full power operation (100% power level).

As previously mentioned, a “LAMP OUT” fault can occur when the bulb does not reach sufficient output to activate the sensing photocell. This will particularly occur at initial startup of the system, after successive “short cycles” (LAMP ON times below 10 seconds), or at the initial startup of a new bulb. In these instances, the bulb fill material has not completely vaporized. With repeated attempts to start the system, the problem may become worse, and can reduce the life of the electrical components.

Refer to Chapter 5, “Troubleshooting” for other possible causes of a LAMP OUT condition.

Power

With the POWER switch in the OFF position, neither the control card nor the high voltage circuitry are energized. With the switch in the ON position, the power supply cooling fans and the control card are energized, and the LAMP Control switches are enabled.

Off/Reset Control

When a fault occurs, the fault must be corrected and the unit(s) reset by pressing the LAMP OFF/RESET switch before operation can be resumed.

1. If a UNIT fault occurs, correct and reset the individual unit.

2. If a SYSTEM fault occurs, reset the Master unit.

3. If a slave has an RF detector connected, reset the Master when the Slave indicates a fault.

4. If a system is operated by a remote ON/STANDBY switch, reset the MASTER power supply when a system fault occurs.

5. If a system uses a remote LAMP OFF/RESET switch, that switch may be used instead of the front panel switch to reset a fault.

Initial Startup Procedure, Single Unit

1. Turn POWER switch to ON position and press the LAMP OFF/RESET switch: The red LAMP OFF indicator is lit.

2. Press the STANDBY switch: the yellow STANDBY indicator blinks, then stays lit.

56 F300S/F300SQ Ultraviolet Lamp System

3. Press the LAMP ON switch: the green LAMP ON indicator blinks, then stays lit.

4. Check the line currents. The line currents should conform to the values in Table

11.

Table 11. P300M/P300MQ/P300MT Current Requirements

System Line

Voltage

Single Phase

200 15 14.5

208 14 13.5

220 14 13

230 13.5 13

240 13.5 12

Modular Blower

Line Currents (A)

with K300M

without K300M

Modular Blower

5. Check RF detector and customer use interlocks as described in Chapter 5,

“Troubleshooting.”

Initial Startup Procedure, Multiple-Unit Systems

1. Turn POWER switches of all units to ON.

2. Press the LAMP OFF/RESET switch of the Master.

3. Press the LAMP ON switch of all slaves.

4. Press LAMP ON switch of the Master.

NOTE: Front panel controls take precedence over remote or master commands.

Master/Slave Operation

One master power supply can control up to five slave units. Review Chapter 2,

“Mechanical Installation” to understand the interconnections and programming

needed.

Operating the System

1. Turn POWER switches of all units to ON.

2. Press the LAMP OFF/RESET switch of the Master.

3. Press the LAMP ON switch of all slaves.

Installation, Operation, and Maintenance Manual # 509252 Rev R 57

4. The LAMP CONTROL switches on the Master may now be used to activate all units in the system at the same time.

NOTE: LAMP CONTROL flashers of slaves will follow LAMP CONTROL on Master.

Resetting the System After a Fault

If a fault occurs in the system, press the LAMP OFF/RESET switch on the Master, or cycle the remote LAMP OFF/RESET switch, then press the Master LAMP ON switch to reset the system.

58 F300S/F300SQ Ultraviolet Lamp System

NOTE: Times indicated are approximate and will vary. The exact interval is determined by conditions within the system.

If additional RF detectors are connected to slaves, an RF fault in one of these slaves will automatically be interpreted as a system fault shutting down the entire system.

In a Master/Slave system, the Slave units must be switched to STANDBY or ON before Master power supply is switched from OFF to STANDBY.

Table 12. Routine Operation

Time

0 sec

1-2 sec

10 sec Steady yellow Interlocks and fault detection

0 sec Lamp On

2-8 sec UV bulb ignites

8-10 sec Steady green UV bulb at full power

0 sec

10 sec

12-18 sec UV bulb ignites

18-20 sec Steady green Full power

0 sec From LAMP

18 sec Steady yellow Ready to restart

Power

Switch

Lamp

Control

Lamp Off Red Control card energized

Standby

from Standby

From LAMP OFF to LAMP ON

ON to STANDBY

Lamp Control

Flasher

Yellow flash Power supply FAN ON;

Modular Blower ON

circuits function. Ready to start.

Green flash Start HV transformers

Slow flash yellow

Fast flash green

Yellow flash UV bulb extinguished

Operation

Remote Operation

The F300S/F300SQ can be operated remotely with a STANDBY/LAMP ON switch connected to the Master. Refer to Chapter 3, “Electrical System” for instructions on connecting remote switches.

The following procedure describes how to operate a lamp remotely:

1. Turn all remote switches OFF (open contacts).

Installation, Operation, and Maintenance Manual # 509252 Rev R 59

2. Turn the Master POWER switch ON and press the LAMP ON switch.

3. The system will now operate from remote switches. Remote switch functions are virtually the same as front panel switch functions.

Table 13. Remote Switch Functions

Remote Switch

Lamp ON Lamp ON Standby Lamp ON

Lamp RESET LAMP OFF/RESET Default to lowest state LAMP OFF/RESET

Equivalent Panel

Control

Switch Open Switch Closed

Lamp Status

Operation with Remote Controls

Table 14. Operation with Remote Controls

Panel Controls on Master

Power Lamp Control Lamp ON Lamp Status

Off/Reset S S Off/Reset

ON LAMP OFF/RESET S LAMP OFF/RESET

ON Remote RESET

STANDBY

ON OPEN

Remote

Switches

LAMP OFF/RESET

Switch CLOSED

OPEN

CLOSED

CLOSED Lamp ON

(overrides remote Lamp ON switch)

STANDBY

KEY:

S- Switch position does not matter.

Quick Restart Option (QRO)

The Quick Restart Option (QRO) provides the ability to restart the lamp at any time, even immediately after the lamp has been switched to Standby mode. Thus, the mandatory 18-second restart cycle time associated with routine operation has been eliminated. The QRO may be installed at the time of the P300MQ power supply construction or may be retrofitted into P300M power supplies in the field by trained personnel.

60 F300S/F300SQ Ultraviolet Lamp System

The QRO consists of a high-voltage, low-current power supply section located in the P300MQ power supply that allows the magnetron in the irradiator to maintain an ignited bulb at a very low input power level (approximately 10%) and a very low UV output level (less than 1%). This feature is intended for use in processes that require occasional periods of decreased UV output, or in the event of a short duration process interruption.

CAUTION: The QRO is not intended for use as a shutter, or in processes that require rapid On-Off cycles. This kind of use may be detrimental to bulb life span

The actual restart time of the bulb will depend upon the elapsed time from when the lamp was switched from the Lamp On state to the Standby state. Representative data for the restart time from the QRO state to the Lamp On state (70%, 80%, and 90% UV output) is shown versus QRO state duration in Figure 16, Figure 17, and Figure 18.

The QRO state, when enabled, will automatically occur when the power supply is switched from the Lamp On state to the Standby state. The QRO state is indicated by the alternate flashing of the green Lamp On and yellow Standby buttons on the front of the power supply. The QRO state will last for a maximum of 40 seconds, after which it will revert to the Standby state and the yellow button only will remain on.

WARNING: While the lamp’s light output is low during the QRO state, both eye and skin protection should be worn in the event of possible direct or indirect exposure. Refer to Chapter 1, “Safety” for detailed information regarding ultraviolet radiation safety.

Installation, Operation, and Maintenance Manual # 509252 Rev R 61

Figure 16. Restart Time Versus QRO State Duration, D-bulb

Figure 17. Restart Time Versus QRO State Duration, H-bulb

62 F300S/F300SQ Ultraviolet Lamp System

Figure 18. Restart Time Versus QRO State Duration, V-bulb

Electrical Installation and Setup

For a power supply with the QRO components installed and properly connected, the QRO can be enabled by setting the control card DIP switch S1-6 (marked QRO) to the YES position. See Chapter 3, “Electrical System” for further programming details.

Operation

The QRO state, when enabled by programming switch S1-6 on the control card, will be active during every transition from the Lamp On state to the Standby state, whether the lamp is operated remotely or from the front panel. The Lamp On state may be reentered by pressing the LAMP ON front panel switch or by remotely switching to Lamp On. If no other action is taken, the Standby state will become active after a QRO state duration of 40 seconds. The Reset state may be entered at any time by pressing the RESET front panel switch or by remotely switching to Reset.

In a multiple-unit configuration, mixing QRO and non-QRO units is unlikely. However, if power supplies with and without the QRO are mixed, units with the QRO will operate as described in the preceding paragraph, and the units without the QRO will operate as described previously for a standard P300M power supply. The Initial Startup Procedure, Master/Slave Operation, and Remote Operation of power supplies with the QRO are the same as for standard non-QRO units.

See Appendix E, “Replacement Parts” for the QRO parts list.

Installation, Operation, and Maintenance Manual # 509252 Rev R 63

64 F300S/F300SQ Ultraviolet Lamp System

Chapter 5. Troubleshooting

DANGER: High Voltage -- Use extreme caution at all times when troubleshooting the power supply. Line voltages are present even when the lamp control switch is set to STANDBY.

Do not measure any voltages not specified in the troubleshooting procedures: dangerously high voltages exist in the power supply.

Do not touch power supply/irradiator cable connectors while the system is on. High voltages are present in the connector.

Do not touch any power supply components or wiring while the unit is operating.

To troubleshoot the power supply, first turn off and disconnect all power to the unit. All high voltage capacitors have an internal discharge resistor which should discharge to a safe level in five seconds. Physically shorting the capacitor terminals with an insulated screwdriver blade is advised as an additional safety measure.

Basic Checks

Check that input power is connected properly. Actual line voltage must be within 10% of the voltage rating shown on the equipment label. Labels are located on the rear of the power supply. If the input voltage does not match, contact Fusion UV Systems.

DANGER: Ultraviolet Radiation -- Do not test the irradiator without using adequate ultraviolet light shielding and never look directly at the UV lamp. Severe ultraviolet burning of the skin and eyes can result without proper safeguards.

Installation, Operation, and Maintenance Manual # 509252 Rev R 65

Safety Interlock Tests

The fault indicators, RF detector, and external interlocks should be tested at regular intervals to assure safe operation of the UV system.

1. With the power supply chassis inserted into the cover and single-phase power applied, depress the IND TEST button on each power supply. All LED indicators should light.

2. Turn all POWER control switches to ON. (No UV light is being produced by the bulb.) Press the STANDBY switches of all units.

3. Operate the external interlock switch(es), by opening light shields, etc. The system should shut down and produce an LED signal. Reset unit by pressing the LAMP OFF/RESET switch on the master units.

4. To actuate self-test of the RF detector, depress the test button on the detector and hold it down for 4 seconds. The system should shut down and produce an RF Interlock LED signal. Reset as before.

Fault Indicators

When an interlock switch is opened or improper equipment operation is detected, a fault signal is generated. Power is removed from the irradiator and blower of one or all units, depending on the type of fault and the programming selected by the user. The type of fault (Unit or System) is indicated on the front panel of the unit detecting the fault.

Unit Faults

Unit faults are those detected within an individual module. The Lamp Control switch and the top five light-emitting diodes on the front panel indicate the unit faults (see

Figure 14 on page 50).

Table 15. Unit Faults

Indicator Description

(HV Cable) If the LAMP OFF/RESET switch is lit when the POWER switch is

ON, but the unit will not go to STANDBY when the switch is pressed, the high voltage cable is not connected or faulty.

LAMP OUT After ON switch pressed: the photocell was not satisfied within 8

seconds of initial startup time, or the light output fell low enough to unsatisfy the photocell at any time after startup. After STANDBY switch: Shorted Photocell detected.

66 F300S/F300SQ Ultraviolet Lamp System

Table 15. Unit Faults (continued)

Indicator Description

PWR ERROR Improper operation of magnetron: either no magnetron anode

current 2-4 seconds after high voltage is applied, or the presence of high voltage when the Lamp system is in OFF or STANDBY.

CAUTION: If a PWR ERROR fault is indicated, press the LAMP OFF/RESET switch immediately. To prevent magnetron damage, single-phase power should be disconnected (see PWR ERROR fault).

PS TEMP The power supply is overheating.

BLWR PRESSURE Cooling air pressure within the irradiator is insufficient.

System Faults

The bottom three LEDs indicate system faults. These faults always shut down ALL units in the system, causing all LAMP CONTROL switches to flash.

System interlock switches and the RF detector may be connected to any unit, but are normally connected to the master. System faults will then be detected and displayed at the master power supply.

Indicator Description

SYS BLWR Insufficient cooling air pressure in an external supply or exhaust

blower causes pressure switch to open.

EXT INTLK Open external interlock switch on a plenum cover, for example,

connected at customer option.

RF INTLK Excessive RF at the RF detector, or loss of power to detector.

Fault Diagnosis Tables

To determine the likely cause of failure in an F300S/F300SQ unit, note the operating sequence when the failure occurs. Also, record which fault indicator LED lights. The indicator may light immediately when the unit is switched from one condition to another (for example, from STANDBY to ON); or the signal may be displayed until after a programmed internal delay has elapsed.

There is a troubleshooting table for each fault indicator, showing secondary symptoms to help localize the problem. The possible causes are listed, followed by testing and repair instructions.

Installation, Operation, and Maintenance Manual # 509252 Rev R 67

Table 16. System Faults

Table 18, “Troubleshooting/Fault Diagnosis,” on page 69 covers miscellaneous faults

and malfunctions.

NOTE: The control card may be responsible for any of the fault conditions described following. If the fault cannot be determined after investigating all possible causes listed, check the control card for damage or improperly secured connectors.

Return malfunctioning control cards to Fusion UV Systems.

Failure Diagnosis Cross-Reference

The F300S/F300SQ system is designed to signal the operator when a failure occurs in one unit or a multiple unit system. Table 18, “Troubleshooting/Fault Diagnosis,” on

page 69 is organized around these signals and observable clues. Use the following

table to locate the fault indicated.

Notice that the failure of some signals to light is also an indication of a fault.

Table 17. Fault Diagnosis Cross Reference

Signal Page

Arcing sound 81

EXT INTLK 74

LAMP OUT 74, 75, 77, 78, 79, 81

LAMP OUT light is off 77, 78, 79

BLWR PRESSURE 75

PS TEMP 76

PWR IMBAL 75, 80

PWR ERROR 76, 80

LAMP OFF/RESET light is off 73

RF INTLK 73, 75, 80

STANDBY switch does not light 75

SYS BLWR 76

Failure with no signal 73, 75

68 F300S/F300SQ Ultraviolet Lamp System

Operation

POWER switch from OFF to ON

Table 18. Troubleshooting/Fault Diagnosis

Signal/

Other

Symptoms

LAMP OFF/RESET button does not light at power up

Possible Cause Corrective Action

Fuses F1 and F2 Check fuse and replace if blown.

Power supply wiring If fuse immediately blows again, replace

Control card Replace control card.

Irradiator cable B. Turn OFF. Reconnect P104. Press

RF detector C. Turn OFF. Reconnect P20 at the RF

Filament transformer

fuses. Then: A. Disconnect P104 on back of power supply, P10 from the irradiator, and P20 at the RF detector. Press STANDBY LAMP CONTROL button. If fuse does not blow, proceed to (B). If the fuse blows, the problem is in the internal wiring or control card.

STANDBY. If the fuse does not blow, proceed to (C). If the fuse blows, the problem is in the connectors or cable.

detector. Press STANDBY. If fuse does not blow, proceed to (D). If the fuse blows, the problem is in the RF detectors or cable.

D. Turn OFF. Reconnect P10 to the irradiator. Press STANDBY. If the fuse blows, the problem is in the filament transformer or connections.

Master turns slaves ON but not OFF

RF INTLK indicator lights on slave with slave OFF, master ON

RF INTLK indicator lights on all units

System shuts down; no fault indicators light

Programming error Close S1-1 (YES) on master.

Cable connection Connect cable H760 to slave.

Programming error Close S1-5 (YES) on master.

Momentary loss of ACTurn off all units and then turn each unit

on. A momentary loss of power to one or more units may be interpreted as a system fault.

Installation, Operation, and Maintenance Manual # 509252 Rev R 69

Operation

Lamp control at OFF, or from OFF to STANDBY

Switch from OFF to STANDBY or from LAMP ON to STANDBY

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

EXT INTLK indicator lights

LAMP OUT indicator lights

Possible Cause Corrective Action

Open control input. A jumper or an external circuit between

J105A-9 and J105A-10 must be closed by a jumper or an external switch.

Poor connection Disconnect all power. Reseat control board

assembly connections. Try again.

Control card Replace the control card.

Shorted photocell Press LAMP OFF switch. Attach voltmeter

probes to Photocell Voltage Test Points. Press the STANDBY switch. Measure the photocell voltage between Photocell Voltage Test Points while in STANDBY. The voltage level indicated should be greater than +9.3 VDC. If the voltage level indicated is less than this value, the photocell is defective. Replace the photocell assembly.

70 F300S/F300SQ Ultraviolet Lamp System

Operation

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

Possible Cause Corrective Action

Switch from OFF to STANDBY

BLWR PRESSURE indicator lights

STANDBY switch does not light

No fault indicators light.

LAMP OUT and/or PWR IMBAL indicators light immediately

Single-phase

See “Basic Checks” on page 65. voltage missing phase

Air pressure Measure air pressure inside irradiator

following the procedure described in

Chapter 6, “Maintenance”. IF PRESSURE

IS LOW:

Dirty air filters Replace dirty air filter on remote or

modular blower.

Pressure switch

Replace the pressure switch. faulty

Air handling design Check for adequate air handling

requirements.

HV cable

Connect HV cable. disconnected

Faulty HV cable Inspect cable, check for continuity.

Control card Replace control card.

Card connectors not secure

Check control card. All connectors must be

properly secured.

Control card Replace control card.

RF INTLK indicator lights or flashes alternately with the lamp control switches

No RF detector connected

Programming error:

1. All units have

Connect RF detector. A system must have

at least one RF detector connected.

1. Close S1-5 on unit with RF detector

connected. S1-5 open.

2. Unit(s) with S1-5

2. Install jumper. open and no jumper between J105A-3 and J105A-4.

RF cable shorted or

Check cable for continuity.

open

RF detector faulty Replace RF detector.

Control card Replace control card.

Installation, Operation, and Maintenance Manual # 509252 Rev R 71

Operation

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

Possible Cause Corrective Action

Switch from OFF to STANDBY or from STANDBY to ON

Lamp Control at STANDBY

PS TEMP indicator lights

SYS BLWR indicator lights

PWR ERROR indicator lights

Power supply fan

Repair or replace fan.

inoperative

Power supply too

Move to cooler location. hot or in poor location

Temperature switch faulty or not connected.

With power off, check the T101 and T102

thermal switches, which should be closed,

with an ohmmeter or DVM. Check that the

thermal switch interconnections are

secure.

Card connectors not

Reseat connectors. secure

Control card Replace control card.

Blower power; pressure

If SYS BLWR input for external blower in

J105A is in use, check external blower

power and pressure in the same manner

as remote blower.

Jumper in J105A If SYS BLWR input not in use, check

jumper is in place in connector J105A.

Control card Replace control card.

K101 Check for presence of magnetron current.

If within specifications, then examine

relays for stuck armature or contacts

welded shut. Check operation of relay with

single-phase power only connected.

Control card Replace control card.

CAUTION: Disconnect single-phase power at main circuit breaker immediately. Magnetron may be severely damaged by application of high voltage when lamp control is in OFF or STANDBY.

72 F300S/F300SQ Ultraviolet Lamp System

Operation

Switch from STANDBY to ON

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

LAMP OUT indicator lights after 8 seconds; Lamp bulb does not light

Possible Cause Corrective Action

High Voltage Cable Check cable connections at J103, J104,

J10, and J11.

Lamp Bulb Measure the Photoresistor output at the

photocell test points and magnetron

current test points on the front panel while

switching to LAMP ON.

If the photocell voltage does not drop when

the magnetron current voltage changes,

replace the bulb.

If the photocell voltage drops, remove and

inspect the bulb for normal mercury

condensation. If normal mercury

condensation is not observed, (if all the

pellets are at one end, or at the center of

the bulb), if possible, test the bulb in a

separate unit. If the bulb starts, check your

process (air handling, duty cycle, etc.). If

the bulb does not start, replace the bulb.

New bulb During its first start, a new lamp bulb may

take up to 8 seconds after ignition before

reaching full intensity if the mercury (Hg) fill

has accumulated at one end or at the

center of the tube.

High Voltage cable Check cable connections at J103, J104,

J10, and J11.

Control Listen for the sound of K101, the high

voltage contactor, inside the power supply.

It should be heard closing with an audible

click when switched ON (after a three

second wait in STANDBY). If not detected:

Disconnect single-phase power. Reseat

control board assembly connectors P8 and

P9. Observe K1 and K102 when switching

to STANDBY. Reconnect the single-phase

power and observe K2 and K101 when

switching to ON.

K1, K2 Relays Replace K1 and K2 on the control board

assembly.

Control card Replace control card.

Installation, Operation, and Maintenance Manual # 509252 Rev R 73

Operation

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

Possible Cause Corrective Action

Switch from STANDBY to ON

(continued)

LAMP OUT indicator lights after 8 seconds; Lamp bulb does not light

(continued)

Diodes, capacitors If the readings are not different, a power

supply fault is indicated. Disconnect all

power and inspect for wiring damage. Test

diodes and capacitors according to the

procedures in Chapter 6, “Maintenance”.

Irradiator Disconnect all power. Remove the

irradiator cover (see Chapter 6,

“Maintenance”). Inspect for obvious

damage to wiring. Inspect the reflector for

pitting near the large slots, which is

evidence of arcing.

Magnetron If no power supply fault can be found,

disconnect all power. Replace magnetron

(see Chapter 6, “Maintenance”).

WARNING: If no magnetron test voltage is measured at the magnetron test points, remove power from the unit immediately. Consult Fusion UV Systems Technical Services.

74 F300S/F300SQ Ultraviolet Lamp System

Operation

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

Possible Cause Corrective Action

Dirty surface Inspect lamp bulb and reflector. Clean or

replace as necessary. Try to start again.

Switch from STANDBY to ON (continued)

LAMP OUT indicator lights after 8 seconds; Lamp Bulb does not light

(continued)

LAMP OUT indicator lights after 8 seconds; UV bulb reaches full intensity

Line voltages out of specification

NOTE: If the magnetron needs to be

replaced prematurely, check that the

single-phase voltage is within specification

(see “Basic Checks” on page 65).

Weak magnetron If photoresistor reading does not fall to

below 9.3 VDC in 8 seconds, a weak

magnetron is commonly indicated.

Photoresistor Measure photoresistor output at Photocell

Voltage Test Points while switching to ON

(see schematic) +12 VDC at STANDBY,

2-5.5 VDC at ON. If voltages are incorrect,

remove the irradiator cover and replace the

photoresistor as described in Chapter 6,

“Maintenance”.

Weak magnetron If photoresistor reading does not fall to

below 9.3 VDC in 8 seconds, a weak

magnetron is commonly indicated.

Connections Disconnect all power. Remove the power

supply cover. Reseat the control card

connectors P6 and P10. Restart.

Control card Replace the control card.

Installation, Operation, and Maintenance Manual # 509252 Rev R 75

Operation

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

Possible Cause Corrective Action

Switch from STANDBY to ON

(continued)

PWR IMBAL indicator lights

PWR ERROR indicator lights

Power Supply Usually, a diode or capacitor failure will

reduce magnetron current by one-half.

Test the diodes and capacitors according

to Chapter 6, “Maintenance”. The voltage

to the primary coils ONLY of the high

voltage transformers should also be

checked.

Filament Transformer

Check the filament transformer and

connections.

Control Card Replace the control card if no power

supply, magnetron, or other malfunctions

are found.

Failing (Moding) Magnetron

Check magnetron current at front panel

test points. If it is not within specifications,

replace magnetron.

Filament transformer

Check filament transformer and

connections.

Magnetron Check for presence of magnetron current.

If it is zero, disconnect all power, and

replace magnetron. If magnetron current is

low or half, check diode block and HV

capacitors.

Control Card Replace the control card.

RF INTLK indicator lights

Lamp bulb faulty Replace the lamp bulb.

RF Screen damaged

RF - arcs forming Inspect reflector for pitting; replace if

RF Detector faulty See “RF Detector” on page 20 to test RF

Position Reposition the detector farther from the

WARNING: The RF detector should at all times be closer to the screen or light shield opening than personnel working nearby. It should be aimed so that it intercepts RF radiation from the irradiators.

76 F300S/F300SQ Ultraviolet Lamp System

Replace the RF screen.

necessary.

detectors.

screen and/or the light shield opening.

Operation

Table 18. Troubleshooting/Fault Diagnosis (continued)

Signal/

Other

Symptoms

Possible Cause Corrective Action

Lamp Control at LAMP ON

LAMP OUT indicator does not light, or UV lamp does not light

Arcing sound from irradiator, a grinding noise

System not responding in accordance with programming switch SW1 settings

Control card Replace control card.

Damaged Reflector Disconnect all power. Inspect reflector for

pitting near large slots. Replace reflector if

necessary.

Wiring or connector Remove irradiator cover and inspect wiring

for damage.

Magnetron Replace the magnetron; see Chapter 6,

“Maintenance”.

Incorrect

See Chapter 3, “Electrical System”. MASTER/SLAVE arrangement or cable hook up

Installation, Operation, and Maintenance Manual # 509252 Rev R 77

78 F300S/F300SQ Ultraviolet Lamp System

Chapter 6. Maintenance

This chapter provides maintenance procedures for the I300M irradiator, the I310M/311M Irradiator, the P300MT power supply, and the K300 modular blower.

I300M Irradiator

Bulb, Screen, and Reflector Maintenance

Cleaning Guidelines

At least every 500 hours of operation, the irradiator should be removed from the light shield, and the screen, lamp bulb, and reflector inspected carefully. Clean as needed. Instructions for removing and replacing these components appear later in this chapter. Guidelines for cleaning these components follow.

If the reflector or bulb surfaces show signs of dirt, oil, or vaporized materials, they should be removed and cleaned with a good industrial cleaner, using a lint-free cloth or tissue. The cleaner should contain no waxes, silicones, dyes or perfumes. Simple Green® and Windex® are recommended. Wipe away any residues, using the cloth or tissue with pure water. Alcohol, isopropyl, or methanol may be used for final removal of residues, except when alcohol is not allowed as a solvent.

If deposits on the screen, bulb, and reflector are consistently found at 500-hour inspections, the blower filters should be changed more frequently, or a more efficient filter should be used. These deposits can cause premature failures when particles burn into the quartz lamp or result in dulling of the reflectors.

Bulb Cleaning

Handle bulbs with a lint-free cloth or tissue taking care not to leave fingerprints.

Baked-on material can be removed from bulbs with a MILD abrasive cleaner such as Soft Scrub®, followed by a thorough rinse with water. If alcohol is allowed, do a final wipe with alcohol. Harsh abrasives and steel wool should NEVER be used on bulbs.

Reflector Cleaning

If the reflector surface is dull or discolored, it should be cleaned. Abrasives should never be used on reflectors.

Installation, Operation, and Maintenance Manual # 509252 Rev R 79

If cleaning reflectors while assembled in the irradiator, drying with compressed air is NOT recommended because particles or residues can be driven into spaces between components and into optical sensing elements.

Screen Cleaning

Screens may be cleaned with the same cleaners cited previously, soaking if necessary, brushing lightly and rinsing well. Take care not to damage the gaskets or the fine screen wires.

I300M Screen Assembly Removal/Replacement

CAUTION: In handling the irradiator or screen assembly, try to avoid all direct contact with the screen, as it punctures easily. Do not apply pressure to the screen.

M3 screen retaining screws (4) (2 per side)

Figure 19. Reflector Assembly (I300M)

80 F300S/F300SQ Ultraviolet Lamp System

RF screen

Cooling air holes

Lamp bulb

Cavity

Reflector

1. Refer to Figure 19. Loosen the four M3 screen retaining screws three turns each. Repeat, this time removing screws. Grasp the screen frame by both ends, taking care not to twist or bend the screen itself, and remove screen assembly.

2. To replace existing screen or install a new one, place the screen assembly in position.

3. Apply pressure to the frame only and press firmly into place. Install the four screws alternately, working from side to side. Tighten each to a snug position; finally tighten to 0.9 N-m (8 inch-lbs.) using a torque-controlled screwdriver.

Figure 20. RF Screen Screw Tightening Sequence

Lamp Bulb Removal/Replacement

WARNING: During operation, the lamb bulb

and adjacent metal surfaces become very hot. Operate the blower for about one minute to cool hot surfaces.

1. Remove the screen as described in “I300M Screen Assembly

Removal/Replacement” on page 80.

2. Next, see Figure 21 on page 82. Using clean cotton gloves or lint free tissue, grasp the lamp bulb at one end between the thumb and fingers and apply firm pressure axially toward the opposite end. When the tip of the bulb has cleared its retaining hole and is free to move past or along the end reflector, gently slide it up and out.

Installation, Operation, and Maintenance Manual # 509252 Rev R 81

CAUTION: Do not apply bending force to the lamp bulb. Do not touch the bulb with bare fingers or allow it to contact dirty or greasy surfaces. Contaminants can be burned into the quartz envelope, causing premature bulb failure.

3. Clean any deposits from the surface of the bulb (see “Cleaning Guidelines” on page

79).

Retaining hole

Figure 21. Removing or Replacing the Bulb

4. To replace a lamp bulb in the reflector, hold it near the middle and insert the tip of the bulb into the retaining hole of one end reflector. Apply pressure in the direction of the length of the bulb, moving it toward the end that is inserted. This will allow the free end to clear the end reflector. Gently slide the end of the bulb down to the retaining hole and allow it to pop into position.

Reflector Removal/Replacement

Replace the reflector only if it becomes dull and its surface cannot be cleaned successfully, or if severe arcing is apparent (dark or burned spots).

1. Remove the screen assembly and the bulb.

2. Remove the six flat head screws and lift the reflector out.

82 F300S/F300SQ Ultraviolet Lamp System

3. Referring to Figure 23, remove and discard the two end reflectors and the gaskets underneath. If evidence of arcing is present, clean the gasket grooves with emery cloth to remove all oxide.

4. Insert both end reflectors, ensuring that they both seat fully and evenly. The replacement end reflectors must be installed before installing the new bulb and reflectors and the new RF Gasket.

5. Install the two pre-cut (long) RF gaskets into the grooves for the end reflectors. Insert one end flush with the top of the mounting surfaces (Figure 22). Working toward the other end of the groove, press the gasket strip down firmly with the thumbnail so that it rests at the bottom of the groove.

Profile of properly installed gaskets

Figure 22. Gasket Installation

6. Examine the cross-guide gaskets for evidence of arcing. Replace if there is any evidence of wear or arcing (dark or burned spots). Also if there is evidence of arcing on the back side of the reflector caused by the cross-guide gaskets (behind the reflector), then replace them.

Install the two pre-cut RF gaskets (short ones) into the grooves for the extrusions. Insert one end flush with one edge of the mounting surfaces. Working toward the other end of the groove, press the gasket strip down firmly with a thumbnail so that it rests at the bottom of the groove.

IMPORTANT: The dichroic reflector and the R350

reflector do not have plastic protective covers on the reflector surface. The dichroic reflector has a dark purple reflective coating. Do not attempt to remove the purple reflective coating.

Installation, Operation, and Maintenance Manual # 509252 Rev R 83

7. Align the reflector squarely over the opening. With gentle pressure and a rocking motion, slide the reflector down in place. It should not bind against the end reflectors as it goes into place. As a final motion, grasp the sides of the reflector and gently force them together a small amount, then settle the reflector down over the mounting surfaces (Figure 23). Start the six flat head screws in the reflector but do not tighten. Tighten the six screws in the sequence 1-6 as shown in Figure 24 to a snug position; finally tighten to 3.4 N-m (30 inch-lbs.) using a torque controlled screwdriver. Repeat tightening the screws as illustrated and at the specified torque.

Figure 23. Reflector Removal or Replacement (I300M)

Figure 24. Reflector Screw Tightening Sequence

84 F300S/F300SQ Ultraviolet Lamp System

CAUTION: Do not use the flathead screws to pull the reflector into place. Excessive pull on these screws will deform the reflector face at its bend radius or loosen its rivets. This would result in a failure of the screen assembly to seat properly and subsequent damage to the screen gaskets.

Figure 25. Correct Reflector Alignment (I300M)

8. When the reflector is properly installed, the face should be flush and even with the outer face of the two end reflectors as shown in Figure 25.

9. Clean the reflector to remove fingerprints.

10. Clean and insert the lamp bulb according to “Cleaning Guidelines” on page 79.

Installation, Operation, and Maintenance Manual # 509252 Rev R 85

11. Replace the screen assembly. After replacing the screen assembly, refer to

Figure 26; hand-tighten the four M3 screws as shown until snug. Tighten them

in sequence to 0.9 N-m (8 inch-lbs.) using a torque-controlled screwdriver. Repeat tightening the fasteners according to the sequence and torque specified.

Figure 26. RF Screen Screw Tightening Sequence (I300M)

NOTE: After installing the reflector in the irradiator, the reflector mounting screws should be retightened (using a torque controlled screwdriver to 3.4 N-m (30 inch-lbs.)) after a minimum of 10 minutes of operation.

I300M Irradiator Housing Removal/Replacement

The I300M irradiator enclosure is removed as described in the following procedure.

1. Disconnect the cables from J10 and J11.

2. Place the irradiator (screen down) on a clean, level surface.

3. Remove two M3 flat head screws from each side of the irradiator housing.

4. Remove four M5 truss head screws that secure the housing to the casting.

5. Remove two M5 truss head screws that secure the perforated panel to the front of the irradiator housing.

6. Disconnect the pressure switch tubing from the perforated panel and remove the panel.

7. Unthread the large plastic nut that secures the J10 connector to the housing and push the connector into the housing.

8. Lift the housing straight up to remove.

9. Reverse these steps to reassemble.

86 F300S/F300SQ Ultraviolet Lamp System

Air intake plenum

Filament transformer

Photo resistor direct view assembly

Air pressure switch

Magnetron

Filament transformer bracket

Die casting

Figure 27. I300M/I301M Irradiator Component Location

Direct View Photoresistor Removal/Replacement

1. Remove the housing as described in the previous section.

2. Unplug the photoresistor 3-circuit connector (P30) from the photoresistor PWB.

3. Remove the two M4 screws securing the photoresistor mounting block to the casting and remove the photoresistor assembly.

4. Remove the single screw holding the photoresistor PWB to the mounting block.

Installation, Operation, and Maintenance Manual # 509252 Rev R 87

RF screen

5. Remove and discard the PWB and inspect the UV filter lens for damage.

6. Replace the photoresistor and UV filter lens assembly.

7. Reinstall the housing.

Photoresistor PWB

Photoresistor mounting block

Photoresistor mating

connector

Photoresistor

UV filter lens

Photoresistor

block mounting

holes

Figure 28. Photoresistor Assembly for Direct View (I300M)

Filament Transformer Removal/Replacement

1. Remove the irradiator housing.

2. Cut the cable ties and slide the PVC tubing off the magnetron connections.

3. Remove the filament terminal screws. Disconnect the leads at the primary terminals. Remove the two anchor screws holding the transformer to the side rail, and remove the transformer.

4. Replace the transformer by reversing the process.

88 F300S/F300SQ Ultraviolet Lamp System

5. Reconnect the filament transformer wires to the magnetron and tighten the terminal screws to 0.9 N-m (8 inch-lbs) using a torque-limiting screwdriver. Reposition the tubing over the terminal screws and install cable ties.

6. Install the irradiator housing as described in “I300M Irradiator Housing

Removal/Replacement” on page 86.

Magnetron Removal/Replacement

1. Remove the irradiator housing as described previously.

2. Disconnect filament transformer wires from magnetron by removing the cable ties and sliding back the tubing. Remove the terminal screws.

3. Remove the filament transformer bracket and air plenum.

4. Remove the four screws fastening the magnetron to the casting. Lift the magnetron off the waveguide assembly and place it upside down in a clear area on a wooden bench, at least five inches from any magnetic materials (such as iron or steel).

5. Install the replacement magnetron and fasten it to the casting using the associated hardware.

6. Refer to Figure 29; hand tighten the magnetron fasteners in sequence as shown until snug. Then, tighten the fasteners ¼ turn in sequence. Finally, tighten the fasteners in sequence to 3.4 N-m (30 inch-lbs) using a torque-controlled driver.

Figure 29. Magnetron Fastener Tightening Sequence (I300M)

7. Install the filament transformer bracket and air plenum.

8. Reconnect the filament transformer wires to the magnetron and tighten the terminal screws to 0.9 N-m (8 inch-lbs) using a torque-limiting screwdriver. Reposition the tubing over the terminal screws and install cable ties.

9. Install the irradiator housing as described in “I300M Irradiator Housing

Removal/Replacement” on page 86.

Installation, Operation, and Maintenance Manual # 509252 Rev R 89

Air Pressure Verification

To test air pressure inside the irradiator, remove one cover plate screw and, using a magnehelic, place the end of the tube over the screw hole (Figure 30 on page 90). For the I300M, the pressure should be 447-596 Pa (1.8-2.4” H (ambient) air.

For the I300MB irradiator (modular blower), pressure should be 447 - 822 Pa (1.8 to

3.3” H

O).

O) with respect to outside

HV Connector (J11)

Cover Plate

Figure 30. Air Pressure Test Points (I300M) - I300 MB Similar

90 F300S/F300SQ Ultraviolet Lamp System

Cover Screws

Air Pressure Switch Replacement

1. Remove the irradiator cover.

2. Pull the silicone tubing off the low pressure port of the switch.

3. Disconnect the two electrical leads from the switch.

4. Reach inside the air distribution plenum and remove the short length of silicone tubing which secures the pressure switch to the plenum wall.

5. Insert the high pressure port (longer) of the new switch through the hole in the plenum wall and secure the switch with a new length of silicone tubing (supplied with the switch.)

6. Reconnect the electrical leads.

7. Reconnect the low pressure tube to the low pressure port (shorter) on the switch.

8. Reinstall the irradiator cover.

I310M/I311M Irradiator

NOTE: The I310M/I311M model is different from the standard I300M irradiator in its internal construction, specifically in the reflector assembly and the RF gaskets used.

Bulb, Screen, and Reflector Maintenance

Cleaning Guidelines

If the reflector or bulb surfaces show signs of dirt, oil or vaporized materials, they should be removed and cleaned with a good industrial cleaner, using a lint-free cloth or tissue. The cleaner should contain no waxes, silicones, dyes or perfumes. Simple Green® and Windex® are recommended. Wipe away any residues, using the cloth or tissue with pure water. Alcohol, isopropyl, or methanol may be used for final removal of residues, except when alcohol is not allowed as a solvent.

Installation, Operation, and Maintenance Manual # 509252 Rev R 91

Bulb Cleaning

Handle bulbs with a lint-free cloth or tissue taking care not to leave fingerprints.

Baked-on material can be removed from bulbs with a mild abrasive cleaner such as Soft Scrub®, followed by a thorough rinse with water. If alcohol is allowed, do a final wipe with alcohol. Harsh abrasives and steel wool should never be used on bulbs.

Reflector Cleaning

If the reflector surface is dull or discolored, it should be cleaned. Abrasives should never be used on reflectors.

If cleaning reflectors while assembled in the irradiator, drying with compressed air is not recommended because particles or residues can be driven into spaces between components and into optical sensing elements.

Screen Cleaning

Screens may be cleaned with the cleaners discussed earlier, soaking if necessary, brushing lightly, and rinsing well. Take care not to damage the gaskets or the fine screen wires.

M3 screen retaining screws (4) (2 per side)

Figure 31. Reflector Assembly (I310M/I311M)

92 F300S/F300SQ Ultraviolet Lamp System

RF screen

Cooling air holes

Lamp bulb

Cavity

Reflector

Screen Assembly Removal/Replacement

CAUTION: In handling the irradiator or screen assembly, try to avoid all direct contact with the screen, as it punctures easily. Do not apply pressure to the screen.

1. Refer to Figure 31. Loosen the four M3 screen retaining screws, using three turns each. Repeat, this time removing screws. Grasp the screen frame by both ends, taking care not to twist or bend the screen itself, and remove the screen assembly.

2. To replace an existing screen or install a new one, place the screen assembly in position.

Figure 37).

Lamp Bulb Removal/Replacement

WARNING: During operation the lamb bulb and adjacent metal surfaces become very hot. Operate the blower for about one minute to cool hot surfaces.

1. Remove the screen as described in “Screen Assembly Removal/Replacement”

on page 93.

2. Refer to Figure 32 on page 94. Using clean cotton gloves or lint free tissue, grasp the lamp bulb at one end between the thumb and fingers and apply firm pressure axially toward the opposite end. When the tip of the bulb has cleared its retaining hole and is free to move past or along the end reflector, gently slide it up and out.

Installation, Operation, and Maintenance Manual # 509252 Rev R 93

CAUTION: Do not apply bending force to lamp bulb. Do not touch the bulb with bare fingers or allow it to contact dirty or greasy surfaces. Contaminants can be burned into the quartz envelope, causing premature bulb failure.

Retaining hole

Figure 32. Removing or Replacing the Bulb (I310M/I311M)

3. Clean any deposits from the surface of the bulb (see “Cleaning Guidelines” on

page 91).

Reflector Removal/Replacement

Replace the reflector only if it becomes dull and its surface cannot be cleaned successfully or if severe arcing is apparent.

1. Remove the screen assembly and the bulb.

94 F300S/F300SQ Ultraviolet Lamp System

2. Remove the six flat head screws and lift the reflector out. Examine the cross-guide gaskets for wear and/or arcing; replace if there is any sign of either. Replace as described in “Replacing the RF Gasket Assembly” on page 99.

3. Refer to Figure 33 on page 95, and remove and discard the two end reflectors and the gaskets underneath. If evidence of arcing is present (dark or burned spots), clean the gasket grooves with emery cloth to remove all oxide.

Figure 33. Reflector Removal or Replacement (I330M/I311M)

Installation, Operation, and Maintenance Manual # 509252 Rev R 95

Profile of properly installed gaskets

Figure 34. Gasket Installation (I330M/I311M)

4. Insert both end reflectors, ensuring that they both seat fully and evenly. The replacement end reflectors must be installed before the new RF Gasket.

5. Install the two pre-cut (long) RF gaskets into the grooves for the end reflectors. Insert one end flush with the top of the mounting surfaces (Figure 34). Working toward the other end of the groove, press the gasket strip down firmly with the thumbnail so that it rests at the bottom of the groove.

6. If you detect evidence of arcing on the back side of the reflector caused by the RF gasket assemblies behind the reflector, then replace the two RF gasket assemblies. Replace as described in “Replacing the RF Gasket Assembly” on

page 99.

IMPORTANT: The dichroic reflector and the R350 reflector do not have a plastic protective cover on the reflector surface. The dichroic reflector has a dark purple reflective coating. Do not attempt to remove the purple reflective coating.

96 F300S/F300SQ Ultraviolet Lamp System

Figure 35. Correct Reflector Alignment (I310M/I311M)

7. Align the reflector squarely over the opening. With gentle pressure and a rocking motion, slide the reflector down in place. It should not bind against the end reflectors as it goes into place. As a final motion, grasp the sides of the reflector and gently force them together a small amount, then settle the reflector down over the mounting surfaces (Figure 33). Start the six flat head screws in the reflector but do not tighten. Tighten the six screws in the sequence 1-6 as shown in Figure 36 to a snug position; finally tighten to 3.4 N-m (30 inch-lbs.) using a torque-controlled screwdriver. Repeat tightening the screws according to the illustrated sequence, and at the specified torque.

Installation, Operation, and Maintenance Manual # 509252 Rev R 97

Figure 36. Reflector Screw Tightening Sequence (I310M/I311M)

8. When the reflector is properly installed, the face should be flush and even with the outer face of the two end reflectors as shown in Figure 35.

9. Clean the reflector to remove fingerprints.

10. Clean and insert the lamp bulb as instructed earlier in this chapter.

11. Replace the screen assembly. Hand-tighten the four M3 screws in sequence as shown in Figure 37 until snug. Tighten the fasteners in sequence to 0.9 N-m (8 inch-lbs) using a torque-controlled screwdriver. Repeat tightening the fasteners according to the sequence and torque specified.

NOTE: After installing the reflector in the irradiator, the reflector mounting screws should be retightened (using a torque-controlled screwdriver to 3.4 N-m (30 inch-lbs) after a minimum of 10 minutes of operation.

Figure 37. RF Screen Screw Tightening Sequence (I310M/I311M)

98 F300S/F300SQ Ultraviolet Lamp System

Replacing the RF Gasket Assembly

1. If you detect evidence of arcing on the back of the reflector caused by the RF gasket assemblies (behind the reflector), then you will need to replace the two RF gasket assemblies with the main reflector removed.

Cross-guide (short) Gasket

Mesh

RF SCREEN (Bottom of Irradiator)

Figure 38. Gasket Installation with Cross-guide (Short) Gaskets

(I310M/I311M)

2. Remove the housing (see “I310M/I311M Irradiator Housing

Removal/Replacement” on page 100).

IMPORTANT: The extrusion and the RF gasket assembly are one assembly, and should not be separated from each other. To replace the RF gasket requires removal of the old extrusion as well as the old RF gasket.

3. Access the casting by placing the lamp on its side and gently sliding the casting out of the housing until the eight extrusion screws are accessible. (There are four screws on each side).

Installation, Operation, and Maintenance Manual # 509252 Rev R 99

4. Remove the extrusions. While holding the extrusion inside the casting, remove the four screws securing the extrusion to the casting. Repeat for the extrusion on the opposite side. Discard the old extrusions and the RF gaskets behind each.

5. Install the gasket assemblies (with extrusions) with the mesh facing outward toward the RF screen (at the bottom of the irradiator) along with the two cross-guide (short) gaskets behind each assembly. Install the replacement extrusions using the same mounting screws. The extrusions should be positioned flush to the casting and as far from the face of the lamp as the mounting screws allow. Tighten the screws to 2.5 N-m (22 inch-lbs.) using a torque-limiting screwdriver.

I310M/I311M Irradiator Housing Removal/Replacement

The irradiator enclosure is removed as follows:

1. Disconnect the cables from J10 and J11.

2. Place the irradiator (screen down) on a clean, level surface.

3. Remove two M3 flat head screws from each side of irradiator housing.

4. Remove four M5 truss head screws that secure the housing to the casting.

5. Remove two M5 truss head screws that secure the perforated panel to the front of the irradiator housing.

6. Disconnect the pressure switch tubing from the perforated panel and remove the panel.

7. Unthread the large plastic nut that secures the J10 connector to the housing, and push the connector into the housing.

8. Lift the housing straight up to view the interior components of the irradiator, as shown in Figure 39 on page 101.

9. Reverse these steps to reassemble.

I310M/I311M Scatter View Photoresistor Removal/Replacement

Figure 39 on page 101 shows the I310M/I311M Irradiator component locations.

1. Remove the irradiator housing.

2. Unsolder the photoresistor lead wires (blue wire next to the diode and a blue/white wire at the top terminal.)

3. Remove the two M5x10 mm photoresistor fastening screws and remove the photoresistor assembly.

4. Reverse these steps to replace the photoresistor assembly.

100 F300S/F300SQ Ultraviolet Lamp System

Fusion F300SQ, F300S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance

Table Of Contents

Introduction

Document Conventions

Indications of Note, Caution, Warning, and Danger

Icon Usage

Table 1. Icons

System Description

Figure 1. F300S/F300SQ Lamp System

System Components

Control

Cooling

Irradiators

Figure 2. Reflector Assembly

Table 2. Irradiator Models

Reflector and Cavity

Lamp Bulb

Figure 3. Lamp Bulb

Mounting

Power Supply

P300M/P300MQ/P300MT

RF Detector

System Interconnections

Warranty Policy

Figure 4. P300M Front Panel

Shipping Instructions

Returned Material Authorization Number

General Packing Instructions

Power Supply

Irradiators

Magnetrons

UV Bulbs

Control Cards

RF Detectors

Chapter 1. Safety

Ultraviolet Radiation

Microwave Radiation

Personnel Effects of Microwave Radiation

Radio Interference

Ozone

Temperature

High Voltage

UV Curable Materials

Chapter 2. Mechanical Installation

Mechanical Installation Checklist

Table 3. Mechanical Installation Checklist

Unpacking and Inspection

Power Supply Unit(s) Placement

Irradiator Mounting

Figure 5. Vertical Mounting Design for Irradiators

Lamps Mounted in Opposing Configuration

Figure 6. Lamps in Opposing Configuration

UV Light Shielding

RF Detector Mounting

Figure 7. Fusion UV Systems RF Detector RF-1

Remote Blowers

Irradiator Exhaust Venting

Quartz Plates

Figure 8. Quartz Plates - Example Mounting Design

Chapter 3. Electrical System

Electrical Installation/Setup Checklist

Table 4. Electrical Installation and Setup Checklist

Accessory Parts List

Interconnect Cables

Connection and Program Log

Installing the External Interlocks Control

User Connections

Figure 9. P300M/P300MQ Power Supply Rear Panel

Power Supply Programming

Settings for Six-Position Switch S1

Figure 10. Location of Programming Switch S1 on PWB

Figure 11. Table A: Programming Switch S1

Single Unit Programming and Connections

Figure 12. F300/F300SQ Single-unit Installation

Programming