Coolwaver 2 610 UV Curing System
Customer Product Manual
Part 1105120-01
Issued 4/13
To order parts call 866-885-1212.
For technical support call 800-524-1322.
This document is subject to change without notice.
Check http://emanuals.nordson.com/uvsystems for the latest version.
NORDSON CORPORATION  AMHERST, OHIO  USA
Address all correspondence to:
Nordson UV Systems Inc.
555 Jackson Street
Amherst, OH 44001
United States
Tel:(800) 717-4228
Fax: (516) 213-8312
Email: emcghee@nordson.com
Website: www.nordsonuv.com
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Trademarks
Coolwave, Nordson, and the Nordson logo are registered trademarks of
Nordson Corporation.
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2013. No part of this document may be
photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained
in this publication is subject to change without notice.
DeviceNet is a trademark of ODVA, Inc.
Part 1105120-01
E 2013 Nordson Corporation
Table of Contents
i
Table of Contents
E 2013 Nordson Corporation
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultraviolet Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Microwave Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ozone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury Bulbs (Lamps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UV-Curable Inks and Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Action in the Event of a Malfunction . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions While Servicing . . . . . . . . . . . . . . . . . . . . . . . . .
Control System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-2
1-2
1-3
1-3
1-5
1-5
1-5
1-5
1-6
1-6
1-7
1-7
1-7
1-8
1-8
1-8
1-8
1-8
1-8
1-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is UV Curing? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The UV Curing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Does it Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetron Operation and Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Inch Focus Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Inch Focus Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flood Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-1
2-1
2-2
2-4
2-5
2-5
2-6
2-7
2-8
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Part 1105120-01
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Load Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . .
Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Stop Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Power Level Control . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Standby and Lamp On . . . . . . . . . . . . . . . . . . . . . . .
Quick Cycle Using Idle Mode . . . . . . . . . . . . . . . . . . . . . . . . .
DeviceNet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamphead Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Mounting Kit for Lampheads . . . . . . . . . . . . . . . . . . . .
Light Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Blower Lampheads . . . . . . . . . . . . . . . . . . . . . . . . . .
External Blower Lampheads . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AirShield Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring Lamphead Air Pressure . . . . . . . . . . . . . . . . . . . . . .
Top Pressure Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom Pressure Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching Pressure Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamphead Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . .
RF Detector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-1
3-1
3-1
3-3
3-4
3-4
3-7
3-7
3-9
3-10
3-10
3-10
3-11
3-11
3-11
3-11
3-12
3-12
3-12
3-12
3-15
3-15
3-15
3-15
3-16
3-16
3-17
3-18
3-18
3-18
3-18
3-21
3-22
3-23
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Bulb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Timing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Sequence with Idle = Y . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Sequence with Idle = N . . . . . . . . . . . . . . . . . . . . . . . . . .
Correcting a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locally Operated Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remotely Operated Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-1
4-3
4-3
4-3
4-3
4-3
4-4
4-4
4-5
4-6
4-6
4-8
4-9
4-9
4-9
4-12
4-13
E 2013 Nordson Corporation
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E 2013 Nordson Corporation
iii
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Message Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curing Process Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Lamphead Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .
Diode Block Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-1
5-2
5-6
5-7
5-7
5-8
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications for System Fasteners . . . . . . . . . . . . . . . . .
System Controller Maintenance and Repair . . . . . . . . . . . . . . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Controller Repair Procedures . . . . . . . . . . . . . . . . . . . .
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning System Controller Cooling Fans . . . . . . . . . . . . . .
Lamphead Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . .
Internal Blower Lamphead Filter Replacement . . . . . . . . . . . . .
Lamphead Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reflector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Blower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Blower Lamphead Complete Cover Removal . . . . . .
Internal Blower Lamphead Cover Replacement . . . . . . . . . . . .
External Blower Lamphead Cover Removal . . . . . . . . . . . . . . .
Lamphead Internal Component Replacement . . . . . . . . . . . . .
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetron Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filament Transformer Replacement . . . . . . . . . . . . . . . . . . .
Light Detector Board Replacement . . . . . . . . . . . . . . . . . . . .
Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . .
Starter Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-1
6-1
6-1
6-2
6-2
6-2
6-3
6-4
6-5
6-5
6-5
6-5
6-7
6-10
6-11
6-12
6-13
6-13
6-13
6-14
6-15
6-18
6-18
6-18
6-19
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CW2 610 System Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Controller Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . .
CW-2 Internal Blower Lampheads . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications for Lamphead Fasteners . . . . . . . . . . . .
Parts Illustration − Internal Blower Lamphead Parts . . . . . . . .
CW-2 External Blower Lampheads . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications for Lamphead Fasteners . . . . . . . . . . . .
Parts Illustration − External Blower Lamphead Parts . . . . . . .
Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reflector Conversion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RF Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Lamphead Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-1
7-1
7-2
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-10
7-10
7-11
7-12
7-13
7-13
Part 1105120-01
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Table of Contents
Part 1105120-01
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Output Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master/Remote Power Setting Examples . . . . . . . . . . . . . . . . .
Lamphead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-1
8-2
8-3
8-3
8-4
8-4
8-4
UV Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
DeviceNet Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governing Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAC ID / Baud Rate Configuration . . . . . . . . . . . . . . . . . . . . . . .
LED Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DeviceNet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group 2 Only Slave Operation . . . . . . . . . . . . . . . . . . . . . . . . . .
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identity Object (01HEX − 1 Instance) . . . . . . . . . . . . . . . . . . . . . . .
Class Attributes (Instance 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instance Attributes (Instance 1) . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Message Router Object (02HEX − 1 Instance) . . . . . . . . . . . . . . .
DeviceNet Object (03HEX − 1 Instance) . . . . . . . . . . . . . . . . . . . .
Class Attributes (Instance 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instance Attributes (Instance 1) . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly Object (04HEX – 2 Instances) . . . . . . . . . . . . . . . . . . . .
Class Attributes (Instance 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instance Attributes (Instances 100 and 112) . . . . . . . . . . . . . . .
Common Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Object (05HEX − 2 Instances) . . . . . . . . . . . . . . . . . .
Class Attributes (Instance 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instance Attributes (Instances 1 − 2) . . . . . . . . . . . . . . . . . . . . .
Common Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S−Device Supervisor Object (30HEX − 1 Instance) . . . . . . . . . . .
Class Attributes (Instance 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instance Attributes (Instance 1) . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exception Detail Alarm / Warning . . . . . . . . . . . . . . . . . . . . . . . .
Lamp Object (64HEX − 16 Instances) . . . . . . . . . . . . . . . . . . . . . .
Class Attributes (Instance 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instance Attributes (Instances 1−15) . . . . . . . . . . . . . . . . . . . . .
Common Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10-1
10-1
10-1
10-1
10-2
10-2
10-3
10-4
10-4
10-4
10-4
10-4
10-4
10-5
10-5
10-5
10-5
10-5
10-6
10-6
10-6
10-6
10-7
10-7
10-7
10-10
10-11
10-11
10-11
10-12
10-12
10-12
10-12
10-13
10-14
10-15
10-15
10-16
10-16
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
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Safety
1-1
Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to all persons operating or servicing equipment.
All equipment is designed and manufactured to International Safety
Standards to ensure that the health and safety of the operator is protected
at all times.
Figure 1-1
Microwave UV Warning
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
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Part 1105120-01
1-2
Safety
Intended Use
Nordson ultraviolet (UV) equipment is intended specifically for integration
into other machines and should NOT be operated as a standalone system
or without appropriate safety guarding, shielding, and interlocks. It is the
responsibility of the integrator and end user to ensure that the final
assembly fulfills all necessary legislation and is completely safe before
operation.
This equipment is designed for the accelerated curing of UV inks,
adhesives, and coatings. Do not use this equipment to cure alternative
materials unless approved by the material supplier.
The equipment is not flame or explosion proof and is not designed for use in
hazardous areas.
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
S
S
S
S
S
S
S
using incompatible materials
making unauthorized modifications
removing or bypassing safety guards, shielding or interlocks
using incompatible or damaged parts
using unapproved auxiliary equipment
operating equipment in excess of maximum ratings
using equipment in hazardous areas
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.
Part 1105120-01
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Safety
1-3
Personal Safety
To prevent injury follow these instructions.
S Do not operate or service equipment unless you are qualified.
S Do not operate equipment unless safety guards, light shields, doors,
and/or covers are intact and automatic interlocks are operating properly.
Do not bypass or disarm any safety devices.
S Keep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the system controller and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
S Obtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials. Always use recommended personal protection devices.
S Make sure the UV area is adequately ventilated.
S The UV equipment runs at extremely high temperatures. Do not touch
the UV lamphead face during operation or immediately after shutting off
the equipment.
S To prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
S Always wear safety glasses that offer UV protection.
S Never expose any part of the body to direct or indirect UV light.
Ultraviolet Radiation
WARNING: Ultraviolet light is a form of electromagnetic radiation and can
be harmful if exposure exceeds recommended levels. Protect eyes and skin
from direct exposure to UV light. All equipment or areas where UV light is
used must be adequately guarded, shielded, and interlocked to prevent
accidental exposure.
Ultraviolet light is not capable of penetrating into the body and interacting
with internal tissues and organs.
The National Institute for Occupational Safety and Health (NIOSH)
document Criteria for Recommended Standard... Occupational Exposure to
Ultraviolet Radiation (PB214 268) establishes guidelines for safe use.
See Figure 1-2. Ultraviolet light is divided into wavelength bands A, B, C,
and V along with vacuum UV. Although values for wavelength bands will
vary depending on the source, the following ranges may be used as a
guide.
S UV-V (450−400 nanometers) – visible UV.
S UV-A (400−315 nanometers) − represents the largest portion of UV
energy and is most responsible for human skin aging and increased
pigmentation. UV−A is at the lower limit of sensitivity to the human eye.
S UV-B (315−280 nanometers) − most responsible for reddening and
burning of the skin and damage to the eyes.
S UV-C (280−100 nanometers)
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Part 1105120-01
1-4
Safety
Exposure to UV radiation can result in
S reddening of skin
S headaches
S sore eyes
ULTRA
VIOLET
X RAYS
INFRA RED
MICROWAVES
RADIO WAVES
VISIBLE
100
200
300
FAR
UV
VACUUM UV
Figure 1-2
400
500
600
700
800
900 1000 nanometers
NEAR
UV
U
U
UVC V UVA V
V
B
Ultraviolet Light Wavelength Bands
It is very important that all precautions are taken to prevent all UV light,
whether direct or indirect, from escaping the curing area. Exposure to UV
light can be harmful to both eyes and skin. Use the following table to
determine the permissible exposure time to UV light on unprotected eyes or
skin.
Permissible Ultra Violet Exposures as Recommended by the
American Conference of Government and Industrial Hygienists
Part 1105120-01
Duration of Exposure (Per Day)
Effective Irradiance (E Micro
Watts/cm sq)
8 hours
0.1
4 hours
0.2
2 hours
0.4
1 hour
0.8
30 minutes
1.7
15 minutes
3.3
10 minutes
5.0
5 minutes
10
1 minute
50
30 seconds
100
10 seconds
300
1 second
3000
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Safety
1-5
First Aid
Seek immediate medical attention for skin burns and direct UV exposure to
the eyes.
Microwave Radiation
WARNING: The lamp system utilizes high powered RF microwave energy
generated by a magnetron to provide power to the UV lamp. This
technology is identical to that of residential microwave ovens and like these
ovens can be dangerous if misused. The lamp system is safe provided that
the RF screen and gasketing are intact. Any damage such as rips or holes
in the screen may cause leakage of dangerous amounts of microwave
radiation. The power to the lamp is interlocked to the RF detector and will
shut down if microwave leakage exceeds safe levels. Any excessive
leakage will cause the system to shutdown.
Currently there are two organizations that set recommended guidelines for
exposure to occupational microwave radiation exposure, OSHA (U.S.
Department of labor, Occupational Safety and Health Administration −
Directive 29cfr 1910.97) and ANSI (American National Standards Institute −
Directive C95.1−1982). The ANSI directive, which is more stringent and
most commonly referred to, states that individuals should not be exposed to
microwave radiation levels above 8 mW/cm2 at 2.45 GHz on a continuous
basis, or an average of 8 mW/cm2 over a six minute period.
RF levels near the CoolWave 2 system installation should be checked
periodically. To measure RF levels, a hand-held survey meter is available
from ETS-Lindgren company. Their HI-1501 Survey Meter is calibrated for
2450 Mhz microwave sources and can measure RF levels from 0−2, 0−10,
and 0−100 mW/cm2 More information can be obtained on the internet from
http://www.ets−lindgren.com/.
Radio Interference
UV lamps are classified as non-consumer industrial, scientific, and medical
(ISM) equipment, as defined in Federal Communications Commission
(FCC) Rules and Regulations Volume 47, Part 18. As required by these
rules, Nordson Corporation 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. This system complies with EN55011 (CISPR-1,
Group 2, Class A).
NOTE: Nordson UV lamps operate at a fundamental frequency of 2.45
GHz. They may cause interference with wireless local area networks
(WLANs) that also operate at this frequency.
Ozone
Ozone (O3) is a colorless gas that is generated by the reaction of
short-wave UV light (around 200−220 nanometers) with air, and it occurs
whenever high-energy electrical discharge is present.
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Safety
Ozone readily reverts to breathable oxygen when mixed with atmospheric
air. Ozone should be removed from the UV source via a sealed duct and
discharged to atmosphere according to local regulations. The discharge
location should be away from pedestrian walkways and window openings
and should be well above the average human breathing height for the area.
Regular ozone checks should be carried out every three months using an
ozone meter. Recommended levels of ozone in the atmosphere of a factory
should not exceed 0.1 parts per million (PPM). This level is easily obtainable
if factory recommended exhaust rates are followed.
Ozone has a very distinct, strong odor even at low levels. Immediate ozone
checks should be made if an operator can smell ozone. Most people can
smell ozone at about one third the maximum allowable 0.1 PPM level.
Ozone exposure will cause headaches and fatigue. It will also irritate the
mouth and throat. Overexposure can lead to respiratory infections.
If ozone is detected,
1. Shut down the UV system.
2. Check exhaust ducting for leaks.
3. Check the operator working area with an ozone meter.
If a person is overcome by ozone,
S Seek immediate medical assistance.
S Move the individual to a warm uncontaminated atmosphere and loosen
tight clothing at the neck and waist.
S Keep the individual at rest.
S If the person has difficulty breathing, oxygen may be administered
provided that suitable apparatus and a trained operator are available.
S If breathing is weak or has ceased, artificial respiration should be
started.
High Temperatures
UV curing systems generally run at extremely high temperatures. A sudden
shock from touching a high temperature surface might cause an operator to
jump or take his attention away from other potential hazards.
When shutting down UV equipment for maintenance, allow the equipment to
cool before beginning work, or wear protective gloves and clothing to
prevent burns.
High Voltage
The UV curing equipment operates at high voltages up to 5000 Vdc. If any
electrical faults develop, the operator should:
1. Switch the equipment off immediately.
2. Make no attempt to service the equipment.
3. Call a qualified electrician trained to service this type of equipment.
Part 1105120-01
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Safety
1-7
Mercury Bulbs (Lamps)
The bulbs used in UV lamp systems contain mercury. Mercury is a toxic
substance and must not be ingested or come into direct contact with the
skin. Under normal UV operating conditions, mercury presents no hazard as
it is completely contained in the sealed quartz tube of the bulb; however, it is
strongly recommended that protective gloves and eye protection be worn
when handling UV bulbs, and that a mercury spill kit be readily available.
Mercury spill kits are commercially available from a number of sources.
These precautions should be followed when disposing of UV bulbs:
S Place the bulb in a rigid protective carton.
S Dispose of used bulbs through a local mercury recycling center.
S Wash your hands if a bulb breaks: mercury could come into contact with
your skin.
S Do not store or handle bulbs near food or beverages.
Nordson Corporation will dispose of UV bulbs free of charge provided the
customer covers all shipping costs associated with returning the bulbs. For
bulb disposal, please clearly mark on the all bulb containers and shipping
packages: BULBS FOR DISPOSAL ONLY.
Bulbs should be shipped to:
Primarc UV Technologies
Bulb Disposal Department
2 Dan Forth Drive
Easton, Pennsylvania 18045
UV-Curable Inks and Products
Some materials used in UV curable inks, adhesives, and varnishes are
toxic. Before handling them, read the Material Safety Data Sheets provided
by the manufacturer, use the recommended personal safety equipment, and
follow the recommended procedures for safe use and disposal.
Fire Safety
Under proper operating conditions, the surface temperature of the bulb is
anywhere between 700−900 _C (1300−1700 _F), and the vapor gas inside
the bulb is several thousand degrees Fahrenheit. Any form of flammable
material (such as paper, lint, powder, or dirt) trapped under the lamp, within
the lamp housing or in the lamp’s vicinity, will result in an increased risk of
fire.
To avoid a fire or explosion, follow these instructions.
S Know where emergency stop buttons, shut-off valves, and fire
extinguishers are located.
S Clean, maintain, test, and repair equipment according to the instructions
in this manual.
Should a fire occur, the operator must de-energize the UV equipment
immediately.
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Safety
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
S Disconnect and lock out electrical power.
S Identify the reason for the malfunction and correct it before restarting the
equipment.
Safety Precautions While Servicing
A qualified competent electrician must carry out all electrical maintenance
and servicing of this equipment.
WARNING: This equipment operates at high voltages up to 5000 volts dc
and is therefore potentially dangerous. The electrician servicing this
equipment must take all precautions.
WARNING: Isolate the equipment at the main, disconnect or lockout before
removing any of the cover panels.
Control System Cleaning
Keep all contactors and relays clean and free from dirt and dust. Check
them regularly.
WARNING: This equipment is not rated for explosive environments. Do not
install in extremely dusty or powder-charged work rooms. Contact your
Nordson representative if in doubt.
High Voltage Connections
Check the high-voltage connections within the equipment carefully to make
sure that these do not become dirty or coated with powder or other possible
conducting material. Clean them regularly, at least whenever the lamp is
changed, possibly more often where a particularly heavily polluted
atmosphere occurs.
Always make sure the unicable connectors are secure and tight before
applying power.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.
Moving and Storage
Moving or storing of the Nordson UV curing system must comply with all
applicable local and state regulations. The lamphead and system controller
should be shipped or stored in the original container or an equivalent and
kept dry and clean at all times.
Part 1105120-01
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Safety
1-9
All electrical power and other services must be disconnected and the
lamphead must be cool before moving or storing this equipment. Remove
the bulb from the lamphead before moving the lamphead. Store or ship the
bulb in the original shipping tube.
Due to the system controller’s weight, it is recommended a mechanical
device be used for handling and they should be kept as low to the floor as
possible. Controllers should be properly fastened to an appropriate fixture
such as a pallet for handling and storing.
Shipping of Nordson UV curing systems and their component parts must be
done in accordance with all applicable shipping regulations including
requirements for shipping of magnetic materials and mercury lamps.
Safety Symbols
The following safety symbols are used in this manual. The symbols are
used along with warnings to help you operate and maintain your equipment
safely. Pay attention to all warnings and follow directions to avoid personal
injury.
WARNING: Mechanical or combined mechanical/electrical hazards.
WARNING: Electrical hazard.
WARNING: UV, microwave, and RF radiation hazards.
WARNING: Hot surface hazard.
CAUTION: Equipment hazard.
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Part 1105120-01
1-10 Safety
Part 1105120-01
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Description
2-1
Section 2
Description
Introduction
This manual covers the Nordson CoolWave 2 610 Ultraviolet Microwave
Curing System. It provides safety, installation, operation, and
troubleshooting and repair information for the system and its components.
What is UV Curing?
Ultraviolet curing is achieved by a chemical reaction in special inks and
coatings when intense UV energy is focused on them. Curing efficiency
depends on UV power, coating weight, operation speed, type of substrates,
material chemistry, and other factors.
The UV Curing System
The system is designed to cure UV inks, adhesives, and coatings for
numerous industrial applications. The system consists of an individual 10-in.
lamphead, a corresponding variable output system controller, a RF detector,
and appropriate cables. Additional lampheads can be lined up end-to-end to
form longer curing widths.
How Does it Work?
Inside the lamphead, a microwave generator (magnetron) operating at 2400
to 2500 MHz excites a 10-inch medium pressure UV bulb. Microwave
energy from a magnetron is directed by a wave guide to the UV bulb. A
screen located at the opening of the cavity allows the UV light emitted by
the bulb to pass through while containing the microwave radiation.
The wavelength of the emitted UV light is between 220 and
470 nanometers. Power output is 600 watts per inch.
Light shielding is required to protect the operator and meet safety criteria. If
shielding cannot fully contain the UV light, then the operator should be
provided with protective equipment (refer to Safety in this manual).
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Part 1105120-01
2-2
Description
In addition to ultraviolet light, the UV bulbs radiate heat. A constant flow of
cooling air through the lamphead is required to remove the excess heat and
make sure that the bulbs, reflectors, and housings remain at an acceptable
operating temperature. Two versions of the lamphead are available: with an
internal blower, or with a duct connection to a customer-supplied external
blower.
The system controller supplies and controls the high voltage to the
lamphead and provides a control circuit to interlock the lamphead with the
curing machine. The unit is fitted with additional interlocks and safety
features that prevent the operation of the system in an unsafe condition.
The front panel of the controller displays operating and fault messages.
System Components
Table 2-1 and Figure 2-1 describe and illustrate the major components of a
typical CoolWave ultraviolet microwave curing system. Your system may
appear different depending on your application requirements.
Table 2-1 System Components
Item
Component
Description
1
Lamphead
The lamphead consists of a bulb housing, UV bulb, starter bulb,
reflectors, wave guide, magnetron and filament transformer assembly,
and a circuit board incorporating a light detector, temperature sensor,
and pressure sensor. The patented wave guide couples the
magnetron output to the bulb. Lampheads are available in internal and
external blower versions.
2
Ultraviolet Bulbs
Use genuine Nordson replacement bulbs with this system.
Alternative bulbs may damage the controls or overheat the
reflector system.
NOTE: The system warranty is void if genuine Nordson UV bulbs are
not used. Contact a Nordson UV representative for ordering
information.
The system uses medium-pressure bulbs. The bulbs consist of
high-purity quartz and have various fills to produce light at different
wavelengths. Bulbs and controls are carefully matched to give
optimum UV output and wavelength requirements.
3
Reflectors
Refer to Reflectors on page 2-5 for more information. Reflectors can
be ordered to suit the application. Focus reflectors are elliptical in
shape to guide the UV light into a tight band across the surface of the
material being cured. Flood reflectors produce a wider band of light.
The reflectors are manufactured from glass with a proprietary coating
to give maximum UV reflectivity while minimizing infrared radiation.
4
Starter Bulb
Acts as the ignitor for the ultraviolet bulb. The starter bulb lights at the
same time the magnetron is energized. After the UV bulb reaches full
power the starter bulb turns off automatically.
5
Light
Detector/Pressure
/Temperature
Board
Monitors UV light and shuts the system down if the bulb fails to emit
enough light. Includes a pressure transducer that monitors the
lamphead cooling air pressure and shuts off system power if the
cooling system fails to prevent a catastrophic lamphead failure.
Monitors temperature inside the lamphead and shuts down the system
if the internal temperature goes over the limit.
Part 1105120-01
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Description
Item
Component
2-3
Description
6
Magnetrons
The magnetrons are 3 KW, 2450 MHz generators that convert high
voltage electrical inputs to RF energy.
6A
Waveguide
The wave guide directs the RF energy into the UV bulb, exciting a
UV-emitting plasma within the bulb.
7A
External Blowers
7B
Internal Blower
Forced air is used to cool the UV bulb and magnetrons. If external
blowers are used, they must be sized appropriately to provide the
required air flow. Contact Nordson UV engineering for external cooling
air guidance.
8
Temperature
Sensor
Monitors the lamphead internal temperature. The sensor consists of a
thermistor potted to a ring-tongue terminal and cable, which is
connected to the light detector board.
9
System Controller
Provides and controls high voltage to the lamphead magnetrons and
controls other system functions.
10
RF Detector
Detects leakage of microwave radiation. Will shut down system if
radiation is detected.
8
1
5
6
2
9
6A
7A
4
3
7B
1
10
1
External Blower Lampheads (Mounted on Curing Machine)
Figure 2-1
Internal Blower Lamphead
System Components (Typical UV Curing System Setup)
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2-4
Description
Magnetron Operation and Life
Magnetrons consist of a cathode built into the center of a circular vacuum
chamber, surrounded by permanent magnets. The chamber itself is the
anode. Like a vacuum tube, a filament in the chamber is heated and bleeds
off electrons which are attracted to the anode, the positive outer part of the
chamber. This starts the magnetron. A high voltage power supply then
apples a high negative potential to the anode, which accelerates the free
electrons generated by the filament.
A magnetic field parallel to the filament is imposed by the permanent
magnets. The magnetic field causes the free electrons to spiral outward
from the cathode in a circular path. Spaced around the rim of the chamber
are cylindrical cavities open along their length and connected to the
common cavity space. As electrons sweep past these openings, they induce
a resonant, high-frequency electrical field in the cavity. A short antenna
directs the high frequency (2.4 GHz) microwave energy into the waveguide
which contains the energy and directs it to the UV bulb.
Although magnetrons have no moving parts, they do eventually wear out
and fail. The filament will slowly lose its ability to emit electrons to the point
where the magnetron cannot start. The filament can fail open, or short to the
anode. Magnetrons generate a lot of heat, and the heat can eventually
cause the permanent magnets to lose energy and cause the magnetron to
fail. Heat can also cause the ceramic antenna cap to crack and lose
vacuum causing magnetron failure. An imbalance in the frequency output
from the magnetrons can shorten their life as they then try to couple energy
into one another. This typically causes the ceramic antenna cap to break,
permanently damaging the magnetron.
Part 1105120-01
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Description
2-5
Reflectors
The reflectors are manufactured from borosilicate glass with a proprietary
coating to provide maximum UV reflectivity while minimizing infrared
radiation. Two types of reflectors are available for the lamphead: focus and
flood.
S The focus reflectors are available in 2.1 (53 mm) and 3.1 inch (79 mm)
focal lengths. The focal point is measured from the bottom of the
lamphead. See Figures 2-2 and 2-3.
S The flood reflectors produce a wider band of UV light. See Figure 2-4.
2.1 Inch Focus Reflector
Figure 2-2
2.1 Inch Focus Reflectors
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Part 1105120-01
2-6
Description
3.1 Inch Focus Reflector
Figure 2-3
3.1 Inch Focus Reflectors
Part 1105120-01
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Description
2-7
Flood Reflector
Figure 2-4
Flood Reflector Diagram
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Part 1105120-01
2-8
Description
Options
Each CoolWave system lamp head can be fitted with optional patented
components for maximum operating performance.
AirShield Ventilation System: The modular patented AirShield ventilation
system installs a high-quality quartz plate between the lamphead and the
product to protect the product while maintaining cooling air flow through the
lamphead.
LightTite Shutter: Installed on the lamphead, the pneumatically powered
proprietary Nordson LightTite shutter opens and closes instantly to block UV
light without turning off the lamp head and system controller. The LightTite
shutter is ideally suited for systems running manually loaded and unloaded
parts, or heat-sensitive parts where accurate control of UV exposure is
required.
ThruCure Continuous Coating System: A hinged aluminum curing
chamber equipped with customer-machinable entrance and exit vestibules
and additional reflectors for a 360 degree cure that mounts on the
lamphead. The ThruCure system can also be fitted with an optional nitrogen
inerting system.
Contact your Nordson representative for more information on these options.
Standard
Closed
90_
Open
LightTite Shutter System
Figure 2-5
AirShield Ventilation System
ThruCure Chamber
Lamphead Options
Part 1105120-01
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Installation
3-1
Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Introduction
This section contains information for installing the CoolWave 2 10-inch
lamphead and system controller. Mounting and shielding are explained in
general terms due to differences for each independent installation.
Inspection and Packaging
The Nordson CoolWave system has been carefully tested, inspected, and
packaged prior to shipping. Upon receipt, inspect the shipping materials and
components for visible damage. Report any damage immediately to the
shipper and to your Nordson representative.
NOTE: When opening the packaging, please take care so that the
packaging can be re-used to ship the unit if necessary. Keep all packaging
materials together and in a location where they will not get damaged.
System Controller Installation
Mounting Guidelines
WARNING: Heavy equipment. Be careful when moving the system
controller. Use approved lifting equipment or get help. Failure to observe
this warning could result in personal injury or equipment damage.
See Figure 3-1.
S The system controller can be mounted on any stable horizontal surface.
S Install the system controller so the operator panel and disconnect switch
are easily accessible.
S The blowers mounted on the front and the rear of the system controller
and the exhaust vents on the sides must not be obstructed.
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Installation
S Leave at least six inches of ventilation clearance on all four sides of the
system controller.
S If the system controller is mounted in an enclosure, there must be free
and unobstructed ventilation from top to bottom and side to side within
the enclosure. Contact your Nordson representative for enclosure
cooling requirements.
453.50 [17.854]
MPS2−610
NORDSON CORPORATION
555 JACKSON STREET
AMHERST, OH 44001, USA
Part No.
Serial No.
Frequency
KVA
257.00 [10.118]
2
2
4
0
6
8
P
RATE
5
P NET
2
1
0
Model
Voltage
4
6
SYSTEM ON
POWER
SETPOINT
STANDBY
SYSTEM OFF
POWER
SETTING
SET−SAVE
LAMP HEAD
MAGNETRON
AIR PRESSURE
143.10
(5.64)
143.10
(5.64)
NETWORK
REMOTE
LOCAL
25.40 [1.00]
790.50 [31.12]
158.19 [6.23]
753.00 [29.67]
25.25 [.99]
ø28.50 [ø1.12]
Sized for
3/4 in. Conduit
703.00 [27.70]
Required Ventilation Clearance
(All Four Sides)
152 mm
(6 in.)
Figure 3-1
System Controller Dimensions and Required Ventilation Clearance
Part 1105120-01
E 2013 Nordson Corporation
Installation
3-3
Power Connections
NOTE: Power must be supplied from a dedicated source with a disconnect
switch.
See Figure 3-2.
The customer power source must be wired in accordance with either the
National Electric Code, Part I or the Canadian Electrical Code, Part I, or
local codes. At a minimum, 10 AWG 600 volt wire is required unless
superseded by local codes. Four #10−32 studs provide for line connection.
Refer to the system controller ID plate for the input voltage and verify the
transformer tap wiring using Tables 3-1 and 3-2. Measure the incoming
power source voltage from the main power supply. Incoming voltage
transients shall not exceed 150 volt amplitude and have a frequency content
of less than 500 Hz.
S The power line input is three phase (three wire with ground).
S Refer to Table 3-1 for the T1 and T2 high-voltage transformers. Each
has a terminal block with H1, H2, and H3 terminals.
S Refer to Table 3-2 for the T3 control transformer.
S All transformers must be wired for the same input voltage.
Table 3-1 High Voltage Transformer Taps (T1 and T2)
Input Voltage Range
Transformer Tap
440−480
H1−H3
380−440
H1−H2
Table 3-2 Control Transformer Taps (T3)
Input Voltage
Transformer Tap
480
H1 and H4
400
H1 and H3
380
H1 and H2
Refer to Tables 8-2 and 8-3 in the Specifications section for current demand
during normal full-power operation. Size supply wiring and circuit breakers
or fuses to allow for heavy current draw during startup.
To connect power to the system controller, remove the voltage cover on the
back of the enclosure. Connect power wiring to the terminals labeled A (L1),
B (L2), C (L3), and Ground.
E 2013 Nordson Corporation
Part 1105120-01
3-4
Installation
Power Connections
(contd)
CW2-610 External Blower
T3 Control Transformer
480V
H4
400V
H3
380V
H2
0V
H1
High Voltage
T2
T1
CW2-610 Internal Blower
T3 Control Transformer
0V
H1
380V
H2
400V
H3
480V
H4
Figure 3-2
System Controller Transformers
Power Load Balancing
Refer to the System Connection Diagrams. If you are supplying power to
more than one system controller from a single source, shift the phases to
balance the load as shown in Figures 3-4 and 3-5. If you have more than
three system controllers, repeat the phase shift sequence again starting
with the fourth system controller.
System Connection Diagrams
Only the network configuration settings are shown in the following diagrams.
All other settings are optional and depend on the application. Refer to Table
3-6 for all configuration settings.
Unicable Connection: Refer to page 3-21.
RF Detector Installation: Refer to page 3-22.
Part 1105120-01
E 2013 Nordson Corporation
Installation
3-5
Lamphead Unicable
RF Detector
Input Power
Source
L1
L2 L3
RF Detector Cable
Lamphead
GND
Network Settings
Master:
ID : 00
FLT: U
NT: CAN or 485
CTRM: N
L1 (A)
L2 (B)
L3 (C)
GND
System Controller
Figure 3-3
System Connection Diagram − Stand Alone System
Lamphead Unicable
Input Power
Source
RF Detector
Lamphead
RF Detector Cable
L1
L2
L3 GND
Network Settings
Master:
ID : 00
FLT: A
NT: CAN or 485
CTRM: Y
First unit on network
L1 (A)
L2 (B)
L3 (C)
GND
RJ45 Network Cable
Lamphead Unicable
Lamphead
Network Settings
Remote:
ID : 01
FLT: A
RFD: N
NT: CAN or 485
CTRM: Y
Last unit on network
L2 (A)
L3 (B)
L1 (C)
GND
Figure 3-4
System Diagram − Two Systems, One RF Detector, One Network
E 2013 Nordson Corporation
Part 1105120-01
3-6
Installation
Power Connections
(contd)
Lamphead Unicable
Input
Power
Source
L1
L2
L3
RF Detector
RF Detector Cable
Lamphead
GND
L1 (A)
L2 (B)
L3 (C)
GND
RJ45 Network Cable
System Controller
Lamphead Unicable
Lamphead
L2 (A)
L3 (B)
L2 (C)
RJ45 Network Cable
GND
RJ45 Network Cable
GND
Lamphead Unicable
Lamphead
Network Settings
Remote:
ID : 02
FLT: A
RFD: N
NT: CAN or 485
CTRM: N
System Controller
Lamphead Unicable
Lamphead
L1 (A)
L2 (B)
L3 (C)
Figure 3-5
Network Settings
Remote:
ID : 01
FLT: A
RFD: N
NT: CAN or 485
CTRM: N
System Controller
L3 (A)
L1 (B)
L2 (C)
GND
Network Settings
Master:
ID : 00
FLT: A
NT: CAN or 485
CTRM: Y
First unit on network
Network Settings
Remote:
ID : 03
FLT: A
RFD: N
NT: CAN or 485
CTRM: Y
Last unit on network
System Controller
System Diagram − Four Systems, Two RF Detectors, One Network
Part 1105120-01
E 2013 Nordson Corporation
Installation
3-7
Network Connections
See Figures 3-3, 3-4, and 3-5. Up to 16 system controllers can be
connected together with RJ-45 cables to form a network, which can then be
operated from the master controller front panel or from a remote source.
Master/Remote: When you configure the system controllers, you can set
one unit (usually the first unit in the chain) as the Master, with the rest as
Remotes. This is done through the ID configuration selection for each
controller. The master is always configured as ID: 00; the Remotes as
ID: 01.......15.
Termination: The first and last units on the network must be terminated to
prevent transmission line data errors. This is done through the CTRM
configuration selection for each controller. CTRM: Y is terminated; CTRM: N
is not terminated.
Refer to System Controller Configuration on page 3-23 to make these
settings.
Remote Inputs and Outputs
Refer to Figure 3-6 and Table 3-3. All inputs and outputs from the Remote
I/O connector are normally open relay contacts and are rated for 24 Vdc. If
you are using the PLC interface, refer to the DeviceNet specifications in
Section 10 of this manual.
RF
DETECTOR
MSTOP
16
RETURN
15
LAMP ON
14
COM
13
STDBY
12
COM
11
OFF/RESET
10
ADDRESS
0
AIN
5
4
SHLD
3
AOUT
2
ACOM
1
6
P
6
8
6
RATE
5
2
1
NETWORK
REMOTE I/O
E 2013 Nordson Corporation
0
7
ACOM
4
4
8
FAULT
Figure 3-6
2
2
9
READY
NOT USED
PLC
INTERFACE
P
NET
MOD
DEVICENET
STATUS
INDICATORS
Remote I/O Connections
Part 1105120-01
3-8
Installation
Table 3-3 Remote Inputs and Outputs
Connector
Type
Pin
Input
16
Machine stop interlock
(MSTOP) +
15
Machine stop interlock
(RETURN) −
14
Lamp ON (LAMPON)
13
Lamp ON (COM)
12
Standby (STDBY)
Input
Input
11
Function
Standby (COM)
Description
If this input is not interfaced to external equipment, a jumper
must be installed across the pins. Opening this input turns
off the lamp, sets the FAULT output, and causes the FAULT
EXTERNAL INTERLOCK OPEN fault message to appear
on the display.
On I/O boards with the DeviceNet option this interlock can
be configured for normal contact closure (Default setting) or
isolated 24VDC. Refer to Machine Stop Interlock Jumper
Setting on page 3-9.
Remotely controls the system controller when operating in
Remote mode. A pulse or momentary contact closure to this
input turns the CoolWave lamphead on. (The Off/Reset
contact must be closed.) The Off/Reset contact must be
opened to turn the lamphead off.
With Idle Mode Disabled (see IDLE in the System
Controller Configuration section on page 3-25) − Controls
the system controller when operating in Remote mode. A
pulse or momentary contact closure to this input places the
system in Standby mode. (The Off/Reset contact must be
closed.)
With Idle Mode Enabled from Lamp ON State− The first
pulse or momentary contact closure to this input places the
system in Idle Mode. A second pulse or momentary contact
closure places the system in Standby mode.
With Idle Mode Enabled from Lamp OFF State − A pulse
or momentary contact closure to this input places the
system in Standby mode.
Note: Idle Mode can only be achieved from Lamp ON state.
Input
10
Off/Reset
Controls the system when operating in Remote mode. This
contact must be closed for the lamphead to be turned on.
Opening the contact turns the lamphead off and clears a
fault condition. Use Pins 11 or 13 as Off/Reset (COM).
Output
9
Ready
8
Ready
Contact closes after the system controller is turned on and
the light detector senses light output. In a networked system
all system controllers must be turned on and all light
detectors sense output.
7
Fault
6
Fault
5
Analog Input (AIN) +
Remote Power Level
Control
Remotely varies the UV light output from 20% to 100% in
1% increments when the system is in Remote mode. This
input can be configured for 4−20 mA or 0−10 Vdc. Refer to
System Controller Configuration on page 3-24 for
instructions.
4
Analog (ACOM) −
Common
Ground
3
Shield (SHLD)
Earth ground
Output
2
Analog Output (AOUT)
Not used. Do not connect.
1
Analog Common
(ACOM)
Not used. Do not connect.
Output
Input
Part 1105120-01
Contact closes whenever there is a fault present on the
system.
E 2013 Nordson Corporation
Installation
3-9
Machine Stop Interlock
CAUTION: Allow only qualified personnel to service the equipment. All
power must be disconnected. Follow the safety instructions in this document
and all other related documentation.
The Machine Stop interlock (Remote I/O pins 15 and 16) can be configured
for Normal or Isolated operation on I/O boards with the DeviceNet option by
changing the J1 and J2 jumper positions on the Remote I/O circuit board.
Jumper Position
Pins
Description
Normal
MSTOP
(15, 16)
Input compatible looking for
contact closure only. This is the
only interlock operation mode
available on controllers without
DeviceNet.
Isolated (ISO)
MSTOP
(15, 16)
External 24 Vdc @ 5 mA is
required to maintain interlock
contact closure. This is available
only on controllers with DeviceNet.
See Figure 3-7. To access the Machine Stop Interlock jumpers remove the
system controller cover. The jumpers are on the back of the I/O connector
circuit board.
S The signal voltage range for the Isolated Machine Stop Interlock is
20−30 volts DC.
S Both jumpers must be set to one of the two positions as shown in
Figure 3-7.
CAUTION: Any other jumper combination is invalid and will cause damage.
NORMAL
J2
J1
ISO
J2
Figure 3-7
E 2013 Nordson Corporation
J1
Machine Stop Interlock Jumper Settings − Shown Set To NORMAL
Part 1105120-01
3-10 Installation
Remote Power Level Control
The Remote Power Level Control (AIN inputs 4 and 5) function adjusts the
UV light output based on an external analog signal. This function must be
enabled and configured for 4−20 mA or 0−10 Vdc.
S Refer to Table 3-3 and Table 3-5 for connection and configuration
instructions.
S Refer to Table 4-4, step 5, in the Section 4, Operation for Power Level
setting instructions.
Idle Mode
Idle Mode is a low power state used to quickly switch the lamp from curing
power to an inactive, low light and heat state. Refer to Table 3-3 and
Table 3-5 for connection and configuration instructions.
The system must be in Lamp ON state to activate Idle Mode from the power
control, the Remote I/O, or through the DeviceNet network.
NOTE: The lamp should not remain in Idle Mode for longer than necessary.
After 10 minutes in Idle Mode the lamp reverts to Standby mode.
Table 3-4 Cycle Timing for Idle Mode
Cycle Timing
Idle to Lamp ON
3 seconds
Lamp ON to Idle
2 seconds
Remote Standby and Lamp On
The Off/Reset contact (I/O 10, 13) must be closed for the unit to go to
Standby or On mode. Once the lamphead is in Standby or On mode the
lamphead remains in that mode until the Off/Reset contact is opened.
Standard Startup: Use to go from off, through the warm-up sequence, to
the SYSTEM ON mode.
1. On the host machine (or the master system controller), press the
SYSTEM ON button.
2. The unit goes through the warm up cycle for 15 seconds before turning
On.
3. After approximately 10 more seconds the unit has stabilized and is
ready to run. The system ready output contact closes.
Quick Startup: Use to go quickly from STANDBY mode to SYSTEM ON
mode.
1. On the host machine (or master system controller), press the STANDBY
button. Power is applied to the magnetron filament to prepare it for
operation.
2. After approximately 15 seconds the magnetron filament is warmed up.
The system goes into standby mode and remains there indefintely.
Part 1105120-01
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Installation
3-11
NOTE: Do not leave the system controller in the standby mode for longer
than 30 minutes. Prolonged standby periods shorten the magnetron life.
3. Press the SYSTEM ON button to turn on the UV lamp. The lamp turns
on instantly but takes approximately 10 seconds to stabilize. After 10
seconds, the system ready output contact closes.
Quick Cycle Using Idle Mode
NOTE: IDLE configuration must be set to IDLE Y to enable Idle Mode. See
IDLE in the System Controller Configuration table on page 3-25.
1. Begin by using the Standard or Quick Startup procedures on page 3-10
to achieve Lamp ON state.
2. Initiate Standby command (locally or remotely).
3. The unit immediately switches to Idle State (within 1 second).
4. To return to curing, initiate the Lamp ON command (locally or remotely).
5. The UV lamp turns on but full output is not available until the bulb has
reached operating temperature, which takes approximately 5 seconds.
This process can be repeated as required.
DeviceNet Installation
Chassis Isolation
DeviceNet Drain to Chassis
The drain wire is referenced to the chassis ground through one
megohm resistance.
V+ and V− to Chassis
The DeviceNet power is not referenced to chassis ground with any
impedance other than the stray capacitance due to the pc board
layout. The board is designed to withstand +/− 500 volt test applied
between the V+ and V− and the chassis.
CAN_H and CAN_L to Chassis
The circuit is designed to withstand the application of a +/− 500 volt
test applied between these data lines and the chassis.
CAN_H to CAN_L Isolation
The CAN transceiver is fully compatible with the ISO 11898−24V
specification. An un-powered node will not disturb the CAN bus lines.
BUS Power
BUS Sense Circuitry
The system controller has an isolated physical layer. An optical isolator
is used to monitor the BUS power, the loss of which results in an
un-powered transceiver.
Hot Plugging
The system controller can be hot plugged into a DeviceNet network.
Inrush current is limited to less than 500 milliamps for less than 50
microseconds.
Mis-Wiring Protection
The system controller supports mis-wiring protection as defined in the
DeviceNet Specification (Section 10 of this manual).
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Part 1105120-01
3-12 Installation
Hardware Specifications
The hardware design of the DeviceNet Interface follows ODVA
recommendations. The interface can be found on the rear of the CoolWave2
system controller.
Interface Connector
Sealed micro connector is specified in ODVA specifications Volume 1,
Release 2.0, Errata 2. Appendix C, table C.3. CoolWave2 uses a Phoenix
connector.
Indicators
Red and green LEDs indicate the status of the module and the network.
Node Address Switches
Two 10-position rotary switches for setting the MAC ID.
Data Rate Switch
A 10-position rotary switch to set the data rate to 125, 250, or 500k Baud.
Software Specifications
Refer to Section 10 for the DeviceNet Interface Module specifications.
Lamphead Installation
The lamphead mounting must include provisions for UV light shielding and
cooling air ductwork and venting. Each application has different constraints
and therefore requires custom-designed enclosures and light shielding.
Contact Nordson UV systems engineering department for help with designs.
Mounting Guidelines
Figures 3-9 and 3-10 provide the physical dimensions of the CoolWave 2
lampheads. See page 2-5 for focal lengths. Install lampheads with focus
reflectors with the base positioned as follows:
2.1 focus reflectors:
3.1 focus reflectors:
53.3-mm (2.1-in.) above the substrate
78.8-mm (3.1-in.) above the substrate
NOTE: Flood reflectors have no set distance. The base to substrate
distance is not as critical and can be adjusted to vary the dosage and
intensity.
Lamphead
2.1 or 3.1 inches
53.3 or 78.8 mm
Lamphead Base
Substrate
Figure 3-8
Part 1105120-01
Focus Reflector Lamphead Mounting
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Installation
3-13
Inlet for 6-in. ID Duct
114.0
(4.488)
115
(4.53)
Unicable
Receptacle
Top Pressure Port *
65.0 (2.559)
150.0
(5.906)
150
(5.906)
Typ. 3 sides
M5 Screws
(Typ. 3 sides)
23.5
(0.925)
150
(5.906
435.9
(17.16)
370
(14.56)
115
(4.53)
53.3 (2.1 Focus)
78.8 (3.1 Focus)
266.4 (10.48)
199.2 (7.84)
9.50 (0.374)
Bottom
Pressure
Port *
76.0 (2.992)
18.25 (0.719)
76.0 (2.992)
182.0
(7.165)
All measurements in mm (in.)
76.0 (2.992)
Bottom
Pressure
Port *
* DO NOT BLOCK PRESSURE PORTS
WHEN MOUNTING LAMPHEADS
M4 Threaded Mounting Holes (8)
Figure 3-9
Lamphead Dimensions − External Blower Version
NOTE: Refer to page 3-18 for top and bottom pressure port usage. It is
important that the pressure port being used to measure differential pressure
not be blocked, and that the appropriate port be used depending on the
cooling air and exhaust air arrangements.
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Part 1105120-01
3-14 Installation
267.00 [10.512]
265.00 [10.433]
DO NOT
BLOCK
FILTER
63.20
[2.488]
150
(5.906)
667.00
[26.260]
Typ. 3 sides
Unicable
Receptacle
23.5
(0.925)
Unicable
Receptacle
150
(5.906
Front
Pressure
Port *
115.00
[4.528]
53.4 (2.1 Focus)
78.75 (3.1 Focus)
Bottom
Pressure
Port *
200.96
[7.91]
9.50 (0.374)
76.0 (2.992)
18.25 (0.719)
76.0 (2.992)
76.0 (2.992)
182.0
(7.165)
Bottom
Pressure
Port *
All measurements in mm (in.)
* DO NOT BLOCK PRESSURE PORTS
WHEN MOUNTING LAMPHEADS
M4 Threaded Mounting Holes (8)
133
(5.24)
Figure 3-10 Lamphead Dimensions − Internal Blower
Part 1105120-01
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Installation
3-15
Optional Mounting Kit for Lampheads
An optional adjustable bracket, mounting plate, and screws are available as
a kit for flexible mounting of lampheads. Refer to page 7-13 in Parts for the
kit part number and mounting instructions.
Adjustable
Mounting
Bracket
Figure 3-11
Optional Adjustable Mounting Bracket
Light Shielding
Personnel in the area should be shielded from the UV light.
S Provide adequate shielding of UV light. The lamphead must be enclosed
so that no UV light is allowed to escape.
S Any louvered material used for exhaust must be a light-shielding design.
S If UV light does escape the operator must wear approved UV-protective
clothing and eyewear.
Cooling Air Installation
Internal Blower Lampheads
Internal blower lampheads do not require a cooling air source. However, the
flow of cooling air must not be restricted or impeded, either at the inlet or the
outlet. If an AirShield ventilation system or any type of exhaust-restricting
devices are used, the exhaust air must be evacuated to ensure adequate
cooling air flow. Refer to the AirShield Ventilation System instructions on
page 3-17.
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Part 1105120-01
3-16 Installation
External Blower Lampheads
For lampheads without internal blowers, the customer must supply cooling
air through ductwork to each lamphead. The duct connection is for 6-in. ID
ducts. If you plan on using variable speed external blowers, contact
Nordson UV engineering for advice on the design of the air handling
system.
The following specifications must be maintained for all applications at all
times or the life of the lamphead will be greatly reduced with the possibility
of failure:
S Unimpeded and unrestricted flow of cooling air through the lamphead.
S Constant static pressure of 7-in. water column measured from the inside
of the lamphead to atmosphere.
S 350+25% CFM of filtered airflow through the lamphead.
It is important to size the cooling air blower to provide at least an additional
25% of cooling air measured at the duct inlet just prior to the lamphead.
Size the blower to accommodate all losses in the ducts and ensure that the
specified air flow and pressure are delivered to the lamphead.
NOTE: Recommended Flexible Duct Hose for External Lamphead cooling
air: McMaster-Carr part number 55125K26, neoprene coated 6-in ID hose.
Use worm clamps to connect the hose to the lamphead.
In many applications cooling air is provided to multiple lampheads from a
common source. In these installations it is recommended that air flow
adjustment dampers such as the Fantech IR-6 iris damper be added to the
ducting as close to the lamphead as possible, within 0.5 meters (1.6 ft), for
proper air flow balancing.
Once the system is up and running, check the pressure inside the lamphead
by pressing the LAMPHEAD − AIR PRESSURE button on the face of the
system controller. Refer to Operation for startup procedures.
Exhaust Requirements
Lamphead cooling air must be exhausted when lampheads are enclosed in
a cure chamber or when the air flow is restricted and/or captured at the
lamphead face.
When lampheads are installed in a cure chamber and the lamphead cooling
air is exhausted to the open air within the chamber you must size the
chamber exhaust system to evacuate at least 125% of the air flow into the
lampheads. You must also factor in the capacity to remove all air in the
chamber including air flow into the chamber through all openings, doors,
conveyors, and cracks. The air flow required is the sum of all the lampheads
and openings and must be at a static pressure great enough to keep a
negative pressure in the chamber.
When an AirShield Ventilation system, quartz plate, or any other device
restricts the lamphead exhaust air flow, the exhaust system must evacuate
at least 125% of the air flow into the lamphead at a static pressure that
ensures that there is an even flow or a slight negative pressure at the lamp
face.
Part 1105120-01
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Installation
3-17
The exhaust blower and duct size for each application will depend on many
variables. Size all blowers to accommodate all losses in the ductwork and
ensure that the specified air flow and pressure for each lamphead is
maintained.
AirShield Ventilation System
Figure 3-12 shows a standard AirShield Ventilation System kit installed on
an external blower lamphead. A high flow AirShield kit is also available.
Before mounting the lamphead on the AirShield enclosure, switch the
pressure hose from the top or front port to the bottom port as described in
Switching Pressure Ports on page 3-18.
Use eight M4 screws to mount the AirShield enclosure to the lamphead.
The internal blower lampheads are mounted to the kits in the same way.
Refer to the Parts section for the AirShield kit part numbers.
NOTE: Recommended Flexible Duct Hose for exhaust extraction:
McMaster-Carr part number 55125K26, neoprene coated 6-in ID hose. Use
worm clamps to connect the hose to the vent stubs.
6-in. Intake
Top Pressure Port
48.1 mm
(1.894 in.)
38.1 mm
(1.5 in.)
6-in. Exhaust
High Flow Kit
Standard Kit
35.4 mm
(1.394 in.)
25.4 mm
(1.0 in.)
Port for Bottom Pressure Reading
8−M4 x 35 Screws (Std Kit)
8−M4 x 50 Screws (High Flow Kit)
(included in kits)
Quartz Plate
Figure 3-12 AirShield Kit Installation (External Blower Lamphead Shown)
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Part 1105120-01
3-18 Installation
Monitoring Lamphead Air Pressure
See Figures 3-13 and 3-14. The lamphead pressure sensor on the light
detector board is connected by a hose to atmosphere at the top/front or
bottom pressure port. (See Figures 3-9 and Figure 3-10 for the location of
the pressure ports on internal and external blower versions.) The hose
must be connected to Port B on the board, as shown.
It is important that the pressure port not be blocked, and that the
appropriate port be used depending on the cooling air and exhaust air
arrangements.
Top Pressure Port
(Factory default.) If the exhaust air from the lamphead is not restricted in
any way the top pressure port should be used. Examples of this type of
installation are when lamps are mounted in a large enclosure. Caution
should be used when using the top pressure port as any restriction of the
exhaust air will influence the pressure sensor readings and possibly
damage the lamphead.
Bottom Pressure Port
In applications where there is a restriction preventing the free flow of
exhaust air from the lamphead, the bottom pressure port must be used.
Examples of this type of application are quartz light shields, AirShield
ventilation systems, dedicated exhaust ducts, or any other type of exhaust
box or lamp face attachment that can restrict the exhaust air flow.
When using the bottom pressure port the lamphead mounting structure
must be designed so that this port is open to the air exiting through the
screen. Do not simply set the lamp in a bracket or on a ledge that could
cover over the bottom pressure port.
Switching Pressure Ports
External blower lampheads are shipped with the pressure transducer
connected to the top port. Internal blower lampheads are shipped with the
transducer connected to the front port.
Use this procedure to switch the hose connection from the top or front port
to the bottom:
1. See Figures 3-13 and 3-14. Remove the lamphead cover.
2. Disconnect the pressure hose and unscrew the barbed fitting from the
top or front pressure port.
3. Install the barbed fitting in the bottom pressure port, then feed the hose
through the lamphead and connect it to the barbed fitting.
Part 1105120-01
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Installation
3-19
Top Pressure Port
(Factory Connection)
Port B
Hose Connection
Hose
Barbed
Fitting
Bottom
Pressure
Port
Figure 3-13 Pressure Port Connections − External Blower Version
E 2013 Nordson Corporation
Part 1105120-01
3-20 Installation
Port B
Hose Connection
Front
Pressure
Port
(Factory
Connection)
Hose
Bottom
Pressure
Port
Barbed
Fitting
Figure 3-14 Pressure Port Connections − Internal Blower Version
Part 1105120-01
E 2013 Nordson Corporation
Installation
3-21
Lamphead Cable Connections
CAUTION: The unicable conducts high and low voltage between the
system controller and the lamphead. It is important that the unicable
connectors be completely engaged and tightened before turning on the UV
system. Failure to properly engage these connectors can result in severe
damage to the system components.
Before inserting the plug into the receptacle check both and ensure that the
pins are not bent, and that the rubber inserts are in good condition and not
damaged. Make sure also that there is no evidence of arcing or other
damage on the pins and sockets.
See Figures 3-3 and 3-15. Connect the unicable to the system controller
and the lamphead.
NOTE: The unicable plugs are keyed and can only be inserted into the
receptacles when correctly oriented. Do not force the plugs into the
receptacles. Do not use the screw rings to pull the plugs into the
receptacles. In most cases, it might help to wiggle the plug slightly while
pushing it into the receptacle to ensure that all the pins mate securely with
the sockets.
Push the plug into the receptacle as far as it will go, then start threading the
screw ring onto the threaded portion of the receptacle. Continue to push on
and wiggle the plug while tightening the screw ring until the plug is firmly
seated into the receptacle.
When fully mated, the red indicator on the plug should not be visible
and there should be no movement between the plug and the
receptacle.
NOTE: When tightening the screw ring, it is recommended to use a 30−32
DIN1810B hook wrench (spanner wrench) to insure that the connection is
secure. There are four holes in the screw ring for the wrench pin.
Red Indicator:
Incorrectly Installed
No Red Indicator:
Correctly Installed
30−32 DIN1810B
Spanner Wrench
(Customer-Supplied)
Figure 3-15 Unicable Connection
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Part 1105120-01
3-22 Installation
RF Detector Installation
See Figures 3-3 and 3-6 for RF Detector connections and Figure 3-16 for
dimensions.
S The RF detector shuts down the system controller when the RF level
detected is above the calibrated trip level. This can happen if the
lamphead RF screen is torn or incorrectly installed.
S One RF detector is normally required for every 16 networked units within
one curing enclosure. However, some applications and systems may
require a RF detector on each unit. Contact your Nordson representative
for more information.
S Do not mount the RF detector directly below the lamphead.
S The RF detector can be damaged by excessive heat and extreme RF
fields. Do not install it less than 8 inches from the lamphead.
S Mount the RF detector so that the antenna faces the lampheads and is
between the operator and the lampheads or the lampheads and any
opening (the major source for RF leakage).
S The detector has a patented self test feature to make sure it is working
properly. The detector is not serviceable. If it fails, fault code 26 appears
on the system controller. Replace the RF detector if it fails.
19.1
(0.75)
Ø7.2
(Ø0.28)
Antenna
88.9
(3.50)
Ø4.0
(Ø0.16)
12.7
(0.50)
38.1
(1.50)
14.0
(0.55)
42.8
(1.69)
203 (8)
203 (8)
No
RF
Detector
No
RF
Detector
203 (8)
No RF Detector
305 (12)
Figure 3-16
Part 1105120-01
All dimensions are in mm (in.)
RF Detector Installation
E 2013 Nordson Corporation
Installation
3-23
System Controller Configuration
Once the system controller and lamphead are mounted and all connections
made, the last step is to configure the controller for your application, using
the front panel display, keys, and configuration menus.
NOTE: The system controller power must be on and the lamphead must be
OFF to enter the configuration menus. Press the SYSTEM OFF button to
turn the lamphead off if LAMPON is displayed.
Use these keys to configure the system controller:
Key
Function
Nordson Logo
(behind the letter “d”)
Press for 5−15 seconds to enter the
configuration menu.
SET−SAVE
Set choice and advance to next configuration
setting.
UP/DOWN
Scroll through setting choices.
UP
DOWN
MPS2-610V
OFF
SET/SAVE
NORDSON LOGO
Figure 3-17 System Controller Front Panel
1. Move the front power switch to the ON position. The system goes
through a power-up test sequence, then displays the installed software
version numbers, then displays OFF.
2. Press the Nordson Logo for 5−15 seconds to enter the configuration
menu. The configuration settings are displayed in the order listed in
Table 3-5.
3. Press the UP or DOWN keys to scroll through the choices available for
each setting. Press the SET−SAVE key to save the displayed choice
and advance to the next setting.
4. The last display is PWROFF. Turn the power supply power switch to the
OFF position to set the configuration in flash memory.
NOTE: The only configuration setting not done through the system
software is the Remote I/O Machine Stop Interlock function. Refer to
page 3-9 for this setting.
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Part 1105120-01
3-24 Installation
Table 3-5 Power Supply Configuration Settings
Display
ID 00..15
(Unit ID)
Function
Unit ID: Sets unit ID for
network, identifies master
or remote.
Configuration 1
Master = ID 00
Configuration 2
Remotes = ID 01..15
For a standalone system controller, set the unit ID to 00. For networked power
supplies, set the master to 00 and set the remotes to 01, 02.....15.
S Each system controller on a network must have a unique ID number.
FLT
(Fault)
Fault State: Sets Unit Fault
to fault units separately or
all together.
FLT U = FAULT UNIT
(Fault this unit only)
FLT A = FAULT ALL
(Shuts down all units on
the network).
This setting is for multiple system master/remote networks. A networked system
controller in a fault condition can fault just itself or the entire network.
S All networked system controllers must have the same fault setting.
RFD
(RF Detector)
Sets RF detector status for
each system controller.
RFD Y = RF Detector
connected
RFD N = No RF detector
connected
A Master controller is automatically set to RFD Yes. Remote power supplies can be set
to Yes or No. Only one RF detector is required for a network.
NT
(Network)
Specifies network
communication protocol.
NT CAN = CAN BUS
protocol
NT 485 = 485 protocol
The CAN BUS protocol is the preferred protocol for system controller networks.
It must be selected for any network using DeviceNet.
S All system controllers on the network must be set to the same protocol.
CTRM
Can termination
CTRM Y = CAN
termination Yes.
CTRM N = CAN
termination No.
Internal network termination setting.
S Set to Yes for networked controllers that have only one network port connected
(and so are on one end of the network). The Master system controller is typically on
one end of the network.
S Set to No for all networked controllers that have both network ports connected.
ANA
Remote Power Level
Control enable/setting
ANA Y = Y (yes)
ANA N = N (no)
Refer to Table 3-3 on page 3-8 for connections.
S If set to ANA Y, then the next setting allows you to choose the input. In Remote
mode, light output is controlled by the input to the AIN and ACOM terminals
(5 and 4).
S If set to ANA N, then the light output is controlled from the system controller front
panel in both Remote and Local modes.
IN
Analog input selector
mA = 4−20 mA control
V = 0−10 Vdc control
Specifies the input type for Remote Power Level Control. This selection appears if
ANA Y is selected. Refer to Table 3-3 on page 3-8 for connections.
CTL
Remote control source
IO = Use discrete remote
I/O terminal
DN = Use DeviceNet for
remote control
Refer to Table 3-3 on page 3-8 for discrete remote I/O connections. IO is the default
setting.
Part 1105120-01
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Installation
Display
PCTL
Function
Power control algorithm
Configuration 1
Y = Enable Power Control
mode
3-25
Configuration 2
N = Use current control
mode (default)
If set to PCTL Y, the power control algorithm controls the total power output to reduce
the variation of power over the life of the magnetron.
PCTL N is the default and preferred method of control (current control).
LAN
Language in which faults
are displayed
ENG=English
FR=French
IT=Italian
GE=German
SP=Spanish
Use this setting to choose the language for fault messages. English is the default
language.
IDLE
Enabling IDLE mode
allows a return to Lamp
ON mode within 3 seconds
(use the Standby
command for activation).
This is done by operating
the lamp system at a low
power, which is not
capable of curing, with
minimal heat on substrate.
IDLE N=No
Not enabled
IDLE Y=Yes
Operation of IDLE mode
(local or remote) through
Standby control. Refer to
the Operation Section for
the proper sequence.
VSPD
Lampheads with an
internal blower may
incorporate variable speed
control to provide
consistent bulb
temperature.
VSPD N=No
Set to N if lamphead is not
equipped with internal
blower
VSPD Y=Yes
Enables speed control
Set to Y only if an internal
blower lamphead is used.
PWROFF
POWER OFF
No selection
No selection
This is a message instructing you to turn the power supply switch OFF to save your
settings in flash memory.
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Part 1105120-01
3-26 Installation
Part 1105120-01
E 2013 Nordson Corporation
Operation
4-1
Section 4
Operation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Introduction
Startup procedures will vary depending on how the UV system is integrated
into other systems and equipment. The startup procedures documented in
this manual are strictly for the UV equipment.
Display and Controls
See Figure 4-1 and Table 4-1.
3
2
4
1
MPS2-610V
10
9
8
7
6
5
Figure 4-1
11
CoolWave 2 System Controller Displays and Controls
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Part 1105120-01
4-2
Operation
Table 4-1 CoolWave 2 Displays and Controls
Item
Control
Description
1
Main Power Switch
Turns system power on and off.
2
SYSTEM ON
Turns the lamphead on when STDBY, IDLE, or OFF is displayed. From
OFF, the system goes into WARMUP mode until the filament is warmed up,
then power is applied to the magnetrons and LMPDLY is displayed while
the magnetrons stabilize. LAMPON is displayed when the lamp lights.
3
STANDBY
When the Standby button is pressed power is removed from the lamp. The
magnetron filaments remain powered. STDBY is displayed. This mode
allows the system to cycle to curing power faster than from OFF.
Excessive use of Standby mode will shorten magnetron life.
IDLE (if enabled)
If the Idle mode is enabled during system configuration, then pressing the
Standby button puts the system in Idle mode. In this mode, the lamp is
powered at a low light and heat state. When SYSTEM ON is pressed, the
lamp will cycle to LMPDLY then to LAMPON.
The lamp should not remain in Idle Mode for longer than necessary. After
10 minutes in Idle Mode the lamp automatically reverts to Standby mode.
4
SYSTEM OFF
Turns the lamphead off.
5
NETWORK
LOCAL
REMOTE
Sets system operation to LOCAL mode (system controlled from front panel)
or to REMOTE mode (system controlled by a remote device or controller
through discrete I/O or DeviceNet).
6
LAMPHEAD
AIR PRESSURE
Displays lamphead pressure in X.X inches w.c. (water column).
7
LAMPHEAD
MAGNETRON
Displays the current through each magnetron in milliamps (mA). Pressing
the MAGNETRON button toggles between MAG A and MAG B current. If
the power control mode is configured, then OPC is displayed.
8
POWER SETTING
Adjusts the UV output of the lamp, as a percentage of full power. Power
can be adjusted from 20% to 100% while the lamp is in the OFF or ON
state. At 100% the lamp produces the maximum UV intensity it is capable
of (600 watts/inch).
The system is factory set to operate at 100% output. To check the power
level set point, press the SET-SAVE button. In network LOCAL mode, you
can change the output in 5% increments by pressing the UP or DOWN
buttons. Press the SET-SAVE button in order to save your changes and
return to normal operation. In network REMOTE mode, power can be
adjusted in 1% increments by a remote PLC. Regardless of the control
method, changes to the power setting take effect immediately.
Remote Units Controlled by a Master: The remote units determine
their power setting by multiplying the master power setting by the remote
set point (set at the front panel of the remote unit). If the Master power
setting is 80%, then the output of a remote unit set at 50% is actually 40%
of its potential output (80% x 0.5 = 40%).
Part 1105120-01
S
S
The remote unit set point is always the value set from its front panel.
S
All systems can only be set to values between 20% and 100%. If any of
the above cases calculate a value below 20% the control will stay at
40% until the calculated value is again above 20%. This will not set an
error but the unit power will not go below 20%.
The Master set point is set from its front panel when it is in Local mode.
In Remote mode it can be set by analog input or DeviceNet.
E 2013 Nordson Corporation
Operation
Item
Control
4-3
Description
9
Digital Display
Displays power levels, operation and fault messages.
10
POWER SETPOINT
When pressed, displays the current power setpoint.
11
Nordson Logo
(System Configuration)
Accesses system controller configuration. Refer to Table 3-4 in the
Installation section for more information.
Additional Functions
Temperature
To display the internal temperatures of the lamphead and system controller
press the OFF and SET-SAVE buttons simultaneously:
LH xxC = Lamphead Internal Temperature
LB xxC = Lamphead Circuit Board Temperature
MB xxC = System Controller Control Board Temperature
Light Detector
To test the light detector and check UV output, press the DOWN button and
STANDBY buttons simultaneously. You can do this on controller power up to
watch the UV output come up to full power.
Sensor Saturation = 900−960 counts
Normal Operation = 920−950 counts
Acceptable Operation = greater than 700 counts
Alarm Trip Point for 50% to 100% Power Level = 600 counts
Alarm Trip Point for less than 50% Power Level = 300 counts
Starter Bulb Test
To test the starter bulb, turn OFF the lamp, press the LOCAL button for
approximately 20 seconds, and check for light output. The starter bulb turns
on for a few seconds during lamp ignition, to help the UV bulb ignite.
Panel Lock
NOTE: For use with systems operated in remote modes.
To lock out all front panel control functions, press REMOTE for
approximately 20 seconds. LOCK is displayed momentarily. The period at
the left of the display remains on as long as the system is locked.
To unlock the system press REMOTE for approximately 20 seconds.
UNLOCK displays and the unit returns to normal operation.
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Part 1105120-01
4-4
Operation
Operating Messages
Table 4-2 lists the messages that indicate operating status.
Table 4-2 Display Messages
Message
Description
OFF
The system controller power is On. The lamphead is in the Off state.
WARMUP
The magnetron filament is energized. This message is only displayed during
filament warm-up (about 15 seconds).
STDBY
The filament is warm and the unit is waiting for an On command.
LMPDLY
Lamp Delay
Lamp ON has been enabled. The power contactor is closed, and high voltage
has been applied to the magnetrons. This message is displayed during lamp
warm-up (about 10 seconds).
LAMPON
Lamp is On at the set power level.
L COOL
Lamp Cool Down
Lamp was On and a Standby command has been received. The magnetron
power is shut off. This message is displayed during lamp cool down (about 20
seconds). The lamphead then goes to a standby state. The unit will not restart
until the lamp cool down is complete.
C DLY
Cool Down Delay
An Off command was received. The lamphead power is turned off. The
message is displayed during lamp cool down (about 60 seconds). The unit will
not restart until the lamp cool down is complete.
IDLE
Lamp is idling at 10% of full power.
Fault Messages
When a fault is detected, the system controller shuts down the high voltage,
turns on the FAULT relay output, and displays a fault message. Table 4-3
lists the fault messages. Refer to Section 5, Troubleshooting, for fault
correction procedures.
Table 4-3 Fault Messages
No.
Fault Message
Description
0
NETWORK CONFIG
Duplicate system IDs on the network.
2
FILAMENT FUSE BLOWN
There is no current detected on the filament transformer circuit
when the system controller is turned on.
3
HIGH CURRENT ON MAG
High current exceeding 950 mA has been detected on the
magnetron high-voltage circuit.
4
CURRENT IMBALANCE
The magnetrons are turned on (LAMPON) and the magnetron
currents differ by more than 100 ma for a period exceeding
about 600 ms.
5
ON NETWORK UNIT
There is a fault on a remote unit.
6
MAG POWER WHEN OFF
Magnetron current sensed in standby mode.
7
NO LIGHT DETECTED
There was insufficient output from the lamp when the system
controller energized the magnetrons in the Lamp On mode.
9
HARDWARE FAILURE
The system controller is not communicating with the light
board.
Part 1105120-01
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Operation
No.
Fault Message
4-5
Description
10
DEVICENET ERROR
There is a DeviceNet communication fault.
11
DEVICENET HARDWARE
FAIL
There is no communication with the DeviceNet processor.
12
MAG VOLTAGE ERROR
The magnetron voltage is not within limits.
13
NETWORK COMM ERROR
The control board can no longer communicate with a
previously detected system.
15
POWER CONTROL AT
LIMIT
The power control cannot control the output within 5% of the
setpoint.
16
LOW LAMPHEAD
PRESSURE
There is insufficient or no air pressure in the lamphead.
17
EXT INTERLOCK OPEN
The external machine stop interlock is open or is not at
24 Vdc, depending on the jumper setting.
18
POWER UNIT OVER TEMP
The system controller is over temperature.
19
RF DETECTOR MISSING
The RF detector is not connected.
20
RF DETECTOR TRIPPED
The RF detector has detected a high RF field.
22
LAMPHEAD OVER TEMP
Lamphead temperature sensor is over temperature.
Transformer thermal switch(es) open. May be caused by
insufficient air flow through system controller cabinet.
23
HV CABLE UNPLUGGED
The system controller is not communicating with the
lamphead. The high-voltage cable from the system controller
to the lamphead is disconnected or damaged.
24
LOW CURRENT ON MAG
The magnetron is below 5 mA minimum current value.
25
PHASE CONTROL AT LIMIT
The system controller cannot regulate to the power setpoint.
26
RF DETECTOR FAILED
The RF detector is defective and must be replaced.
27
PHASE CONTROLLER
ERROR
The system control is not communicating with the phase
board.
28
MAG FILAMENT IS OPEN
One of the two magnetron filaments has failed.
Resetting Faults
Operating in Local Mode: Press the Off button to reset a fault once it has
been corrected.
Operating in Remote Mode: Open and close the Reset contact to reset a
fault once it has been corrected.
NOTE: Once the fault has been corrected you can reset a fault on a unit
operating in Remote Mode from the host controlling the master unit through
either a discrete I/O or DeviceNet.
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Part 1105120-01
4-6
Operation
System Timing Sequences
NOTE: Refer to Section 5, Troubleshooting if the system fails during
startup.
Timing Sequence with Idle = Y
(Also see Table 3-5)
Powering ON the System Controller
Total Seconds
12 seconds
Turn on main disconnect switch on front panel.
Controller goes through initial boot sequence with a full display test.
When complete, controller displays OFF.
Changing system status from OFF to LAMP ON
Total Seconds
25 seconds
Press SYSTEM ON button.
Display reads WARMUP.
Display reads LMPDLY.
Display reads LAMPON.
Changing system status from LAMP ON to IDLE
Total Seconds
~ 1 second
Press STANDBY button Once.
Display reads IDLE.
NOTE: The controller automatically switches to Standby after 10 minutes in Idle
mode. Idle is a configurable mode. If not enabled, only the Standby mode is active.
Changing system status from IDLE to LAMP ON
Total Seconds
~ 2 seconds
Part 1105120-01
Display reads IDLE.
Press SYSTEM ON button.
Display reads LMPDLY.
Display reads LAMPON.
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Operation
4-7
Changing system status from LAMP ON to STANDBY
Total Seconds
20 seconds
Display reads LAMPON.
Press STANDBY button Twice.
Display reads IDLE followed by L COOL.
Display reads STDBY.
NOTE: If Idle is not enabled, pressing the Standby button Once switches the
controller to Standby mode.
Changing system status from STANDBY to LAMP ON
Total Seconds
10 seconds
Display reads STDBY.
Press SYSTEM ON button.
Display reads LMPDLY.
Display reads LAMPON.
Changing system status from LAMP ON to OFF
Total Seconds
60 seconds
E 2013 Nordson Corporation
Display reads LAMPON.
Press SYSTEM OFF button.
Display reads C DELY.
Display reads OFF.
Shutdown timing at completion of process allows for proper cooling.
Part 1105120-01
4-8
Operation
Timing Sequence with Idle = N
(Also see Table 3-5)
Powering ON the System Controller
Total Seconds
12 seconds
Turn on main disconnect switch on front panel.
Controller goes through initial boot sequence with a full display test.
When complete, controller displays OFF.
Changing system status from OFF to LAMP ON
Total Seconds
25 seconds
Press SYSTEM ON button.
Display reads WARMUP.
Display reads LMPDLY.
Display reads LAMPON.
Changing system status from LAMP ON to STANDBY
Total Seconds
20 seconds
Display reads LAMPON.
Press STANDBY button Once.
Display reads L COOL.
Display reads STDBY.
Changing system status from STANDBY to LAMP ON
Total Seconds
10 seconds
Display reads STDBY.
Press SYSTEM ON button.
Display reads LMPDLY.
Display reads LAMPON.
Changing system status from LAMP ON to OFF
Total Seconds
60 seconds
Part 1105120-01
Display reads LAMPON.
Press SYSTEM OFF button.
Display reads C DELY.
Display reads OFF.
Shutdown timing at completion of process allows for proper cooling.
E 2013 Nordson Corporation
Operation
4-9
Correcting a Fault Condition
Correcting a fault condition
Total Seconds
Max 60 seconds
25 seconds
Display reads fault condition (message scrolls).
Correct the reason for the fault, then push SYSTEM OFF button.
Display reads C DELY.
Press SYSTEM ON button.
Display reads WARMUP.
Display reads LMPDLY.
Display reads LAMPON.
Startup
Locally Operated Units
Table 4-4 Startup Procedures for Locally Operated Units
Step
Single Unit
Operated Locally
Multiple Units Networked to a Master Unit
Operated Locally
1
Switch system electrical power ON.
2
Turn the main power switch on the front of the system controller unit to the ON position.
After a brief power-up test sequence, OFF appears on the display.
3
Make sure that all interlocked access doors are closed and that external cooling and
exhaust fans are running if not directly connected to the system controller blower contacts. If
external interlocks are wired and open, FAULT EXT INTERLOCK will be displayed.
4
On the NETWORK selector, press LOCAL.
Set the NETWORK configuration.
S On the master unit NETWORK selector,
press LOCAL.
S On the remote unit NETWORK
Selectors, press REMOTE.
Continued...
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Part 1105120-01
4-10 Operation
Step
5
Single Unit
Operated Locally
Multiple Units Networked to a Master Unit
Operated Locally
Set the POWER SETTING.
Set the POWER SETTING.
1. Press the SET-SAVE button on the
POWER SETTING selector until the
power level is displayed.
1. On the master unit, press the SET-SAVE
button on the POWER SETTING selector
until the power level is displayed.
2. Press the UP or DOWN arrows to set the
desired power level. The power level
changes immediately.
2. Press the UP or DOWN arrows to set the
desired power level.
3. Press the SET-SAVE button to save the
setting and exit the power setting
function.
NOTE: The power level can be changed at
any time during operation with the lamp ON
or OFF.
3. Press the SET-SAVE button to save the
setting.
4. Set the POWER SETTING at each
remote unit between 20 and 100 using
the same procedure as the master unit.
Each remote POWER SETTING can be
different.
The actual power output of each remote
is dependent on the Master POWER
SETTING.
For example, if your master unit POWER
SETTING is 80 and your first remote unit
POWER SETTING is 50, the actual
output of the first remote unit will be 0.5 x
0.8 or 40%.
NOTE: In most cases, remote units should
be set to 100%.
6
External Blower Units: Turn on the external blower. If there is insufficient pressure the
system faults and FAULT LOW LAMPHEAD PRESSURE is displayed. (Check for proper
pressure with the appropriate instrumentation.) The internal blower automatically turns on
and off as required.
Continued...
Part 1105120-01
E 2013 Nordson Corporation
Operation
Step
7
Single Unit
Operated Locally
4-11
Multiple Units Networked to a Master Unit
Operated Locally
Press SYSTEM ON to start the lampheads.
LAMPON is displayed when the lamphead is ready to cure.
Standard Startup − Preferred Method
Use this procedure to go directly through the warm-up to the LAMPON mode.
1. On the single unit or master unit, press SYSTEM ON. WARMUP will appear on the
display. The magnetron filaments are warmed up for 15 seconds.
2. LMPDLY now displays while lamphead takes approximately 10 seconds to stabilize.
3. LAMPON appears in the display and the system is ready to run.
Or
Quick Startup from Standby Mode
NOTE: Excessive use of the standby mode will shorten magnetron life. This method
should only be used when a quick startup is required.
Use this procedure to put the system in Standby mode before moving to the SYSTEM
ON mode.
1. On the single unit or master control unit, press the STANDBY button. WARMUP
appears on the display for approximately 15 seconds, then STDBY appears.
NOTE: Do not leave the system controller in the standby mode for longer than 30
minutes. Prolonged standby periods shorten magnetron life.
2. Press the SYSTEM ON button to turn on the lamps. LMPDLY appears for
approximately 10 seconds while the lamphead stabilizes, then LAMPON appears.
Quick Cycle Using Idle Mode
NOTE: IDLE mode must be enabled. See IDLE in the System Controller Configuration
table on page 3-25.
1. Use the Standard or Rapid startup procedures to achieve LAMPON state.
2. Initiate Standby command (locally or remotely).
3. The unit will immediately switch to Idle State (achieved in 1 seconds).
4. To return to curing, initiate LAMPON command (locally or remotely).
5. The lamp is ready to cure within approximately 5−7 seconds.
NOTE: After 10 minutes in Idle mode, the unit automatically switches to Standby mode.
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Part 1105120-01
4-12 Operation
Remotely Operated Units
NOTE: The system can be wired to initiate lamphead start from either the
process machine or from the UV system controller.
The system controller I/O and a simple panel can be used to control the UV
system. Or, if the DeviceNet protocol is used, the UV system can be fully
automated to work in concert with a complete production system.
Table 4-5 Startup Procedures for Remotely Operated Units
Step
Single Unit and Units Networked to a Master Unit Operated Remotely
1
Switch the electrical disconnect to ON.
2
Turn the main power switch on the front of the system controller to the ON position. After a
brief power-up test sequence, OFF appears on the display.
3
Make sure that all interlocked access doors are closed and that the exhaust fan is running. If
external interlocks are wired and open, the fault message FAULT EXT INTERLOCK appears
in the display.
4
On the front panel under NETWORK, press REMOTE.
NOTE: For networked units, press REMOTE on each unit.
5
Set the POWER SETTING. See Table 4-1 item number 8 on page 4-2.
6
Turn on the external blowers. If there is insufficient pressure a system fault occurs and the
message FAULT LOW LAMPHEAD PRESSURE appears in the display. (Check for proper
pressure.) The internal blower automatically turns on and off as required.
Part 1105120-01
E 2013 Nordson Corporation
Operation
4-13
Shutdown
CAUTION: Do not shut off the system with the main power switch while the
lamps are operating. Bulbs and magnetrons can and will be damaged.
The lamp turns off if any of the following conditions occur:
Normal Shutdown
S SYSTEM OFF button on the system controller is pressed.
S REMOTE OFF command through discrete I/O or DeviceNet.
Fault Shutdown
S Cooling air for the lamphead ceases or is insufficient.
S Any of the safety interlocks wired into the UV equipment are interrupted.
These include exhaust fan, access panels, doors and process
equipment.
S Any fault condition occurs.
Table 4-6 Shutdown Procedures
Step
Shutting Down Systems Locally
Shutting Down Systems Remotely
1
Press the SYSTEM OFF button.
Press the SYSTEM OFF button on the
remote or host machine.
2
External Blower units: Allow the lampheads
at least 60 seconds of cool down time before
shutting off the cooling air. On units with
internal blowers, the system shuts off the
blower when the internal temperature falls to
a safe level.
External Blower units: Allow the lampheads
at least 60 seconds of cool down time before
shutting off the cooling air. Typically the
external blowers are controlled by the
remote or host machine. On units with
internal blowers, the system shuts off the
blower when the internal temperature falls to
a safe level.
CAUTION: Failure to provide cool down time
can cause problems restarting the lamps as
well as greatly reduce the life of the
lamphead bulbs.
CAUTION: Failure to provide cool down time
can cause problems restarting the lamps as
well as greatly reduce the life of the
lamphead bulbs.
3
Turn off main power to all units.
E 2013 Nordson Corporation
Part 1105120-01
4-14 Operation
Part 1105120-01
E 2013 Nordson Corporation
Troubleshooting
5-1
Section 5
Troubleshooting
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
These troubleshooting procedures cover only the most common problems.
If you cannot solve a problem with the information given here, contact your
local Nordson representative for help or call 800−524−1322 for technical
support.
System Software Versions
If you call for technical support, you may be asked to provide the version
numbers for the software installed in your system. During power up, the
system controller displays the software versions for the following
components, in this order:
V DXXX = Display Board
V MXXX = Main Control Board Microprocessor
V PXXX = Phase Board Microprocessor
V IXXX = Main Control Board CAN Interface
V LXXX = Light Detector Board (Lamphead)
V OXXX = I/O Board to DeviceNet
NOTE: V OXXX only present for systems using DeviceNet.
General Troubleshooting
Use the charts on the following pages to troubleshoot your system.
NOTE: If a system controller does not start up, disconnect power to the
controller, then remove the cover and check the fuses. Refer to page 6-2 in
Section 6, Maintenance and Repair for fuse locations.
E 2013 Nordson Corporation
Part 1105120-01
5-2
Troubleshooting
Fault Message Troubleshooting
Problem
Possible Cause
Corrective Action
Incorrect controller ID setting, two
or more controllers with same ID.
Reconfigure ID settings so that each
controller has a unique ID number.
Refer to System Controller
Configuration beginning on page
3-23.
Filament transformer fuse F4 on
main control board blown.
Excessive power line noise. Refer to
Power Line Connections on page
3-3.
Open in filament control circuit to
transformer.
Verify proper continuity within system
controller and lamphead. See Figure
8-1, System Schematic.
Magnetron has failed.
Replace the magnetrons.
Short in unicable cable.
Inspect the unicable for shorts.
Short in the lamphead.
Inspect the high voltage white and
black cables from the unicable
receptacle to the magnetrons for
shorts.
Fault 4:
FAULT CURRENT
IMBALANCE
End of magnetron life.
Replace the magnetrons.
Magnetron current
imbalance.
The current level of
magnetron A and B differs
by more than 100 mA.
Improper magnetron wiring.
Verify the magnetron wiring
connections. See Figure 8-1, System
Schematic.
Fault 5:
FAULT ON NETWORK
UNIT
Fault has occurred on remote
system controller.
Correct fault on remote system
controller.
Phase control board has failed.
Replace phase control board.
Fault 0:
FAULT NETWORK
CONFIGURATION
Network detecting multiple
units with same ID.
Fault 2:
FAULT FILAMENT FUSE
BLOWN
Open filament transformer
circuit. No filament current.
Fault 3:
FAULT HIGH CURRENT
ON MAG
High current on
high-voltage circuit.
Current exceeds limit.
Fault on remote unit.
Fault 6:
FAULT MAG POWER
WHEN OFF
Phase control board failure
Magnetron current
detected when in Standby
or Off mode.
Continued...
Part 1105120-01
E 2013 Nordson Corporation
Troubleshooting
Problem
Fault 7:
FAULT NO LIGHT
DETECTED
Lamp Fault
The light detector does not
sense sufficient light
output.
Fault 9:
FAULT HARDWARE
FAILURE
Possible Cause
5-3
Corrective Action
Bulb has failed.
Replace the bulb.
Light sensor D1 on light detector
board blocked.
Refer to page 4-3 to check the light
output seen by the sensor. Clean the
sensor on with isopropyl alcohol, or
replace the board.
Light sensor D1 has degraded, or
light detector board failed.
Replace the light detector board. The
recommended replacement interval is
10,000 hours of operation.
Refer to page 6-18 in Section 5,
Maintenance and Repair.
Magnetrons are approaching end
of life.
Replace magnetrons.
Main control board has failed.
Replace main control board.
DeviceNet is not properly
configured.
Review DeviceNet software
specification and reconfigure.
Controller hardware failure.
Replace the I/O board or main control
board, or replace the ribbon cables.
Arcing or opens in the high voltage
circuit.
Check the high voltage wiring, from
the inside of the controller to the
magnetrons.
Failed diode block in system
controller.
Test diode block as described on
page 5-8. Replace diode block if
failed.
Magnetrons have failed.
Check the high voltage wiring, from
the inside of the controller to the
magnetrons. Replace the
magnetrons.
Remote controllers not powered or
connected to network.
Turn on remote controllers, check
connections.
Damaged network cables.
Replace the network cables.
Improper network setup.
Refer to Network Connections and
System Controller Configuration in
Section 3, Installation.
Control board failure
Main controller not
communicating with
lamphead interface chip.
Fault 10:
FAULT DeviceNet ERROR
DeviceNet Error.
DeviceNet communications
failure.
Fault 11:
FAULT DEVNET
HARDWARE
DeviceNet Hardware Error.
Communication between
main control board and I/O
board is lost.
Fault 12:
FAULT MAG VOLTAGE
ERROR
Magnetron voltage error.
Magnetron voltage
maximum exceeded or the
difference between the
magnetrons is too great.
Fault 13:
FAULT NETWORK COMM
Network Fault
Master/remote network
connection lost.
Continued...
E 2013 Nordson Corporation
Part 1105120-01
5-4
Troubleshooting
Problem
Fault 15:
FAULT POWER CTRL AT
LIMIT
Possible Cause
Corrective Action
Magnetrons have failed.
Replace the magnetrons.
Low voltage to magnetrons.
Transformer taps set incorrectly.
Check transformer in system
controller.
Fault 16:
FAULT LOW LAMPHEAD
PRESSURE
External blower is off.
Turn external blower on.
Internal blower failure.
Check blower wiring, transformer,
fuse. Replace blower if necessary.
Pressure Fault
Lamphead air pressure is
below setpoint at selected
power setting.
Air flow through lamphead is
restricted.
Remove any restrictions in lamphead
air flow.
Large pressure drop in external
blower ducting.
Correct restrictions in external blower
ductwork. Ducts must be sized
properly with minimum bends to
supply proper air pressure. If low
pressure faults persist, consider
mounting the blower closer to the
lamphead, increasing the duct size,
or increasing the blower size.
Pressure hose connected to wrong
port.
Check port connection. Refer to
page 3-18 for instructions.
Pressure port is blocked.
Unblock the pressure port.
Damaged pressure hose.
Check hose and replace if necessary.
Open external interlock.
Check all system interlocks and the
MSTOP connection. There must be
continuity between Pins 15 and 16 on
the rear panel Remote I/O connector.
I/O jumpers are set incorrectly
(DeviceNet capable system).
Verify that the jumper position
matches the interlock method. Make
sure 24Vdc is available to interlock
circuit.
24Vdc not being supplied to
interlock.
Check voltage and correct if
necessary.
Fault 18:
FAULT POWER UNIT
OVER TEMP
System controller cooling fans are
restricted or not operating.
Remove fan restrictions or replace
the fans. Make sure fans are rotating
in the correct direction.
System controller
temperature is over 65 _C.
Ambient temperature is above
specification.
Reduce the ambient temperature to
5−40 _C (41−104 _F).
Fault 19:
FAULT RF DETECTOR
MISSING
RF detector is not properly
connected.
Check the RF detector connections.
RF cable is damaged.
Check the continuity of the RF cable.
Replace the cable if necessary. See
Figure 8-1, System Schematic.
RF detector is damaged.
Replace the RF detector.
Power control at limit.
System controller is unable
to regulate output.
Fault 17:
FAULT EXT INTERLOCK
Interlock Fault
MSTOP I/O open or under
voltage.
RF Fault.
System does not sense the
RF detector.
Continued...
Part 1105120-01
E 2013 Nordson Corporation
Troubleshooting
Problem
Fault 20:
FAULT RF DETECTOR
TRIP
Possible Cause
5-5
Corrective Action
RF Detector is detecting a high
level of RF
Make sure the RF screen is not
missing, loose, or damaged.
Incorrect RF detector mounting
location.
Refer to page 3-22 for mounting
requirements.
Cooling air is being restricted.
Make sure air flow through lamphead
is not restricted. Refer to Corrective
Actions for Fault 16.
Fault 23:
FAULT HV CABLE
UNPLUGGED
Unicable not connected or
damaged.
Check unicable connections and
continuity. See Figures 8-1 and 8-2,
System Schematics.
System controller not
communicating with
lamphead.
Light detector board in lamphead
unplugged or failed.
Check the internal connections to the
light detector board. Replace board if
all connections are good.
Fault 24:
FAULT LOW CURRENT
ON MAGS
Open HV circuit to magnetrons.
Check black and white high-voltage
cables to magnetrons.
Wiring to magnetrons not
connected properly.
Verify wiring connections.
HV transformer taps set incorrectly
in system controller.
Refer to the Transformer Tap Table
on page 3-3 to verify settings.
Failed diode block in system
controller.
Test diode block as described on
page 5-8. Replace diode block if
failed.
Magnetrons at end of life.
Replace magnetrons.
Failed contactor.
Replace contactors.
Failed diode block (open diode) in
system controller.
Test diode block as described on
page 5-8. Replace diode block if
failed.
Damaged main control board
(defective relay #1).
Replace main control board.
HV transformer taps set
incorrectly.
Refer to the Transformer Tap Table
on page 3-3 to verify settings.
Phase control board failed.
Replace phase control board.
Fault 26:
FAULT RF DETECTOR
FAILED
RF detector self test fails or
detector has been permanently
damaged by a very high RF field.
Replace RF detector. Refer to RF
Detector Installation on page 3-22.
RF Fault.
RF Detector failed self-test.
NOTE: This failure is only
possible under extreme conditions.
RF Fault.
High RF field detected.
Fault 22:
FAULT LAMPHEAD
OVER TEMP
Lamphead temp is over
95 _ C.
Magnetron Current Fault
Magnetron current cannot
be maintained.
Fault 25:
FAULT PHASE CTRL AT
LIMIT
Phase control at limit.
System controller is unable
to regulate the system to
the specified output level.
Continued...
E 2013 Nordson Corporation
Part 1105120-01
5-6
Troubleshooting
Problem
Fault 27:
FAULT PHASE
CONTROLLER ERROR
Possible Cause
Corrective Action
Phase control board failure.
Replace phase control board.
Magnetron has failed.
Replace magnetrons.
Control does not detect the
phase board.
Fault 28:
FAULT MAG FILAMENT
IS OPEN
Low filament current.
Bulb Troubleshooting
NOTE: Any bulb that has been touched with bare hands or otherwise
contaminated should be cleaned with isopropyl alcohol prior to use. Clean
latex or nitrile gloves must be worn when handling bulbs. Failure to keep
bulbs clean may result in premature failure.
Problem
Possible Cause
Corrective Action
1.
Bulbs have white
fingerprints
Dirt and oils on the bulb were
burned in while the bulb was
operating.
Replace the bulb. Wear clean latex or
nitrile gloves whenever handling
bulbs.
2.
Bulb does not start
Bulb is damaged or system
controller has faulted.
Check the system controller for fault
messages. Replace the bulb.
3.
Bulb is rippled
Bulb is overheating.
Clean all air filters.
Check the lamphead pressure by
pressing the LAMPHEAD AIR
PRESSURE button.
Make sure the proper bulb for the
lamp is installed.
4.
Bulb has a white or
gray cloudy
appearance
End of bulb life.
Replace the bulb.
Bulb is overheating.
If UV output is below acceptable
levels, check the system cooling then
replace the bulb if necessary.
Make sure the proper bulb for the
lamp is installed.
5.
Bulb does not fit
securely in lamphead
Bulb mounting tips are chipped or
broken.
Replace the bulb.
6.
Bulb is overheating
Reflectors not properly installed.
Check reflectors and install correctly
if necessary. Refer to page 6-7 in the
Section 6, Maintenance and Repair
for installation instructions. Replace
the reflectors if necessary.
Wrong bulb used.
Make sure the proper bulb for the
lamp is installed.
Part 1105120-01
E 2013 Nordson Corporation
Troubleshooting
5-7
Curing Process Troubleshooting
Problem
Possible Cause
Corrective Action
System running correctly
but material not curing
Reflectors are installed incorrectly.
Check reflectors; make sure they are
installed correctly in the brackets and
supports.
Reflectors are dirty or damaged.
Clean or replace the reflectors.
RF screen dirty.
Replace the RF screen.
Lamp not in focus.
Focus the lamphead.
Incorrect bulb type.
Replace with the correct bulb type.
Low power level setting.
Increase the power level on the
system controller.
Material issue.
Contact the material supplier to verify
the UV spectrum/intensity output.
General Lamphead Troubleshooting
Problem
Low lamphead pressure
Possible Cause
Corrective Action
Refer to Fault Message Troubleshooting in this section.
Magnetron failure
RF fault on system
controller
The lamphead is
showing signs of
electrical arcing
E 2013 Nordson Corporation
Tear in the RF screen in front of
the bulb.
Replace the screen.
RF screen not securely fastened.
Tighten the screen.
Lamphead bulb has failed.
Replace the lamphead bulb.
RF detector was improperly
installed.
Check RF placement and
connections to system controller.
Refer to the Section 3, Installation for
installation requirements.
Loose component or debris in the
lamphead.
Tighten all fasteners. Clean the
lamphead interior.
Refer to Section 6, Maintenance and
Repair to replace any damaged
lamphead parts.
Part 1105120-01
5-8
Troubleshooting
Diode Block Testing
WARNING: Shut off power to the system controller, allow the capacitors
time to bleed off voltage, then remove the diode blocks from the controller
before performing the following tests. Failure to observe this warning can
result in equipment damage or personal injury.
There are two diode blocks in the system controller. Each diode block
contains 4 high voltage rated diodes connected in a bridge network.
Diode 1 Connection: HV− and AC-1 (Anode to HV−, Cathode to AC-1)
Diode 2 Connection: HV− and AC-2 (Anode to HV−, Cathode to AC-2)
Diode 3 Connection: AC-2 and C (Anode to AC2, Cathode to C)
Diode 4 Connection: C and AC-1 (Anode to AC1, Cathode to C)
TP−
GND
Pin 1
TP+
FB
C
AC-2
AC-1
HV−
Figure 5-1
Diode Block Terminals and Connector Pins
Tests:
GND to pin 1
GND to pin 2
GND to pin 3
GND to pin 4
GND to pin 5
GND to pin 6
GND to pin 7
GND to pin 8
GND to pin 9
GND to pin 10
TP− to pin 2
TP− to TP+
C to FB
C to GND
Part 1105120-01
1005 ohm 1%
short, less than 0.2 ohm
20,000 ohm 1%
short, less than 0.2 ohm
open, over 20 M ohm
open, over 20 M ohm
open, over 20 M ohm
open, over 20 M ohm
open, over 20 M ohm
open, over 20 M ohm
short, less than 0.2 ohm
200 ohm 1%
1000 ohm 1%
4.9 ohm 1%
E 2013 Nordson Corporation
Maintenance and Repair
6-1
Section 6
Maintenance and Repair
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Introduction
Establish acceptable curing levels for your process and then develop a
maintenance schedule that fits your needs. Radiometers can be used to
measure relative readings for spectral output as a means of monitoring
spectral intensity.
The maintenance and replacement schedule for the system will depend
upon your:
S
S
S
S
application process.
plant environment.
quality of cooling air passing through the system.
coating formulation.
Torque Specifications for System Fasteners
Torque specifications for controller and lamphead fasteners are contained in
tables following the controller and lamphead parts lists in the Parts section.
They are identified in the tables and illustrations by item number. Use these
tables to prevent over- or under-tightening the fasteners.
System Controller Maintenance and Repair
Maintenance Schedule
Recommended maintenance for the system controller consists of removing
dust from the enclosure and components. This should be done as
necessary.
E 2013 Nordson Corporation
Part 1105120-01
6-2
Maintenance and Repair
System Controller Repair Procedures
Preparation
1. Turn off the UV system from the process equipment controller or at the
system controller panel.
2. Allow the lamphead fan to complete its cooling cycle before shutting off
power to the controller.
NOTE: Always shut down the system before shutting off controller power.
Shutting off the system while the UV lamp is on could result in equipment
damage.
3. Turn off the main electrical disconnect. Follow all relevant OSHA
established lockout procedures or local codes as appropriate.
4. Allow time for all capacitors to bleed off their stored energy before
removing the system controller cover.
CAUTION: The integrated circuits on the system controller printed circuit
boards can be damaged by small electrostatic charges. Always wear an
approved grounding strap when handling circuit boards.
Fuses
See Figures 6-1 and 6-2 to identify the replaceable fuses in the system
controller. Use an appropriate tool to remove the fuses. Replace them with
identical fuses. Refer to the Section 7, Parts for ordering information.
S
S
S
S
Part 1105120-01
F1: Blower, 3A, slow blow, 250V
F2: Blower, 3A, slow blow, 250V
F3: Board Power, 160mA, slow blow, 250V
F4: Filament Transformers, 2A, slow blow, 250V
E 2013 Nordson Corporation
Maintenance and Repair
6-3
Fuse F3
160 mA
Fuse F2
3A
Fuse F1
3A
Fuse F4
2A
Figure 6-1
Main Control Board Fuses
F1
30 Amp Fuses*
F2
10 Amp Fuses*
(for internal blower)
* These fuses must be FNQ rated or equivalent
Figure 6-2
System Controller Fuses
Cleaning System Controller Cooling Fans
1. Turn off the main electrical disconnect. Follow all relevant
OSHA-established lockout procedures or local codes as appropriate.
2. The system controller cooling fans are located on the front and rear
panels. Make sure the safety covers are clean and free of debris.
3. Examine the fan blades for contamination or damage. Clean the blades
or replace the fan if necessary.
E 2013 Nordson Corporation
Part 1105120-01
6-4
Maintenance and Repair
Lamphead Maintenance and Repair
Table 6-1 lists typical maintenance guidelines and replacement schedules
for the components of the CW2 10-inch lamphead.
Recommended maintenance to the lamphead consists of changing bulbs
and reflectors and cleaning or replacing filter material. It is also
recommended that reflectors be cleaned periodically.
Table 6-1 Typical Lamphead Maintenance Schedule
Component
UV Bulb
Maintenance Guidelines
Replace
component
Bulbs are warranted for a specific number of hours when operating
under the manufacturer specifications (hours vary with differing
bulbs). Depending on your application, some installations may
provide acceptable curing well beyond the warranty.
as needed
NOTE: Do not touch or handle the bulb with bare hands. Wear
clean latex or nitrile gloves. Clean the bulbs with isopropyl alcohol
and a clean lint-free cloth or tissue to remove any fingerprints or
other contamination.
Magnetrons
The magnetrons are warranted for a specific number of hours when
operating under the manufacturer specifications. Each application
will be different and, in many cases, the magnetron life will last well
beyond the warranty.
as needed
Screen
The screen should be free of all debris such as cured material, lint,
dust or anything that might impede cooling or UV transmittance.
as needed
Do not use damaged screens. This can result in RF
radiation leakage.
Reflectors
Filters
S Remote blower
(see Note)
S Internal blower
lamphead
DO NOT USE A CLEANING SOLUTION THAT CONTAINS
AMMONIA. Never use any abrasive media to clean the
reflectors. This will damage the reflector surface.
Reflector surfaces should be cleaned as needed (more frequently in
dirty environments) and at every bulb change. Wipe the reflector
surface and the cavity with a clean, lint-free cloth dipped in a
suitable solvent such as isopropyl alcohol. No residue should be left
on the reflector surface. Do not touch reflectors with bare hands;
use clean latex or nitrile gloves.
Be careful when replacing reflectors. They are made of glass and
may break if dropped or forced into position.
as needed
Filters are designed to prevent dust and contaminants from entering
the UV equipment. Eventually, the filters become clogged and start
to impede the cooling air flow, causing excessive heat which will
result in premature failure of the UV equipment. A dirty filter can
also release contaminates into the air flow that may deposit on the
part being cured as well as the bulb and reflector.
Internal blower filters cannot be cleaned. They are coated with a
tacky material that traps contaminants.
Weekly
or as needed
NOTE: Nordson does not supply filters on the system controller or external blowers. Filters must be
supplied by the customer. For Internal blower lampheads, a filter is provided (refer to page 6-5 for
replacement instructions ). Refer to Section 7, Parts for replacement filters.
Part 1105120-01
E 2013 Nordson Corporation
Maintenance and Repair
6-5
Internal Blower Lamphead Filter Replacement
WARNING: Turn off the lamp and allow the system to proceed through the
cool down cycle and shut down the blower before replacing the filter.
The lamphead filters are held in place by a lip around the air inlet opening
and supports across the opening. Pull the used filter out from under the lip
and discard it.
Lamphead filters have a white, coarse side and a colored, fine side.
Replace the filter with the colored side down, white side showing, making
sure that the filter is tucked under the lip all around the opening.
WARNING: Filters cannot be cleaned. They contain a tacky material that
traps dirt. Do not attempt to clean or reuse dirty filters. Do not flip dirty filters
over and re-install them, as this will allow dirt and other contaminants to
enter the lamphead and damage the bulb and reflector, and possibly
contaminate the product being cured.
Lamphead Repair Procedures
Preparation
1. Turn off the UV system from the process equipment controller or at the
system controller control panel.
2. Allow the lamphead fan to complete its cooling cycle. If this has been
prevented by shutting off power to the system controller or to the
external blowers prematurely, always allow sufficient time for the bulb to
cool before proceeding.
3. Turn off the main electrical disconnect. Follow all relevant OSHA lockout
procedures or local codes.
4. Disconnect the unicable from the lamphead.
5. If necessary, loosen the lamphead mounting fasteners and remove the
lamphead from its mounting.
Bulb Replacement
CAUTION: Use only the Nordson bulbs listed in this manual. Equipment
damage may occur if bulbs from any other source are used.
1. Perform the Preparation procedure in this section.
2. See Figure 6-3. Turn or place the lamphead assembly so that the entire
bulb area is exposed and accessible.
3. Remove the eight screws from the screen flanges to remove the RF
screen.
E 2013 Nordson Corporation
Part 1105120-01
6-6
Maintenance and Repair
Bulb Replacement
Figure 6-3
(contd)
RF Screen Removal
CAUTION: Do not touch the bulb or reflectors with bare hands. Wear clean,
residue-free nitrile or latex gloves.
4. See Figure 6-4. The bulb is held in place by springs inside the retaining
holes at each end of the lamp. Grasp both ends of the bulb and push
one end into its retaining hole until the other end comes free. Carefully
tilt the bulb to the side just enough to remove the retained end from the
hole. Tilting the bulb too much could break off the tip of the bulb.
5. Place one end of the new bulb into a retaining hole and carefully push
down on that end to force the spring down. Guide the other end of the
bulb into the opposite retaining hole and allow the springs to secure the
bulb in place.
6. Place the old bulb in the new bulb packaging and dispose of according
to your company disposal policies. Refer to the Section 1, Safety section
for the bulb return policy.
7. Install the RF screen on the lamphead base with the eight M4 screws.
Torque the screws to 1.18−1.57 NSm (0.87−1.16 lb-ft).
Figure 6-4
Part 1105120-01
Bulb Removal and Replacement.
E 2013 Nordson Corporation
Maintenance and Repair
6-7
Reflector Replacement
Two types of reflectors may be used in the lamphead: Flood or Focus.
Each type uses different retaining brackets and supports.
Use these outlines to find out what kind of reflectors and supports are
installed in your lamphead.
3.1 Focus
2.1 Focus
Flood
Scale 1:1
Figure 6-5
Reflector and Reflector Support Outlines
Different retaining brackets are used to secure the reflectors in place in the
lamphead. Figure 6-6 illustrates the differences in their retaining brackets.
Note that two retainers are stamped into the flood bracket.
253.8 mm
(9.99 in.)
Springs
32.732 mm
(1.28 in.)
Focus Reflector Bracket
253.8 mm
(9.99 in.)
Retainers
Springs
42.338 mm
(1.66 in.)
Flood Reflector and Bracket
Figure 6-6
Reflector Brackets
E 2013 Nordson Corporation
Part 1105120-01
6-8
Maintenance and Repair
Reflector Replacement
(contd)
NOTE: Great care should be taken when replacing reflectors as they are
made of glass and may break if dropped or forced.
1. Perform the Preparation procedure on page 6-5.
2. Turn or place the lamphead so that the entire bulb area is exposed and
accessible.
CAUTION: Do not touch the bulb or reflectors with bare hands. Wear clean
latex or nitrile gloves.
3. Remove the screen and bulb as described on page 6-5.
4. See Figure 6-7. Loosen the six mounting screws, then remove the two
retaining brackets from the lamphead base.
Figure 6-7
Retaining Bracket Removal
5. Carefully slide the two reflectors from the lamphead base.
Inside Edge of
Reflector
Support
Figure 6-8
Reflector Removal and Replacement
NOTE: The outside edges of the reflectors are printed with the part
number.
6. Slide the new reflectors into the lamphead base and slide the inside
edges into the notches in the white supports.
Part 1105120-01
E 2013 Nordson Corporation
Maintenance and Repair
6-9
7. Set the retaining brackets in place. The placement of the retaining
brackets differs between focus and flood reflectors.
Focus Reflectors: See Figure 6-9. The edge of the reflector sits on the
springs next to the lip of the bracket. The lip wraps around the edge of
the reflector.
Line up the retaining bracket mounting holes with the three mounting
holes in the lamphead base.
Focus Reflector and Retaining Bracket
Installing the Focus Retaining Bracket
Lip
Figure 6-9
Focus Reflector Installation
Flood Reflectors: See Figure 6-10. The edge of the reflector sits on
the springs next to the inside lip of the bracket and between the curved
retainers and the lip.
The lip on the flood bracket goes inside of the lamphead and wraps
around the edge of the reflector. Line up the retaining bracket mounting
holes with the three mounting holes in the lamphead base.
Flood Reflector and Retaining Bracket
Installing the Flood Retaining Bracket
Curved
Retainers
Lip
Figure 6-10 Flood Reflector Installation
8. Torque the six retaining bracket screws to 1.8−1.57 NSm
(0.87−1.16 lb-ft) to secure the retaining brackets.
9. Install the bulb and RF screen as described on page 6-6.
E 2013 Nordson Corporation
Part 1105120-01
6-10 Maintenance and Repair
Internal Blower Replacement
1. See Figure 6-11. Remove the blower cover by removing the 6 M4 x 10
Philips head screws (3 front and 3 rear). Set the blower cover aside.
2. Disconnect the blower cable from the receptacle in the cover.
3. Remove the four M6 x 20 machine screws, lock washers, flat washers,
and ground wire from the blower base, then lift the blower off the bottom
cover.
4. Plug the new blower harness into the blower connector.
5. Install the blower on the cover and secure it in place with the four M6 x
20 machine screws, lock washers, and flat washers, making sure to
connect the ground wire to the blower base with one of the screws.
Torque the screws to 2.25 NSm (20 in-lbs).
6. Plug the blower harness into the receptacle on the cover.
7. Install the blower cover and secure it with the six M4 x 10 screws.
Torque the screws to 1.35 NSm (12 in-lbs).
Blower Connector
Blower Harness
Ground Wire
Receptacle
M4 x 10 Screws
M6 x 20 Screws
Figure 6-11
Removing Blower Cover
Part 1105120-01
E 2013 Nordson Corporation
Maintenance and Repair
6-11
Internal Blower Lamphead Complete Cover Removal
1. Disconnect the unicable from the lamphead.
2. See Figure 6-12. Remove the top blower cover by removing the 6 M4 x
10 Philips screws (3 front and 3 rear) and set aside.
3. Remove the 2 M4 x 20 screws on either side of the unicable receptacle.
Removing Screws from Top Cover
Removing Screws at Unicable Receptacle
Figure 6-12 Removing Top Blower Cover
4. See Figure 6-13. Remove the M4 x 10 Philips screw next to the blower
cable receptacle. Unplug the blower cable from the receptacle.
5. Remove the 8 screws at the base of the lamphead (4 front and 4 rear).
Remove Blower Plug
Remove Top Screw
Remove 8 Screws
− 4 Front and 4 Rear
Figure 6-13 Removing Blower Plug and Screws
6. See Figure 6-14. Lift the bottom cover straight up and then push the
unicable receptacle into the cover until it clears the cover housing.
E 2013 Nordson Corporation
Part 1105120-01
6-12 Maintenance and Repair
Internal Blower Lamphead Complete Cover Removal
Unicable Receptacle Clearing Cover
(contd)
Lifting Bottom Cover
Figure 6-14 Removing the Cover
7. Pull the cover the rest of the way up and off the lamphead and set it
aside.
Internal Blower Lamphead Cover Replacement
1. Slide the bottom cover down over the lamphead until the unicable
receptacle drops into the slot and the 8 holes at the bottom of the cover
line up.
2. See Figure 6-13. Replace the 8 screws at the base of the lamphead (4
front and 4 rear). Install the two screws into the cover on both sides of
the unicable receptacle. Tighten the screws to 1.35 NSm (12 in-lbs).
3. Reconnect the blower cable and install the screw next to the plug.
4. See Figure 6-12. Replace the top blower cover and secure with 6
screws (3 front and 3 rear). Tighten the screws to 1.35 NSm (12 in-lbs).
5. Refer to page NO TAG. Reconnect the unicable to the lamphead.
Part 1105120-01
E 2013 Nordson Corporation
Maintenance and Repair
6-13
External Blower Lamphead Cover Removal
See Figure 6-15. Remove the 11 screws (3 top, 8 bottom) from the
lamphead cover. Lift the cover off the lamphead.
Remove Top Three Screws
Remove Bottom 8 Screws − 4 On Each Side
Pressure Port
DO NOT BLOCK
Figure 6-15 External Blower Lamphead Cover Removal
Lamphead Internal Component Replacement
Remove the lamphead cover to replace the following internal components:
S
S
S
S
Magnetrons
Filament transformers
Light detector/temperature/pressure board
Starter bulb
Preparation
NOTE: Step 2 is taken to prevent damage to the RF screen or bulb.
1. Perform the Preparation procedure on page 6-5.
2. Remove the RF screen and bulb as described on page 6-5.
3. Remove the lamphead cover as described in the Internal Blower or
External Blower Lamphead Cover Removal procedures.
4. Remove the two M4 screws shown in Figure 6-16.
Bracket
Screws
Figure 6-16
E 2013 Nordson Corporation
Transformer Bracket Screws
Part 1105120-01
6-14 Maintenance and Repair
Preparation
(contd)
5. See Figure 6-17. Pull the the transformer bracket from the wave guide
assembly far enough out to access the wiring connections.
Figure 6-17
Removing the Transformer Bracket (External Blower Version Shown)
Magnetron Replacement
NOTE: Each lamphead contains two magnetrons. The replacement
procedure is the same for each magnetron.
1. Follow steps 1−5 under Preparation on page 6-13.
2. See Figure 6-18. Cut the four ties securing the black HV insulation
sleeves to the HV cables. Slide the sleeves down to expose the two
ring-tongue terminal connections.
3. Remove the two terminal screws and disconnect the cables from the
magnetron pigtails. Remove the sleeves and discard them. Save the
screws for re-use.
HV Insulation Sleeves
Terminal Screws
Figure 6-18 Magnetron Removal
Part 1105120-01
E 2013 Nordson Corporation
Maintenance and Repair
6-15
4. See Figure 6-19. Remove the four nuts that secure each magnetron to
the wave guide. Remove the magnetrons. Save the nuts for re-use.
Nuts
Antenna
Figure 6-19 Magnetron Removal
5. See Figure 6-19. Inspect the gasket around the antenna of the new
magnetron, making sure it is smooth and free of debris.
6. Carefully insert the antenna through the hole in the wave guide.
7. Make sure the magnetron gasket is sealed evenly on the flange, then
secure the magnetron to the wave guide with the four nuts, washers,
and screws. Tighten the nuts to 1.9 NSm (17-in. lb).
8. Install one new black insulating sleeve (shipped with the magnetrons)
over the X1and HV cables. Install the other new sleeve over the X2
cable.
9. Use the screws removed in step 3 to connect the X2 secondary cable to
the magnetron F terminal pigtail. Connect the X1 secondary cable and
the 20 AWG HV cable with ferrite to the FA terminal pigtail.
10. Pull the black insulation sleeves over the terminals so that they are
completely covered. Secure the top and bottom of the sleeves with
cable ties.
Filament Transformer Replacement
NOTE: To replace both filament transformers, order two filament
transformer kits. The filament transformer kit contains one transformer, one
ferrite, two insulation sleeves, and four cable ties for the sleeves.
1. Follow steps 1−5 under Preparation on page 6-13.
2. See Figure 6-18. Cut the four ties securing the black HV insulation
sleeves to the HV cables at the magnetron. Slide the sleeves down to
expose the ring-tongue terminal connections.
3. Remove the two terminal screws and disconnect the cables from the
magnetron pigtails. Remove the sleeves and discard them. Save the
screws for re-use.
4. Remove the transformer bracket from the wave guide assembly.
E 2013 Nordson Corporation
Part 1105120-01
6-16 Maintenance and Repair
Filament Transformer Replacement
(contd)
5. See Figure 6-20. Note the colors of the primary wires connected to the
transformer H1 and H2 terminal tabs, then disconnect the wire
receptacles from the tabs.
6. Remove the four M4 screws and nuts securing the transformer and
transformer ground wire to the bracket. Cut the cable ties around the
secondary cables as necessary, then remove the transformer from the
bracket.
Primary
Wires
Ground
Wire
Screws
and
Nuts
Figure 6-20
Screws
and
Nuts
Transformer Removal
7. See Figure 6-21. Install the new transformer on the bracket. If replacing
the outer transformer, route the secondary cables under the inner
transformer.
8. Secure the transformer to the bracket with the M4 screws and nuts,
securing the green transformer ground wire to the bracket with the
screws.
Secondary
Cables
Ground
Wire
Screws
Figure 6-21
Part 1105120-01
Transformer Installation
E 2013 Nordson Corporation
Maintenance and Repair
6-17
9. See Figure 6-22. Arrange the secondary cable ferrites of both
transformers as shown. Install cable ties below the ferrites to prevent
them from sliding down the secondary cables, then install another cable
tie joining both pairs of secondary cables approximately 2 inches
(51 mm) above the ferrites.
Install Cable Ties Below Both Ferrites
Cable Tie Bundling
Secondary Cables
Ferrites
Figure 6-22
Installing Cable Ties on Secondary Cables
10. Slide new insulation sleeves over X2 secondary cables, and another
over both the X1 secondary cables and the 20AWG HV harness cables.
11. Slide the transformer bracket part way back into the wave guide
assembly.
12. Connect the bracket harness wires to the transformer H1 and H2 tabs
exactly as removed in step 5.
13. See Figure 6-18. Use the screws removed in step 3 to connect the X2
secondary cable to the magnetron F terminal pigtail. Connect the X1
secondary cable and the 20 AWG HV cable with ferrite to the FA
terminal pigtail.
14. Pull the black insulation sleeves over the terminals so that they are
completely covered. Secure the top and bottom of the sleeves with
cable ties.
15. Slide the transformer bracket all the way into the wave guide assembly.
Secure the bracket with the two M4 screws shown in Figure 6-16.
E 2013 Nordson Corporation
Part 1105120-01
6-18 Maintenance and Repair
Light Detector Board Replacement
1. Follow steps 1−5 under Preparation.
2. See Figure 6-23. Disconnect the temperature sensor harness, the
controller harness, and the pressure sensor hose from the light detector
board.
3. Remove the three screws and the light detector board.
4. Install and connect the new board. Note that the pressure sensor hose
must be connected to the barbed fitting labeled “B”.
Light Detector
Board
Pressure Sensor
Hose Connector
Temperature Sensor
Controller Harness
Figure 6-23
Light Detector Board Replacement (External Blower Version Shown)
Temperature Sensor Replacement
See Figure 6-23. The internal temperature sensor (thermistor) is also
replaceable separately. It consists of a two-wire harness with plug and
ring-tongue terminal. The thermistor is potted to the ring-tongue terminal.
To replace the sensor, unplug the harness from the light detector board and
remove the screw securing the ring-tongue terminal to the bracket.
Starter Bulb Replacement
1. Follow steps 1−5 under Preparation.
2. See Figure 6-24. Cut the RTV sealant at the bulb base and unscrew the
bulb.
3. Screw the new bulb into the socket. Apply a small dot of RTV sealant
between the bulb and socket. The RTV sealant keeps the bulb from
vibrating out of the socket.
Part 1105120-01
E 2013 Nordson Corporation
Maintenance and Repair
6-19
Socket
RTV
Figure 6-24
Starter Bulb Replacement
Re-Assembly
1. Check all wiring connections and make sure they are secure and that
insulation is intact.
2. Install the cover on the lamphead.
3. Install the bulb and RF screen as described in Bulb Replacement on
page 6-6.
E 2013 Nordson Corporation
Part 1105120-01
6-20 Maintenance and Repair
Part 1105120-01
E 2013 Nordson Corporation
Parts
7-1
Section 7
Parts
Introduction
To order parts, call the Nordson Industrial Coating Systems Customer
Support Center at (800) 433-9319 or contact your local Nordson
representative.
CW2 610 System Controllers
Part
Description
Note
60 Hz Applications:
1084113
System controller, 480V
1084110
1086251
1086252
System controller, 480V, with DeviceNet
System controller, 480V, internal blower
System controller, 480V, internal blower, with DeviceNet
50 Hz Applications:
1084112
System controller, 400V
1079706
1084625
1083276
System controller, 400V, with DeviceNet
System controller, 400V, internal blower
System controller, 400V, internal blower, with DeviceNet
E 2013 Nordson Corporation
Part 1105120-01
7-2
Parts
System Controller Repair Parts
See Figure 7-1.
Item
Part
Description
Quantity
Note
−
------
50/60 HZ System Controller, CW2
1
1
1077135
S CONNECTOR, I/O board, CW2, kit
1
2
1077121
S TRANSFORMER, HV, CW2, kit
2
3
1089207
S TRANSFORMER, control, CW2, kit
1
4
772214
S FAN, 6 in x 1.5 in, 240 VAC
2
A
5
1098890
S MAIN CONTROL BOARD with contactor, CW2,
standard, kit
1
C
6
775142
S PCB, display, CW10, kit (display board)
1
7
1102449
S PHASE CONTROL BOARD AND CABLE,
CW2, kit
1
8
1077131
1
D
8
1083974
S I/O CONNECTOR BOARD, CW2,
with DeviceNet, kit
S I/O CONNECTOR BOARD, CW2,
without DeviceNet, kit
1
D
9
1091465
S FUSE, CW2, kit
1
A, B
9a
−−−−−−
S S FUSE, 30 amp, slow-blow, 500V
3
B
9b
−−−−−−
S S FUSE, 10 amp, time-delay, 250V
2
B
9c
−−−−−−
S S FUSE, 160 ma, 250V, slow-blow, 5 x 20 mm
1
B
9d
−−−−−−
S S FUSE, 2 amp, slow-blow, 250V, 5 x 20 mm
1
B
10
103200
S FUSE, 3 amp, slow-blow, 250 volt
2
A
11
1077128
S DIODE, HV, CW2. Kit (diode block)
2
12
13
14
15
16
17
18
19
20
21
22
23
NS
−−−−−−
772236
1077129
1077130
1077127
−−−−−−
1078306
1077134
1077132
−−−−−−
1077125
1089206
1077126
S
S
S
S
S
S
S
S
S
S
S
S
S
24
1086731
DETECTOR, RF, kit, CW
SCREW, truss head, M5 x 8
SWITCH, control, MPS-410/610
FUSE BLOCK, 3 pole, CW2, kit
FUSE BLOCK, 2 pole, CW2, kit
CONTACTOR, CW2, kit
CONTACTOR, 4 pole, 600V, 20A
CAPACITOR, CW2, kit
POWER COVER, CW2, kit
BUMPER, CW2, kit
FILTER, 3 phase, line
MEMBRANE, CW2, kit
HARNESS, unicable, internal, kit
COVER, system controller, kit, CW2
6
1
1
1
1
1
1
1
1
1
1
1
1
C
1
NOTE A: Recommended spare part. Keep this part in inventory to avoid unplanned downtime.
B: Fuse kit 1091465 contains three 30 amp, 500 volt main fuses; two 10 amp, 250 volt fuses for the step
down transformer; one 160 microamp, 250 volt control board fuse; one 2 amp, 250 volt fuse for the
filament transformer.
C: This part is a 4 pole, 600V, 20A, 24V coil contactor.
D: Choose correct I/O board kit for your application.
NS: Not Shown
Part 1105120-01
E 2013 Nordson Corporation
7-3
Parts
9c
5
10
13
2
T2
9d
T3
6
CR1
1
T1
5
7
19
2
24
4
8
16
17
T1
15
9A
23
20
9B
14
CR1
CR2
C
T3
T2
B
A
21
22
3
12 (Cover)
18
4
Figure 7-1
CoolWave 2 610 System Controller and RF Detector
E 2013 Nordson Corporation
Part 1105120-01
7-4
Parts
CW-2 Internal Blower Lampheads
See Figure 7-2.
Item
Part
Description
Quantity
Note
−
1103923
LAMPHEAD, focus, 2.1, internal blower
1
−
1103924
LAMPHEAD, focus, 3.1 internal blower
1
−
1103925
LAMPHEAD, flood, internal blower
1
−−−−−−
S BULB, UV, microwave, CW2-610
1
A
2
775060
S RETAINER KIT, reflector, focus, CW10, pair
1
E
2
775061
S RETAINER KIT, reflector, flood, CW10, pair
1
E
3
3A
3B
1077320
1080150
1074544
S LIGHT DETECTOR board kit, CW2
S S TUBING, neoprene, 0.625 ID x .125 OD
S S FITTING, barbed, 1/16 x to 10−32
1
AR
1
B
4
1086973
S HARNESS, thermistor, CoolWave
1
5
1079419
S TRANSFORMER, filament, kit, CW2
1
6
775040
S STARTER BULB, kit, CW10/6
1
B
7
1101443
S REFLECTOR, CW10, focus, 2.1, kit
2
B, C, D
7
775092
S REFLECTOR, CW10, focus, 3.1, kit
2
B, C, D
7
1103118
S REFLECTOR, CW10, flood, kit
2
B, C, D
8
775115
S DEFLECTOR, strip, quartz, CW10, kit
1
B
9
775120
S SCREEN KIT, lamphead, CW10
1
B
10
1075164
S MAGNETRON PAIR KIT, 3.0 Kw
1
B
11
−−−−−−
S SCREW, truss, M4 x 10, Phillips, steel, zinc
AR
12
−−−−−−
S SCREW, button head, socket, M3 x 4, zinc
8
13
1053767
S MOUNTING kit, reflector and bulb, 2.1 focus,
CW10
1
D
13
1053768
S MOUNTING kit, reflector and bulb, 3.1 focus,
CW10
1
D
13
1053769
S MOUNTING kit, reflector and bulb, flood,
CW10
1
D
14
775116
S REFLECTOR, end, CW10, pair, kit
1
15
1089205
S KIT, HARNESS, lamphead, CW2, internal
blower
1
16
1092143
S KIT, internal blower
1
17
1102567
1
F
17
1601884
1
F
18
19
20
21
22
23
24
25
26
27
982617
983409
983410
982881
983416
−−−−−−
984101
983044
−−−−−−
984727
S KIT, 4 pack, filter, air, CW2, internal blower
MERV4, blue
S KIT, 4 pack, filter, air, CW2, internal blower,
MERV11, orange
S MACHINE SCREW, hex, M6 x 20, zinc
S WASHER, lock, split, M6, steel, zinc
S WASHER, flat, narrow, M6, steel, zinc
S SCREW, pan head, recessed, M4 x 6, zinc
S WASHER, lock, internal, M4, steel, zinc
S SCREW, slotted pan head, 6−32 x .250 in.
S NUT, hex, machine, 6−32, steel, zinc
S WASHER, lock, internal, 6, steel, zinc
S NUT, lock, nylon, M3, steel, zinc
S NUT, hex, M4, brass
B
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
Continued...
Part 1105120-01
E 2013 Nordson Corporation
Parts
Item
Part
Description
28
29
30
31
32
33
34
−−−−−−
−−−−−−
−−−−−−
983416
−−−−−−
−−−−−−
−−−−−−
S
S
S
S
S
S
S
35
36
−−−−−−
−−−−−−
S SCREW, truss, M4 x 10, Phillips, steel, zinc
S SCREW, pan head, slotted, M4 x 8, brass
WASHER, flat, regular, M4, brass
WASHER, lock, split, M4, brass
SCREW, pan head, recessed, M4 x 16
WASHER, lock, internal, M4, steel, zinc
NUT, hex, w/external toothed washer, M5
SCREW, pan head, Phillips, M4 x 40, steel
NUT, hex, w/external toothed washer, M4
Quantity
7-5
Note
AR
AR
AR
AR
AR
AR
AR
AR
AR
NOTE A: Order the correct bulb for your application from the list on page 7-10.
B: Recommended spare part. Keep this part in inventory to avoid unplanned downtime.
C: Order the correct reflector for your application. A kit includes one reflector. To replace both, order 2 kits.
D: Order the correct reflector and bulb mounting kit for your reflectors. Kit includes 2 TPFE reflector
supports, 2 bulb spring retainers, 4 M3 x 10 screws, and 4 M3 lock nuts.
E: Retainer kit includes 2 reflector retaining brackets. If you are not sure what type of reflectors, supports,
and retaining brackets you have, refer to page 6-7.
F: MERV4 blue filters are standard. For dirty environments, use MERV11 orange filters.
Both are 270 x 370 mm.
NS: Not Shown
AR: As Required
Torque Specifications for Lamphead Fasteners
Item
Description
Torque
11
SCREW, truss, M4 x 10, Phillips, steel, zinc
1.18−1.57 NSm (0.87−1.16 lb-ft)
12
SCREW, button head, socket, M3 x 4, zinc
0.50−0.65 NSm (4.5−6.0 lb-in)
13
SCREW, button head, socket, M3 x 10, zinc
0.34−0.57 NSm (0.25−0.42 lb-ft)
18
MACHINE SCREW, hex, M6 x 20, zinc
21
SCREW, pan head, recessed, M4 x 6, zinc
1.18−1.57 NSm (0.87−1.16 lb-ft)
23
SCREW, slotted pan head, 6−32 x .250 in.
0.51−0.68 NSm (0.37−0.49 lb-ft)
26
NUT, lock, nylon, M3, steel, zinc
0.51−0.68 NSm (0.37−0.49 lb-ft)
33
SCREW, pan head, phillips, M4 x 40, steel
1.18−1.57 NSm (0.87−1.16 lb-ft)
34
NUT, hex, w/external toothed washer, M4
1.18−1.57 NSm (0.87−1.16 lb-ft)
35
SCREW, truss, M4 x 10, Phillips, steel, zinc
E 2013 Nordson Corporation
2.26 NSm (20 lb-in)
1.35 NSm (12 lb-in)
Part 1105120-01
7-6
Parts
Parts Illustration − Internal Blower Lamphead Parts
21
22
3
15
26
10
3A, 3B
23
25
27
28
29
27
29
36
4
23
24
25
34
5
32
33
34
30
31
8
7
12
2
6
5
9
35
(Cover
Screws)
13
14
1
17
16
18
19
20
11
Figure 7-2
CoolWave 2 Internal Blower Lamphead (shown with cover removed)
Part 1105120-01
E 2013 Nordson Corporation
Parts
7-7
CW-2 External Blower Lampheads
See Figure 7-3.
Item
Part
Description
Quantity
Note
−
1074677
LAMPHEAD, focus, 2.1, external blower
1
−
1075554
LAMPHEAD, focus, 3.1, external blower
1
−
1075555
LAMPHEAD, flood, external blower
1
1
−−−−−−
S BULB, UV, microwave, CW2-610
1
A
2
775060
S RETAINER KIT, reflector, focus, CW10, pair
1
E
2
775061
S RETAINER KIT, reflector, flood, CW10, pair
1
E
3
3A
3B
1077320
1080150
1074544
S LIGHT DETECTOR KIT, CW2
S S TUBING, norprene, 0.625 ID x .125 OD
S S FITTING, barbed, 1/16 x to 10−32
1
2 ft
1
B
4
1086973
S HARNESS, thermistor, CoolWave
1
5
1079419
S TRANSFORMER KIT, filament, CW2
1
6
775040
S STARTER BULB KIT, CW10/6
1
B
7
1101443
S REFLECTOR KIT, CW10, focus, 2.1
2
B, C
7
775092
S REFLECTOR KIT, CW10, focus, 3.1
2
B, C
7
1103118
S REFLECTOR KIT, CW10, flood
2
B, C
8
775115
S DEFLECTOR KIT, strip, quartz, CW10
1
B
9
775120
S SCREEN KIT, lamphead, CW10
1
B
10
1075164
S MAGNETRON PAIR KIT, 3.0 Kw
1
B
11
−−−−−−
S SCREW, truss, M4 x 10, Phillips, steel, zinc
AR
12
−−−−−−
S SCREW, button head, socket, M3 x 4, zinc
8
C
13
1053767
S MOUNTING kit, reflector and bulb, 2.1 focus,
CW10
1
C
13
1053768
S MOUNTING kit, reflector and bulb, 3.1 focus,
CW10
1
C
13
1053769
S MOUNTING kit, reflector and bulb, flood,
CW10
1
C
14
15
16
775116
982881
983416
S REFLECTOR, end, RR, kit, CW10
S SCREW, pan head, recessed, M4 x 6, zinc
S WASHER, lock, internal, M4, steel, zinc
1
3
3
NS
17
18
19
20
21
22
23
24
25
26
27
28
1083258
−−−−−−
984101
983044
−−−−−−
984727
−−−−−−
−−−−−−
−−−−−−
983416
−−−−−−
−−−−−−
−−−−−−
KIT, HARNESS, lamphead, CW2, external blower
S SCREW, slotted pan head, 6−32 x .250 in.
S NUT, hex, machine, 6−32, steel, zinc
S WASHER, lock, internal, 6, steel, zinc
S NUT, lock, nylon, M3, steel, zinc
S NUT, hex, M4, brass
S WASHER, flat, regular, M4, brass
S WASHER, lock, split, M4, brass
S SCREW, pan head, recessed, M4 x 16
S WASHER, lock, internal, M4, steel, zinc
S NUT, hex, w/external toothed washer, M5
S SCREW, pan head, Phillips, M4 x 40, steel
S NUT, hex, w/external toothed washer, M4
1
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
29
30
−−−−−−
−−−−−−
S SCREW, truss, M4 x 6, Phillips, steel, grade 8
S SCREW, pan head, slotted, M4 x 8, brass
AR
AR
B
D
Continued...
E 2013 Nordson Corporation
Part 1105120-01
7-8
Parts
Item
31
32
33
34
Part
−−−−−−
760529
982178
983401
Description
S
S
S
S
Quantity
SCREW, flat head, phillips, M3 x 10, steel, zinc
HANDLE, lamphead
SCREW, socket, M5 x 50, black
WASHER, lock, split, M5, steel, zinc
Note
AR
2
4
4
NOTE A: Order the correct bulb for your application. Bulbs are listed on page 7-10. Bulbs are recommended spare
parts.
B: Recommended spare part. Keep this part in inventory to avoid unplanned downtime.
C: Order the correct reflector and bulb mounting kit for your reflectors. Kit includes 2 TPFE reflector
supports, 2 bulb spring retainers, 4 M3 x 10 screws, and 4 M3 lock nuts.
D: Optional equipment.
E: Retainer kit includes 2 reflector retaining brackets. If you are not sure what type of reflectors, supports,
and retaining brackets you have, refer to page 6-7.
NS: Not Shown
Torque Specifications for Lamphead Fasteners
Item
Description
Torque
11
SCREW, truss, M4 x 10, Phillips, steel, zinc
1.18−1.57 NSm (0.87−1.16 lb-ft)
12
SCREW, button head, socket, M3 x 4, zinc
0.50−0.65 NSm (4.5−6.0 lb-in)
13
SCREW, button head, socket, M3 x 10, zinc
0.34−0.57 NSm (0.25−0.42 lb-ft)
15
SCREW, pan head, recessed, M4 x 6, zinc
1.18−1.57 NSm (0.87−1.16 lb-ft)
17
SCREW, slotted pan head, 6−32 x .250 in.
0.51−0.68 NSm (0.37−0.49 lb-ft)
20
NUT, lock, nylon, M3, steel, zinc
0.51−0.68 NSm (0.37−0.49 lb-ft)
27
SCREW, pan head, phillips, M4 x 40, steel
1.18−1.57 NSm (0.87−1.16 lb-ft)
28
NUT, hex, w/external toothed washer, M4
1.18−1.57 NSm (0.87−1.16 lb-ft)
29
SCREW, truss, M4 x 10, Phillips, steel, zinc
1.6−1.8 NSm (14−16 lb-in)
33
SCREW, socket, M5 x 50, black
4.6−5.1 NSm (40−45 lb-in)
Part 1105120-01
E 2013 Nordson Corporation
7-9
Parts
Parts Illustration − External Blower Lamphead Parts
3A, 3B
3
10
15
16
4
17
18
19
21
22
23
20
31
21
23
30
28
26
5
27
28
24
25
8
7
12
6
2
9
11
Figure 7-3
14
29
(Cover
Screws)
5
13
1
29
32
33
34
CoolWave 2 External Blower Lamphead (shown with cover removed)
E 2013 Nordson Corporation
Part 1105120-01
7-10 Parts
Bulbs
Order the correct bulb for your application. Keep spare bulbs on hand to
avoid unplanned downtime.
Part
Description
1087356
BULB, UV, microwave, CW610, H (Mercury)
775043
BULB, UV, microwave, CW610, D, (Iron)
775044
BULB, UV, microwave, CW610, V (Galium)
775045
BULB, UV, microwave, CW610, Q (Indium)
775246
BULB, UV, microwave, CW610, H+ (Mercury Plus)
1051461
BULB, UV, microwave, CW610, M (Lead)
Note
Reflector Conversion Kits
Use these kits to convert your lamphead between focus lengths, or between
focus and flood reflectors.
Part
1053794
Description
KIT, reflector conversion, 3.1 focus, CW10
Note
A
1103600
KIT, reflector conversion, 2.1 focus, CW10
A
1103601
KIT, reflector conversion, flood, CW10
B
NOTE A: Kit includes 2 reflectors, 2 reflector supports, 2 bulb retainer springs, 4 screws, 4 locknuts. If switching
from flood reflectors to focus reflectors, you must also order a 775060 focus reflector retainer bracket kit
(contains 2 brackets).
B: If switching from focus reflectors to flood reflectors, order this kit. It includes 2 flood reflectors, 2 reflector
supports, 2 bulb retainer springs, 4 screws, 4 locknuts. You must also order a 775061 flood reflector
retainer bracket kit (contains 2 brackets).
RF Detector
Part
1086731
Description
Detector, RF
Note
A
NOTE A: Refer to System Cables on page 7-11 for proper length RF Detector cables.
Part 1105120-01
E 2013 Nordson Corporation
Parts
7-11
System Cables
See Figure 7-4. Order the correct cable length for your system.
Item
1
1
1
1
1
2
2
2
2
2
3
Part
775374
775023
775375
775377
775380
1061134
775029
775050
775051
775052
775031
Description
12-ft UNICABLE
25-ft UNICABLE
50-ft UNICABLE
75-ft UNICABLE
100 ft UNICABLE
12 ft CABLE, RF detector
25 ft CABLE, RF detector
50 ft CABLE, RF detector
75 ft CABLE, RF detector
100 ft CABLE, RF detector
NETWORK CABLE, 6 ft
Quantity
Note
1
1
1
1
1
1
1
1
1
1
1
1
2
3
Figure 7-4
System Cables
E 2013 Nordson Corporation
Part 1105120-01
7-12 Parts
Accessories
Part
Description
AirShield Ventilation System − Captures the heated exhaust air from the lamphead and exhausts it into a separate
exhaust duct. Refer to page3-17 for installation.
775055
KIT, duct, exhaust, CW10, encl, quartz (for CW-410/CW-610T lampheads)
1068608
KIT, duct, exhaust, deep, CW10, encl, quartz (for CW-410/CW-610T lampheads using a bottom
pressure port)
1600656
KIT, duct, exhaust, CW10, encl, quartz, 90 degree (for CW410/CW610T lampheads)
775056
KIT, plate, quartz, duct, exhaust, CW10 enclosure (replacement quartz plate for AirShield Ventilation
Kits)
LiteTite Shutter System − A pneumatically powered shutter opens and closes instantly to block UV light without
turning off the lamphead or power supply.
775198
KIT, shutter, LH, CW10
ThruCure Continuous Coating System − A hinged aluminum chamber equipped with customer-machinable entrance
and exit vestibules and additional reflectors for a 360 degree cure that mounts on the lamphead.
1100919
Chamber, ThruCure, 10 in.
External Blowers − Contact your Nordson representative for information on external blowers.
Closed
Standard
Open
90_
LiteTite Shutter System
Figure 7-5
AirShield Ventilation System
ThruCure Chamber
Accessories
Part 1105120-01
E 2013 Nordson Corporation
Parts
7-13
Optional Lamphead Mounting Kit
See Figure 7-6.
Item
−
1
2
3
4
Part
1106333
−−−−−−
−−−−−−
981340
982432
Description
Quantity
KIT, bracket, adjustable, 10 in. lamphead
S BRACKET, adjustable, lamphead, UV
S PLATE, interface, 10 in. lamphead
S SCREW, socket, 5/16−18 x 0.750 in., black
S SCREW, pan, recessed, M5 x 16, zinc
Note
1
1
8
4
4
1
3
2
Figure 7-6
Optional Lamphead Mounting Bracket Kit
Mounting Kit Installation
1. Install the mounting plate (2) on the bracket (1) with four 5/16−18
socket-head screws (3).
2. Install the mounting plate on the lamphead with four M5 x 16 pan-head
screws(4). Three sides of the lamphead have M5 threaded mounting
holes that match up to the mounting plate holes.
3. Mount the bracket on a suitable surface or rack, using the extra four
5/16−18 socket-head screws (3).
Use the bracket handles to tighten and loosen the pivot joints and position
the lamphead as desired.
E 2013 Nordson Corporation
Part 1105120-01
7-14 Parts
Part 1105120-01
E 2013 Nordson Corporation
Specifications
8-1
Section 8
Specifications
System Controller
Specifications
Table 8-1 Standard and Enclosure Mounted System Controller Specifications
Item
Specification
Dimensions
length
753 mm (29.65 in.)
width
465.5 mm (18.33 in.)
height
256.3 mm (10.09 in.)
Weight
118 kg (260 lb)
Voltage
480 Vac 10%, 3, @ 60 Hz or 400 Vac 10%, 3, @ 50 Hz
Current
Refer to Table 8-2
Environmental Operating Conditions
Ambient Temperature
5−40 _C (41−104 _F)
Altitude
Contact Nordson UV Engineering
Relative humidity
80% up to 31 _C (88 _F), decreasing linearly to 50% at 40 _C (104 _F)
Ingress Protection Rating
IP−21
RF Detector
Max. Temperature
E 2013 Nordson Corporation
60 _C (140 _F) Ambient
Part 1105120-01
8-2
Specifications
Current Draw
Table 8-2 Power Line Current for 610 External Blower
Line
60 Hz
50 Hz
Amps @ 440 Vac
Amps @ 480 Vac
Amps @ 380 Vac
Amps @ 440 Vac
L1
14
13
17
16
L2
22
19
26
24
L3
14
15
17
16
Table 8-3 Power Line Current for 610 Internal Blower
Line
60 Hz
50 Hz
Amps @ 440 Vac
Amps @ 480 Vac
Amps @ 380 Vac
Amps @ 440 Vac
L1
14
13
17
17
L2
22
20
28
27
L3
14
15
17
17
Part 1105120-01
E 2013 Nordson Corporation
Specifications
8-3
Light Output Settings
Nordson CW2 UV Output
Remote Input
% of UV Light Output
100
80
60
40
20
4 mA
8 mA
2V
4V
12 mA
6V
16 mA
8V
20 mA
10 V
Remote Input  mA/VDC
Figure 8-1
Light Output Settings
Master/Remote Power Setting Examples
If the Master Unit is set at
and the Remote Unit is set at
The Remote Unit will run at
100%
100%
100% of 100%
100%
75%
75% of 100%
50%
75%
75% of 50%
75%
50%
50% of 75%
NOTE: The standard setting is Master Unit 100%, Remote unit 100%.
E 2013 Nordson Corporation
Part 1105120-01
8-4
Specifications
Lamphead
Table 8-4 Lamphead Specifications
Item
Specification
Dimensions
Refer to Section 3, Installation for lamphead dimensions.
Weight
With External Blower − 19 kg (42 lb), With Internal Blower − 27.67 kg (61lb)
Cooling Air
350 cfm @ 7 in. W.C.; measured at lamphead (9.9 mm3 @ 1780 Pascal)
Reflector
Glass with a proprietary coating 220−470 nm; focus/flood profiles
Focal Length
2.1 in., 3.1 in., flood
Interlocks
S
S
S
S
Light on detector
Cooling air sensor
Unicable detection
RF leakage detection
Bulb
Table 8-5 Bulb Specifications
Item
Specification
Length
254 mm (10 in.)
Power
600 watts/in. maximum
Types
Mercury, Mercury +, Iron, Gallium, Indium, Lead
System Schematic
See Figures 8-1 and 8-2.
Part 1105120-01
E 2013 Nordson Corporation
Specifications
F1
2
30uF
3
4
BRN
BRN 1
ORN 2
ORN
YEL 3
YEL
1
2
30 AMP
F2
2 AMP
3
4
480 V
24
BLK 14
SCR PHASE
CONTROLER #2
CONN6−6
CONN6−12
CONN6−7
CONN6−5
CONN6−11
CONN6−1
AC2
CR1
240 V
43 RED 480
400
RED 44
HV XFM
T2
(FRONT)
RED 34
20
HV BRIDGE
ASSEMBLY
33 RED
20
A1
(TO MAG B)
AC2
10
20
−HV BLK
AC1
CONN 1
CONN 4
(TO MAG A)
HV BRIDGE
ASSEMBLY
13 BLK
20
DISPLAY
KEYPAD
−HV WHT
AC1
10
CONN
T3
23 BLK 480
400
COM
A2
CONN6−3
CONN6−9
FERRITE
10
CONN1
FILAMENT
TRANS 1
FA
CONN5
F
FA
MAGNETRON A
(LEFT)
40
16
FILAMENT
TRANS 2
FERRITE
PCB−1
CONN3
FERRITE
FERRITE
G
BRN L1
B ORN L2
YEL L3
C
SW1
30uF
HV XFM
T1
(REAR)
SCR PHASE
CONTROLER #1
CONN 4
A
LINE
A
B
C
LOAD
1
2
3
G
1
CAP 1 CAP 2
LINE
FILTER
LINE
IN
BLK
FAN 1
CONN 5
FAN 2
8-5
F
MAGNETRON B
(RIGHT)
40
TWIST WIRE PAIRS
CONN1 CONN4
7
P8
7
CONN1−2
CONN2−10
2
2
CONN1−4
CONN2−9
1
1
CONN1−3
CONN2−4
CONN3−7
RF DETECTOR
CONN3−2
I/O BOARD
CONN6−1
CONN6−2
CONN6−3
CONN6−4
CONN6−5
CONN6−6
CONN6−7
CONN3−5
SHIELD
4
13
BLK
INTERCONNECT
CABLE
8
11
3
(UNICABLE)
SHIELD
8
SHIELD/DRAIN
3
9
9
10
10
5
5
4
4
3
2
1
6
WHT
13
11
LIGHT
DETECTOR
CONN1−1
12
CONN2−3
ANALOG COMMON
5
24V COM.
WHT
CONN2−1
SHIELD
7 6
PLC INTF −− CANL
+24V IN
ANALOG OUT
8
ANALOG COMMON
READY
REMOTE OFF/RESET
COMMON
REMOTE STDBY
COMMON
COMMON
REMOTE LAMP ON
MACHINE STOP
TB1
16 15 14 13 12 11 10 9
12
PLC INTF −− CANH
CONN3−9
CONN3−3
CONN2−6
FAULT
1
2
3
4
5
6
7
ANALOG IN
P10
1
2
3
4
5
6
7
READY
FAULT
CONN3−1
CONN3−2
CONN3−3
CONN3−4
CONN3−5
CONN3−6
NC
P3
CONN2−5
BLK
FERRITE
16
CORCOM
FILTER
STARTER
BULB
6
SHIELD/DRAIN
LAMP HEAD
Figure 8-1
External Blower System Schematic
E 2013 Nordson Corporation
Part 1105120-01
8-6
Specifications
SYSTEM CONTROLLER
FAN 2
G
BRN L1
B ORNL2
YEL L3
C
BRN1
ORN2
30uF
30uF
3
4
BRN
CONN 4
SW1
F1
2
SCR PHASE
CONTROLER #1
ORN
YEL
YEL3
30 AMP
1
2
400/480 V
T3
3
240 V
4
BLK
CONN6−6
CONN6−12
CONN6−5
CONN6−11
CONN 4
AC2
CR1
RED 44
43 RED 480
400
HV XFM
T2
(FRONT)
RED 34
HV BRIDGE
ASSEMBLY
33 RED
A1
PCB−1
(TO MAG B)
AC2
10
20
−HV BLK
AC1
CONN 1
20
(TO MAG A)
10
20
20
−HV WHT
AC1
HV BRIDGE
ASSEMBLY
BLK
CONN
DISPLAY
KEYPAD
HV XFM
T1
(REAR)
13 BLK
14
SCR PHASE
CONTROLER #2
F2
10 AMP
23 BLK 480
400
24
CONN 5
B
C
LINE
A
2
3
G
A
LOAD
1
1
CAP 1 CAP 2
LINE
FILTER
LINE
IN
FAN 1
COM
A2
CONN6−3
CONN6−9
FERRITE
FERRITE
10
CONN1
CONN6−10
CONN6−4
33
40
7
2
CONN2−9
1
CONN3−5
SHIELD
ANALOG COMMON
CONN1−2
1
CONN1−4
12
12
8
8
13
BLK
(UNICABLE)
CONN1−1
2
11
3
CONN1−3
WHT
13
SHIELD
11
SHIELD/DRAIN
3
BLK
SHIELD
CONN1−5
CONN1−6
STARTER
BULB
CONN2−1
9
9
10
10
CONN2−8
6
6
CONN1−3
CONN1−4
4
4
CONN1−1
5
5
CONN1−2
3
2
1
ANALOG COMMON
FAULT
ANALOG IN
24V COM.
WHT
INTERCONNECT
CABLE
LIGHT
DETECTOR
P8
7
CONN2−3
SHIELD
4
PLC INTF −− CANL
+24V IN
ANALOG OUT
5
FAULT
READY
READY
REMOTE OFF/RESET
COMMON
COMMON
REMOTE STDBY
COMMON
REMOTE LAMP ON
MACHINE STOP
7 6
PLC INTF −− CANH
CONN3−9
CONN3−3
CONN2−6
8
P3
CONN2−5
I/O BOARD
CONN6−1
CONN6−2
CONN6−3
CONN6−4
CONN6−5
CONN6−6
CONN6−7
MAGNETRON B
(RIGHT)
CORCOM
FILTER
CONN2−10
CONN3−2
1
2
3
4
5
6
7
F
CONN3−4
34
FA
FERRITE
43
CONN2−4
CONN3−7
TB1
16 15 14 13 12 11 10 9
Figure 8-2
44
F
MAGNETRON A
(LEFT)
TWIST WIRE PAIRS
RF DETECTOR
P10
1
2
3
4
5
6
7
FA
CR2
CONN1 CONN4
CONN3−1
CONN3−2
CONN3−3
CONN3−4
CONN3−5
CONN3−6
NC
BLK
CONN3−3
13
CONN6−2
BLK 14
CONN5
CONN6−3
23 BLK
40
16
16
CONN3
BLK 24
FILAMENT
TRANS 2
FERRITE
CONN6−1
CONN6−7
FILAMENT
TRANS 1
A2
FERRITE
A1
INTERNAL
BLOWER
SHIELD/DRAIN
TEMP
SENSOR
LAMP HEAD
Internal Blower System Schematic
E 2013 Nordson Corporation
Part 1105120-01
UV Glossary
9-1
Section 9
UV Glossary
absorption
Not reflecting. The partial loss in energy that results when light passes
through or reflects off a medium.
additive bulb
A mercury bulb that contains metal additives such as iron, gallium,
indium, or others. These bulbs produce variations in spectral output as
compared to mercury only bulbs.
ASTM spec D3359−95a
Refer to tape test.
black light UV
Low powered UV composed of wavelengths in the UVA band. Usually
powered with several 100-watt power supplies or less instead of
several 1000-watt power supplies. Nordson’s UV Star and CoolWave
product lines are much higher in irradiance and energy density than
black light UV products.
bulb
A sealed quartz tube that contains a mixture of inert gas and mercury
under medium pressure. Electrode bulbs are fitted with electrical
connections at the ends of the bulb. Microwave bulbs contain no
electrical connections. The mercury and inert gas are energized
(vaporized) by either a voltage arc or microwave energy. The
vaporized plasma gas emits UV light.
capacitor
Corrects the power factor in the main power supply to reduce current
levels in the UV system.
cold mirror
A reflector that is coated with a dichroic material that absorbs or
passes wavelengths in the infrared range while reflecting those in the
UV range. Refer to dichroic.
cross hatch test
Refer to tape test.
cure
A UV drying process that occurs through a chemical reaction between
a UV ink or coating and UV light.
dichroic
A coating designed to pass certain wavelengths and reflect other
wavelengths. In UV lampheads, dichroics are used on reflectors to
pass or absorb infrared energy and reflect UV energy.
devitrification
The act of making quartz glass opaque and porous through prolonged
heating and UV exposure.
doped bulb
Refer to additive bulb.
E 2013 Nordson Corporation
Part 1105120-01
9-2
UV Glossary
dose (dosage)
Refer to energy density.
dose rate (dosage rate)
Refer to irradiance.
dynamic exposure
Exposure to a varying irradiance. It occurs when a lamphead passes
over a substrate without pausing or when a substrate passes under a
lamphead without pausing.
dynamic range
The span between the minimum irradiance and the maximum
irradiance to which a radiometer will accurately respond. Measured in
joules/cm2.
effective cure length
The length of a bulb that delivers optimal UV output. For electrode
bulbs, the effective cure length is always less than the arc length. For
microwave bulbs, the effective cure length is the length of the bulb.
electrodeless
A microwave-powered UV system.
electromagnetic spectrum
The full wavelength range of electromagnetic radiation, including
microwave, ultraviolet, visible, and infrared energy.
energy density
The total amount of UV energy delivered to a particular area,
measured in joules/cm2. Also referred to as total energy. Improperly
referred to as dose.
flood
An unfocused band of UV light that is more evenly and diffusely
distributed across the width of the reflector.
flux
The flow of photons, measured in einsteins/second.
focal distance (length)
The perpendicular distance from the edge of the lamphead to the point
where the UV light emitting from the bulb converges. This is the
location of maximum UV concentration.
focus
The band where the UV energy reflected from the lamphead is at the
highest concentration.
frequency
The number of times a periodic wavelength cycle occurs in one
second, measured in Hertz (Hz).
gallium
A bluish-white metallic element used in additive mercury bulbs. The
gallium additive provides a yellowish tint to an un-energized UV bulb
and a violet coloration to the UV output. Gallium bulbs have a spectral
peak around 417 nm and a spectral concentration between 400 and
450 nm. They are often used when deeper cure is required or with
white coatings containing titanium oxides. In some industries,
microwave gallium bulbs are referred to as V bulbs.
Part 1105120-01
E 2013 Nordson Corporation
UV Glossary
9-3
germicidal UV
Low-powered UV in the UVC band. Usually powered with several
100-watt power supplies or less instead of several 1000-watt power
supplies. Nordson’s UV Star and CoolWave product lines are much
higher in irradiance and energy density than germicidal UV products.
indium
A silver-white metallic element used in additive mercury bulbs. The
indium additive provides a yellowish tint to an un-energized UV bulb
and a violet coloration to the UV output. Indium is used to shift the
spectral output past 400 nm. In some industries, indium bulbs are
referred to as Q bulbs.
infrared energy
Energy having wavelengths between 1 and 100 m.
integral cooling fan
(blower)
The bulb-cooling fan when it is mounted to the lamphead.
integral shutter
A shutter assembly that is built into the lamphead. Common designs
include a pneumatically actuated clam shell that blocks the light when
closed and acts as a reflector when open and a pneumatic slide
mechanism that moves the lamphead behind an internal louver when
shuttered. Shutters are typically associated with electrode systems.
intensity
The amount of UV energy delivered to a particular area per unit time,
measured in joules/cm2/sec or watts/cm2/sec. Also referred to as watt
density. Improperly referred to as dose rate.
iron
A white metallic element used in additive mercury bulbs. The iron
provides a reddish tint to an un-energized UV bulb and a bluish
coloration to the UV output. Iron is used to concentrate the spectral
output between 350 and 400 nanometers. In some industries, iron
bulbs are referred to as D bulbs.
irradiance
Radiant power arriving at a surface from all forward angles per unit
area, measured in watts/cm2.
irradiator
Refer to lamphead.
joule
Metric unit for measuring work or energy. One joule is equivalent to the
work done by a force of one Newton acting through a distance of one
meter. (1 KW-hour equals 3.6 x 106 joules).
lamp
Refer to bulb.
lamphead
Assembly containing a sheet metal housing and cover and integral or
remote cooling fan. An electrode system also contains cradles and a
microwave system contains magnetrons, a cavity, and a screen.
light detector
A photocell inside a microwave lamphead that confirms UV output.
long UV
Refer to UVA.
E 2013 Nordson Corporation
Part 1105120-01
9-4
UV Glossary
louver
A part of a UV shutter system or shielding section that blocks the UV
light while allowing cooling air to pass through.
magnetron
Assembly contained inside a microwave lamphead that converts
high-voltage electrical input into RF energy.
mercury
A silver-white metallic element that is liquid at room temperature and is
used to create a vaporized, UV-emitting gas plasma inside a quartz
tube when it is energized through the use of either a voltage arc or
microwave energy. When energized the bulb produces a bright white
UV output. Mercury bulbs have a peak spectral output around 365 nm
and a concentration around 254 nm. In some industries, mercury
bulbs are referred to as H bulbs.
mercury plus (H+)
Mercury plus bulbs are only available in microwave systems as it is
difficult to vaporize the additional mercury in an electrode bulb.
metal halide bulb
Refer to additive bulb.
micrometer (mm)
Unit of length equivalent to one millionth of a meter.
microwave
That part of the electromagnetic spectrum associated with the larger
infrared waves and the shorter radio waves.
monomers
A molecule of relatively low molecular weight and simple structure
capable of combining with itself or other similar molecules to form
polymers.
nanometer (nm)
Unit of length equivalent to one billionth of a meter.
negative cooling
When the cooling air for the lamphead is drawn from the area
surrounding the substrate being cured and through the lamphead.
Negative cooling provides exhaust for the UV system if it is ducted to
atmosphere. Negative cooling is most often supplied through a remote
cooling fan.
nitrogen blanketing
Refer to nitrogen inerting.
nitrogen inerting
When the coating or ink is flooded with a nitrogen blanket to prevent
the coating or ink from oxidizing before cure. Nitrogen inertion reduces
oxygen inhibition.
oligomers
A low molecular weight resin or polymer used in a radiation curable
coating.
out-of-focus
When a lamphead is located further away from the substrate or closer
to the substrate than the focal distance.
oxidizing
When the coating or ink reacts with oxygen and slows the
polymerization process of the cure.
Part 1105120-01
E 2013 Nordson Corporation
UV Glossary
9-5
oxygen inhibition
Oxygen slows the cure response of UV curable coatings. The higher
the ratio of exposed surface area to coating mass, the greater the
impact oxygen has on the coating.
ozone (O3)
An unstable, colorless gas with a penetrating odor that is generated by
the reaction of short-wave UV light (184 nanometers) with air.
ozone-inhibiting
(ozone-free) bulbs
Bulbs where the quartz is manufactured with an additive that prevents
the transmission of UV beneath 200 nm in wavelength. It is the
reaction of short-wave UV light (184 nanometers) with air that
produces ozone.
Parts Per Million (PPM)
The units of the Threshold Limit Value (TLV) when referring to the
maximum level of a substance that a person should inhale over an
8-hour shift during a 40-hour week without producing an ill effect. Also
refer to Threshold Limit Value.
peak irradiance (peak
power density)
The maximum irradiance measured over a sample period, measured
in joules/cm2/sec or watts/cm2.
photoinitiator
A molecule which when exposed to a specific wavelength of energy
forms a reaction that begins the cure process.
photopolymerization
Turning a liquid (wet) into a solid (dry) through exposure to UV light.
planar shutter
A shutter assembly that is attached to the outside of a lamphead. The
louvered shutter moves perpendicular to the emitted UV light.
polymer
A macromolecule consisting of a large number of monomer units.
positive cooling
When the cooling air for the lamphead is blown through the lamphead
and onto the substrate being cured. Positive cooling can be supplied
through either an integral or remote cooling fan. With positive cooling,
an additional exhaust system is required to remove heat and ozone.
post cure
The continuation of chemical reactions in the ink or coating after
exposure to UV has ceased.
power density
Refer to irradiance.
quartz plate
Plates that allow UV energy to penetrate with minimal loss in intensity
and are mounted in front of the lamphead. The plates are used to
prevent positive cooling air and airborne contaminants from contacting
the substrate, negative cooling air from contaminating the bulb and
reflectors, or to remove some of the infrared that is radiated from the
UV bulb. If the goal is to reduce the amount of heat contacting the
substrate, additional cooling air must be blown across the quartz. If
additional air is not used, the quartz will eventually heat up and begin
radiating heat onto the substrate. To further reduce heat, the quartz
can be coated with a material that passes UV light and absorbs
infrared energy.
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Part 1105120-01
9-6
UV Glossary
quartz tube
(1) A sealed tube made from a silicate material that is filled with a
precise mixture of mercury and various inert gases and sometimes
fitted with electrical connections. The vapor emits light when it is
energized through the use of either a voltage arc or microwave energy.
Often used to refer to the bulb.
(2) An open tube made from a silicate material through which a
substrate can pass. The tube is often placed in front of a UV lamphead
and flooded internally with Nitrogen. Parts traveling through the tube
are then safeguarded from exposure to the oxygen and ozone in the
lamphead cooling air.
reflector
Reflect and concentrate the UV light onto the substrate. Rolled from
highly polished aluminum sheet metal or formed from borosilicate into
elliptical or parabolic profiles. Elliptical profiles optimize the
concentration of UV energy that is reflected by guiding the radiation
into a tightly focused UV band while parabolic reflectors result in a
flood of UV light. Holes or slots in the reflector allow cooling air to pass
through. The holes or slots are engineered for size and location to
provide both optimal and balanced airflow across the length of the
bulb.
remote cooling fan (blower)
The cooling fan when it is mounted separate from the lamphead and
ducted in to the lamphead.
RF
Radio Frequency. Any frequency between normally audible sound
waves and the infrared light portion of the spectrum lying between
10 KHz and 1,000,000 MHz.
RF detector
Monitors RF levels in the vicinity of the UV system and signals the
power supply to shut off the UV if RF levels exceed allowable limits.
screen
A wire mesh assembly attached to a microwave lamphead that allows
UV to pass through but prevents RF from leaking from the unit.
short UV
Refer to UVC.
single
An electrode lamphead assembly with a cradle that supports only one
bulb and one reflector.
shutter
An assembly designed to block UV light while passing cooling air.
solarization
The effect of the UV light on the quartz bulb. Over time, UV light and
heat will cause the quartz to devitrify or revert back to a crystalline and
porous state.
spectral output
The various wavelengths of light emitted from a UV bulb.
spectral output efficiency
graph
A graph or chart showing the relative concentration of UV at various
wavelengths for a particular bulb type. Typically, the concentration is
provided as a normalized percentage where the energy is integrated
over 10-nanometer bands to reduce the difficulty of quantifying the
effects of line emission spectra.
Part 1105120-01
E 2013 Nordson Corporation
UV Glossary
9-7
starter bulb
Used in the start up of microwave systems to ignite the mercury vapor
in the bulb.
static exposure
Exposure to a constant irradiance for a controlled period of time.
surface cure
When the UV material is cured only on the surface exposed to the UV.
tape test for measuring
adhesion
When an X-cut or lattice pattern of 6 or 11 cuts are scratched through
the UV cured material to the substrate. Pressure-sensitive tape is then
applied over the cuts and removed. Pulling the tape away from the
substrate will reveal the degree of adhesion. If any material between
the lines is pulled off with the tape, the adhesion is poor. If the material
remains, the adhesion is good. The recommended guidelines for
testing and evaluation are documented in the ASTM spec D3359-95a
under Methods A and B. Method A employs the X-cut and is used for
coatings that are 5 mils or greater. Method B calls for lattice cuts and
is recommended for coatings with 0−5 mils of thickness.
through cure
When the UV material is cured down to and including the material /
substrate interface.
Threshold Limit Value
(TLV)
The maximum exposure a person should receive over an 8-hour shift
during a 40-hour week without producing an ill effect. Often reported in
(mg / m3) or ppm.
Time-Weighed Average
(TWA)
Refer to Threshold Limit Value (TLV).
total energy
Refer to energy density.
transmittance
The ratio of the radiant energy passed through a body to the total
radiant energy received by the body.
ultraviolet light
Radiant energy in the wavelength band of 100 to 400 nanometers.
UVA (315−400 nanometers)
The portion of the electromagnetic spectrum ranging between 315 and
400 nm. UVA represents the largest portion of UV energy and is
commonly referred to as long UV. UVA is most responsible for skin
aging and increased skin pigmentation. UVA is at the lower limit of
sensitivity to the human eye.
UVB (280−315 nanometers)
The portion of the electromagnetic spectrum ranging between 280 and
315 nm. UVB is most responsible for reddening and burning of the
skin and damage to the eyes.
UVC
(200−280 nanometers)
The portion of the electromagnetic spectrum ranging between 200 and
280 nm. UVC is typically referred to as short UV.
UVV
(400−445 nanometers)
The portion of the electromagnetic spectrum ranging between 400 and
445 nm. The V stands for visible UV.
E 2013 Nordson Corporation
Part 1105120-01
9-8
UV Glossary
vacuum UV
(100−200 nanometers)
The portion of the electromagnetic spectrum ranging between 100 and
200 nm. UVV does not transmit in air.
viscocity
The state or quality of having a cohesive and sticky fluid consistency.
vitrification
The act of changing pure opaque quartz into clear non-porous quartz
through a fusion process.
watt
One joule per second.
watt density
Refer to irradiance.
waveguide
Directs microwaves toward the bulb in microwave UV systems.
wavelength
The measured cycle length of a wave in the direction of propagation.
Part 1105120-01
E 2013 Nordson Corporation
DeviceNet Specifications
10-1
Section 10
DeviceNet Specifications
Introduction
This section covers the specifications and requirements for the CoolWave 2
DeviceNet Interface Module Revision 0.62. This specification describes the
unit configuration, unit initialization, the DeviceNet Network Model and the
interface to the Nordson Coolwave2 module. It describes the functionality
required of the network interface module. It does not describe
implementation details or specify the requirements for the PCB or
enclosure.
Definitions
Network Host: The DeviceNet network Host (commonly a scanner card in
a Programmable Controller).
Network Slave: A DeviceNet device which implements server functionality
in a DeviceNet system.
Programmable Controller: Programmable Logic Controller − the
DeviceNet Network Host.
Reference Documents
The CIP Networks Library Volume 1: Common Industrial Protocol, Edition
3.1, 2007 ODVA
The CIP Networks Library Volume 3: DeviceNet Adaptation of CIP, Edition
1.3, 2007 ODVA
Governing Body
Open DeviceNet Vendor Association, Inc. (www.odva.org) ODVA is an
independent supplier organization that manages the DeviceNet specification
and supports the worldwide growth of DeviceNet.
E 2013 Nordson Corporation
Part 1105120-01
10-2 DeviceNet Specifications
System Operation
MAC ID / Baud Rate Configuration
Three rotary switches are defined for user configuration of the device. The
three rotary switches are defined as follows:
Rotary switches S2 (MSD) and S3 (LSD) are used to select the DeviceNet
MAC ID address. The valid range of addresses is 0 – 63. All combinations
above 63 set the device address to the last address the device was
powered up at and allow software configuration tools to modify the MAC ID
address.
ADDRESS
2
2
4
0
4
0
6
MSD
Figure 10-1
6
8
P
LSD
MAC ID Switches S2 and S3
Rotary switches S1 (BAUD) is used to select the DeviceNet Baud Rate. The
valid range of baud rates is 0−3 (0=125K, 1=250K, 2=500K). All values
above 2 set the baud rate to the last baud rate the device was powered up
at and allow software configuration tools to modify the baud rate.
DATA RATE
500 Kb
PGM
250 Kb
125 Kb
Figure 10-2
Part 1105120-01
Baud Rate Switch S1
E 2013 Nordson Corporation
DeviceNet Specifications
10-3
LED Operation
There are two LEDs on the rear panel. The first bicolor LED indicates
Network Status as listed in the following table:
Table 10-1 Network Status LED Operation
Color
None
Red
State
Off
Solid
Flashing
Solid
Flashing
Green
Indication
No Power
Unrecoverable Fault
Output error or configuration error
Normal runtime operation
Device is in idle or not allocated to a
master
The second bicolor LED indicates Module Status as listed in the following
table:
Table 10-2 Module Status LED Operation
Color
None
Red
State
Off
Solid
Flashing
Indication
No Power
Fatal Error
S If the Network Status Led is Solid
Red, DeviceNet Power is not present
S Baud Rate / Mac ID switch value
changed, next power up uses a new
configuration
Green
Red/Green
Solid
Flashing
Normal Operation
Device is in self test mode
LEDs
Figure 10-3
E 2013 Nordson Corporation
DeviceNet Status LEDs
Part 1105120-01
10-4 DeviceNet Specifications
DeviceNet Interface
Overview
DeviceNet is a low cost and open industrial network which links industrial
devices (such as limit switches, photoelectric sensors and motor starters) to
machine controllers over the Controller Area Network (CAN). DeviceNet
eliminates expensive hardwiring and provides improved communication
between devices as well as important device level diagnostics.
The following sections describe the network Object Model (the interface
from the DeviceNet point-of-view).
Configuration
The unit supports the standard DeviceNet MAC ID and Baud Rate
selections. MAC ID and Baud Rates can be selected from user accessible
rotary switches or through DeviceNet configuration software.
See page 10-2 for more details. All configuration data is stored in
non-volatile memory.
Initialization
The unit provides standard duplicate MAC ID detection processing during
power-on initialization.
Group 2 Only Slave Operation
The unit supports allocation of the DeviceNet Group 2 Master/Slave
connection set through the Group 2 Unconnected message port.
Certification
The unit must be certified as a compliant DeviceNet device through an
ODVA certified testing facility. This device is not required to pass SEMI-SIG
optional conformance testing.
Part 1105120-01
E 2013 Nordson Corporation
DeviceNet Specifications
10-5
Identity Object (01HEX − 1 Instance)
The Identity Object provides descriptive information.
Class Attributes (Instance 0)
Attribute
ID
1
Name
Revision
DeviceNet
Data Type
Data
Value
Access
Rule
UINT
1
Get
DeviceNet
Data Type
Data
Value
Access
Rule
UINT
UINT
UINT
USINT
416DEC
64HEX
100DEC
1
Get
Get
Get
Get
USINT
WORD
UDINT
1
0
Unique
32 Bit Value
Get
Get
String
of USINT
“CoolWave2”
Get
Instance Attributes (Instance 1)
Attribute
ID
1
2
3
4
Name
Vendor Number
Device Type
Product Code Number
Product Major Revision
Product Minor Revision
5
6
Status Word
Serial Number
7
Product Name
Common Services
Service Code
0EHEX
05HEX
Implemented for
Class Level
Instance Level
Yes
No
Yes
Yes
Service Name
Get_Attribute_Single
Reset −− no attribute data −−
Normal: Class 1, Instance 1, 1 byte data = 0
Out of Box: Class 1, Instance 1, 1 byte data = 1
Message Router Object (02HEX − 1 Instance)
No supported attributes or services.
E 2013 Nordson Corporation
Part 1105120-01
10-6 DeviceNet Specifications
DeviceNet Object (03HEX − 1 Instance)
Class Attributes (Instance 0)
Attribute
ID
DeviceNet
Data Type
Data
Value
Access
Rule
UINT
2
Get
DeviceNet
Data Type
Data
Value
Access
Rule
Mac ID
Baud Rate
Structure of:
Allocation Choice Byte
Master Mac ID
MAC ID Switch Changed
(since last power up)
USINT
USINT
63
0
Get / Set
Get / Set
BYTE
USINT
BOOL
0xFF
0
0
Get
Get
Get
7
Baud Rate Switch Changed
(since last power up)
BOOL
0
Get
8
9
Actual MAC ID Switch Value (0−99)
Actual Baud Rate Switch Value (0−9)
USINT
USINT
63
0
Get
Get
1
Name
Revision
Instance Attributes (Instance 1)
Attribute
ID
1
2
5
6
Name
Common Services
Service Code
0EHEX
10HEX
Part 1105120-01
Implemented for
Class Level
Instance Level
Yes
No
Yes
Yes
Service Name
Get_Attribute_Single
Set_Attribute_Single
E 2013 Nordson Corporation
DeviceNet Specifications
10-7
Assembly Object (04HEX – 2 Instances)
Class Attributes (Instance 0)
Attribute
ID
Name
DeviceNet
Data Type
Data
Value
Access
Rule
1
2
100
Revision
Max Instance
Polled Input Assembly Instance
(valid values are 100)
UINT
UINT
UINT
2
112
100
Get
Get
Get / Set
101
102
Polled Input Size
Polled Output Assembly Instance
(valid values are 112)
UINT
UINT
14
112
Get
Get / Set
103
Polled Output Size
UINT
4
Get
DeviceNet
Data Type
Data
Value
Access
Rule
USINT
0
Get / Set
Instance Attributes (Instances 100 and 112)
Attribute
ID
3
Name
Data
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Part 1105120-01
10-8 DeviceNet Specifications
Instance 100 – Input Assembly 1 (Common)
Byte
Index
Description
0
Exception Status:
Defined in S−Device Supervisor Object
1
System Ready:
0 – Not Ready; 1 – Ready
DeviceNet
Data Type
USINT
Class
ID
Instance
ID
Attribute
ID
0x30
1
12
USINT
0x64
0
100
2–3
Units Present Bitmap:
Bit 0 – Master
Bit 1 – Slave 1
Bit 15 – Slave 15
0 – Not present; 1 – Present
UINT
0x64
0
102
4–5
Fault Bitmap:
Bit 0 – Master;
Bit 1 – Slave 1
Bit 15 – Slave 15
0 – OK; 1 – Fault
UINT
0x64
0
101
6–7
Lamp Number
0: Master
1−15: Slaves
Lamp State:
1 – Off
2 – Filament On Time Delay
3 – Standby
4 – Lamp Start
5 – Lamp On
6 – Fault
7 – Reset
8 – Cool Off
9 – Lamp Cool
10 – Test
11 – Start Power Delay
UINT
N/A
N/A
N/A
USINT
0x64
varies
103
Lamp Power Level:
0 −100%
USINT
0x64
varies
106
Lamp Fault:
32−bits Defined in S−Device Supervisor
Object
UDINT
0x64
varies
104
8
9
10 – 13
Part 1105120-01
E 2013 Nordson Corporation
DeviceNet Specifications
10-9
Instance 101 – Input Assembly 2 (Master/Slave 1−2)
Byte
Index
0
1
2
3
4
5
6
7
DeviceNet
Data Type
USINT
Class
ID
Instance
ID
Attribute
ID
0x30
1
12
Status Bitmap
See Below
Master Lamp State
1 – Off
2 – Filament On Time Delay
3 – Standby
4 – Lamp Start
5 – Lamp On
6 – Fault
7 – Reset
8 – Cool Off
9 – Lamp Cool
10 – Test
11 – Start Power Delay
USINT
0x64
0
USINT
0x64
0
100, 101,
102
101
Master Lamp Power Level:
0 −100%
Slave 1 Lamp State:
1 – Off
2 – Filament On Time Delay
3 – Standby
4 – Lamp Start
5 – Lamp On
6 – Fault
7 – Reset
8 – Cool Off
9 – Lamp Cool
10 – Test
11 – Start Power Delay
USINT
0x64
0
102
USINT
0x64
1
103
Slave 1 Lamp Power Level:
0 −100%
Slave 2 Lamp State:
1 – Off
2 – Filament On Time Delay
3 – Standby
4 – Lamp Start
5 – Lamp On
6 – Fault
7 – Reset
8 – Cool Off
9 – Lamp Cool
10 – Test
11 – Start Power Delay
USINT
0x64
1
104
USINT
0x64
2
103
Slave 2 Lamp Power Level:
0 −100%
USINT
0x64
2
104
Description
Exception Status
Defined in S−Device Supervisor Object
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Part 1105120-01
10-10 DeviceNet Specifications
System Bitmap (default in bold)
Bit
Value
Bit
7
Bit
6
Bit
5
Bit
4
Bit
3
Bit
2
Bit
1
Bit
0
1
(ON)
Master
Faulted
Slave 1
Faulted
Slave 2
Faulted
n/a
Master
Present
Slave 1
Present
Slave 2
Present
System
Ready
0
(OFF)
Master
OK
Slave 1
OK
Slave 2
OK
n/a
Not
Present
Not
Present
Not
Present
Not
Ready
Instance 112 – Output Assembly 1 (Common)
Byte
Index
Description
DeviceNet
Data Type
Class
ID
Instance
ID
Attribute
ID
0
Master Lamp Command (See Notes):
1 – Off / Stop
2 – On / Start
3 – Standby
5 – Reset
USINT
0x64
0
110
1
Light Intensity Command:
20 – 100%
USINT
0x64
0
111
2–3
Lamp Status Select:
UINT
N/A
N/A
N/A
0: Master
1−15: Slaves
NOTE: Receive_Idle condition (0 byte length message) is treated as a DeviceNet fault condition by the
CoolWave2 unit.
NOTE: Commands other than those listed are not implemented, and will be ignored by the CoolWave2
unit.
Common Services
Service Code
0EHEX
10HEX
Part 1105120-01
Implemented for
Class Level
Instance Level
Yes
Yes
No
Yes
Service Name
Get_Attribute_Single
Set_Attribute_Single
E 2013 Nordson Corporation
DeviceNet Specifications 10-11
Connection Object (05HEX − 2 Instances)
Class Attributes (Instance 0)
Attribute
ID
Name
1
Revision
DeviceNet
Data Type
Data
Value
Access
Rule
UINT
1
Get
Instance Attributes (Instances 1 − 2)
Attribute
ID
1
Name
State
DeviceNet
Data Type
USINT
2
3
4
Instance Type
Transport Trigger
Produced
Connection ID
5
Consumed
Connection ID
uint
6
Initial Comm.
Character
7
Access
Rule
Get
1
82HEX
01111xxxxxxBIN
xxxxxx
= Node Address
10xxxxxx100BIN
xxxxxx
= Node Address
01HEX
Get
Get
Get
USINT
0
83HEX
10xxxxxx011BIN
xxxxxx
= Node Address
10xxxxxx100BIN
xxxxxx
= Node Address
21HEX
Produced
Connection Size
uint
0 – 30
14 / 8
Get
8
Consumed
Connection Size
uint
0 – 30
4
Get
9
Expected Packet
Rate
uint
2000 msec
0
Get / Set
12
Watchdog Timeout
Action
USINT
3 = Deferred
Delete
0 = Timeout
Get
13
Produced
Connection Path
Length
Produced
Connection Path
UINT
0
6
Get
USINT Array
NULL
20h 04h 24h
65h 30h 03h
Get
UINT
0
6
Get
USINT Array
NULL
20h 04h 24h
70h 30h 03h
Get
14
15
16
Consumed
Connection Path
Length
Consumed
Connection Path
E 2013 Nordson Corporation
USINT
usint
uint
Data Value
Instance 1 (EM)
Instance 2 (Poll)
0 = NonExistent
0 = NonExistent
3 = Established
1 = Configuring
5 = Deferred
3 = Established
Delete
4 = Timed Out
Get
Get
Part 1105120-01
10-12 DeviceNet Specifications
Common Services
Service Code
Implemented for
Class Level
Instance Level
0EHEX
10HEX
Yes
No
Yes
Yes
Service Name
Get_Attribute_Single
Set_Attribute_Single
S−Device Supervisor Object (30HEX − 1 Instance)
Class Attributes (Instance 0)
Attribute
ID
Name
1
Revision
DeviceNet
Data Type
Data
Value
Access
Rule
UINT
1
Get
Instance Attributes (Instance 1)
Attribute
ID
Name
DeviceNet
Data Type
Data
Value
NV?
Access
Rule
3
Device Type
SHORT
STRING8
“Generic”
NV
Get
4
SEMI Standard Revision Level
SHORT
STRING8
“E54−0997”
NV
Get
5
Manufacturer’s Name
SHORT
STRING20
“Nordson Inc.”
NV
Get
6
Manufacturer’s Model Number
SHORT
STRING20
“CoolWave2 “
NV
Get
7
Software Revision Level
SHORT
STRING6
“1.01“
NV
Get
8
Hardware Revision Level
SHORT
STRING6
“Rev A“
NV
Get
11
12
13
14
15
16
Device Status
Exception Status
Exception Detail Alarm
Exception Detail Warning
Alarm Enable
Warning Enable
USINT
BYTE
STRUCT
STRUCT
BOOL
BOOL
0
0
00
00
1
1
V
V
V
V
NV
NV
Get
Get
Get
Get
Get / Set
Get / Set
Part 1105120-01
E 2013 Nordson Corporation
DeviceNet Specifications 10-13
Common Services
Service Code
0EHEX
10HEX
05HEX
06HEX
07HEX
4BHEX
4CHEX
4EHEX
Implemented for
Class Level
Instance Level
Yes
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Service Name
Get Attribute Single
Set Attribute Single
Reset
Start
Stop
Abort
Recover
Perform_Diagnostics
S The Coolwave2 enters the “Nordson Off State” as a result of S−Device
Supervisor commands “Reset”, “Stop” or “Abort”.
S The S−Device Supervisor “Start” command transitions to the S−Device
“Executing” state which allows the Nordon commands: “On, Ready,
Standby and Stop” via the I/O data.
S The S−Device Supervisor command “Perform_Diagnostics” has no
supported behavior.
E 2013 Nordson Corporation
Part 1105120-01
10-14 DeviceNet Specifications
Exception Detail Alarm / Warning
Both the Exception Detail Alarm and the Exception Detail Warning use the
same 9 byte array.
Table 10-3 Exception Detail Structure Definition
Bytes 1−8
Bit 7
Bit 6
Bit 5
Common
Exception
Detail Size
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
= 2 (2 bytes to follow)
Common
Exception
Detail Byte 0
0
0
0
0
EEPROM
Exception
0
0
0
Common
Exception
Detail Byte 1
0
0
0
0
0
0
0
0
Device
Exception
Detail Size
= 0 (0 bytes to follow)
Manufacturer’s
Exception
Detail Size
= 4 (4 bytes to follow)
Manufacturer’s
Exception
Detail Byte 0
Lamp Out
Magnetron
Fault
Current
Slave unit
fault
Current
Magnetron
Imbalance
over
current
Filament
Fuse
Magnetron
Fault
Local Net
config
error
Manufacturer’s
Exception
Detail Byte 1
Power
Regulation
Fault
unassigned
Slave Unit
not
present
Magnetron DeviceNet
Voltage
Bus OFF
Fault
Duplicate
MAC ID
PC Board
hardware
fail
Unassigned
Manufacturer’s
Exception
Detail Byte 2
HV Cable Lamphead
unplugged over temp
Manufacturer’s
Exception
Detail Byte 3
Unassigne Unassigne Unassigne
d
d
d
Part 1105120-01
MSTOP
open
RF
Detector
Fault
RF
Detector
missing
Power
Unit over
temp
External
Interlock
Low
Lamphead
Pressure
Mag
Filament
Open
Phase
Controller
Fault
RF
Detector
Failed
Phase
Control at
Limit
Low
magnetron
current
E 2013 Nordson Corporation
DeviceNet Specifications 10-15
Lamp Object (64HEX − 16 Instances)
Class Attributes (Instance 0)
Attribute
ID
Name
1
100
Revision
System Ready:
0 – Not Ready
1 – Ready
255 – DeviceNet Disabled (not reported over
DeviceNetJ)
101
Faulted Node Bitmap:
Bit 0 – Master
Bit 1 – Slave 1.....Bit 15 – Slave 15
Units Present Bitmap:
Bit 0 – Master
Bit 1 – Slave 1.....Bit 15 – Slave 15
Master Lamp State
1 – Off
2 – Filament On Time Delay
3 – Standby
4 – Lamp Start
5 – Lamp On
6 – Fault
7 – Reset
8 – Cool Off
9 – Lamp Cool
10 – Test
11 – Start Power Delay
102
103
DeviceNet
Data Type
Data
Value
Access
Rule
UINT
USINT
1
0
Get
Get
UINT
0
Get
UINT
1
Get
USINT
0
Get
104
Master Lamp Fault
See S−Device Supervisor for bit definitions
UDINT
0
Get
105
106
110
Master Light Intensity Level Set (0−100%)
Master Magnetron Power Level Actual (0−100%)
Master Lamp Command:
1 – Off
2 – On
3 – Standby
5 – Reset
USINT
USINT
USINT
0
0
0
Get
Get
Get / Set
111
Light Intensity Command
20−100% (0−255% accepted)
USINT
0
Get / Set
E 2013 Nordson Corporation
Part 1105120-01
10-16 DeviceNet Specifications
Instance Attributes (Instances 1−15)
Attribute
ID
Name
DeviceNet
Data Type
Data
Value
Access
Rule
103
Slave Lamp State
See “Master Lamp State” definition above
USINT
0
Get
104
Slave Lamp Fault
See S−Device Supervisor for bit definitions
UDINT
0
Get
105
106
Slave Light Intensity Level Set (0−100%)
Slave Magnetron Power Level Actual (0−100%)
USINT
USINT
0
0
Get
Get
Common Services
Service Code
0EHEX
10HEX
Part 1105120-01
Implemented for
Class Level
Instance Level
Yes
Yes
Yes
No
Service Name
Get Attribute Single
Set Attribute Single
E 2013 Nordson Corporation
Index
i
Index
A
Accessories, part numbers, 7-12
Airshield ventilation system
installation, 3-17
parts, 7-12
B
Balancing, power supplies, 3-4
Blowers, description, 2-3
Bulb
handling, 6-4
maintenance, 6-4
replacement, 6-5
specifications, 8-4
troubleshooting, 5-6
Bulbs
part numbers, 7-10
see Mecury bulbs, 1-7
UV bulbs, description, 2-2
C
C DLY, message, 4-4
Cables, part numbers, 7-11
Cleaning, system controller cooling fans, 6-3
Clearance, Controller, 3-2
Connections
network, 3-7
power, 3-3
remote I/O, 3-7
Controls
configuration, accessing, 4-3
Idle, 4-2
lamphead, 4-2
light output, displaying, 4-3
Network, 4-2
operation, 4-1
panel lock, 4-3
power setpoint, 4-3
power setting, 4-2
Standby, 4-2
starter bulb, testing, 4-3
System off, 4-2
System on, 4-2
temperature display, 4-3
Cover, lamphead
removal, internal blower, 6-11
removal, external blower, 6-13
replacement, 6-12
Curing process, troubleshooting, 5-7
Current Draw, 8-2
D
DeviceNet
BUS power, 3-11
chassis isolation, 3-11
hardware specifications, 3-12
installation, 3-11
specifications, 10-1
Diagrams
connections, four systems, 3-6
connections, stand−alone system, 3-5
system connection, 3-4
connections, two systems, 3-5
Dimensions
bulb, 8-4
lamphead, external blower, 3-13
lamphead, internal blower, 3-14
System Controller, 3-2, 8-1
Display, messages, operation, 4-1
E 2013 Nordson Corporation
Part 1105120-01
ii
Index
E
maintenance, 6-4
replacement, internal blower, 6-5
Electrical
connections, system controller, 3-3
requirements, 3-3
Focal lengths, 2-5
Exhaust, requirements, 3-16
Fuses, replacing, 6-2
External blower, description, 2-3
Frequency, of operation, 1-5
External blower lampheads, parts, 7-7
G
External blowers, installation, 3-16
Glossary, 9-1
F
H
Fault, messages, 4-4
High voltage, safety, 1-6
Fault output, 3-8
FAULT CURRENT IMBALANCE, 5-2
FAULT DeviceNet ERROR, 5-3
FAULT DEVNET HARDWARE, 5-3
FAULT EXT INTERLOCK, 5-4
FAULT FILAMENT FUSE BLOWN, 5-2
FAULT HARDWARE FAILURE, 5-3
FAULT HIGH CURRENT ON MAG, 5-2
I
Idle
function, 4-2
message, 4-4
Idle mode
activation, 3-10
cycle timing, 3-10
FAULT LOW LAMPHEAD PRESSURE, 5-4
Input
Lamp on, 3-8
Machine stop interlock, 3-8
Off/reset, 3-8
remote power control, 3-8
Standby, 3-8
FAULT MAG FILAMENT IS OPEN, 5-6
Inspection, before installation, 3-1
FAULT MAG POWER WHEN OFF, 5-2
Intended Use, Of equipment, 1-2
FAULT MAG VOLTAGE ERROR, 5-3
Internal blower, description, 2-3
FAULT HV CABLE UNPLUGGED, 5-5
FAULT LAMPHEAD OVER TEMP, 5-5
FAULT LOW CURRENT ON MAGS, 5-5
FAULT NETWORK COMM, 5-3
FAULT NETWORK CONFIGURATION, 5-2
FAULT NO LIGHT DETECTED, 5-3
FAULT ON NETWORK UNIT, 5-2
FAULT PHASE CONTROLLER ERROR, 5-6
FAULT PHASE CTRL AT LIMIT, 5-5
FAULT POWER CTRL AT LIMIT, 5-4
FAULT POWER UNIT OVER TEMP, 5-4
FAULT RF DETECTOR FAILED, 5-5
FAULT RF DETECTOR MISSING, 5-4
Faults, resetting, 4-5
Filament transformer, replacement, 6-15
Filters
Part 1105120-01
E 2013 Nordson Corporation
Index
L
L COOL, message, 4-4
Lamp on input, 3-8
Lamphead
air pressure, 4-2
blowers, 3-15
cable connection, 3-21
description, 2-2
dimensions, external blower version, 3-13
dimensions, internal blower version, 3-14
installation, 3-12
mounting kit, optional, 3-15
light shielding, 3-15
magnetron, 4-2
mounting guidelines, 3-12
moving and storage, 1-8
pressure monitoring, port selection, 3-18
repair, 6-5
specifications, 8-4
troubleshooting, 5-7
iii
filters, 6-4
lamphead, 6-4
magnetrons, 6-4
reflectors, 6-4
screen, 6-4
system controller, 6-1
Malfunctions, action in case of, 1-8
Mercury bulbs
disposal of, 1-7
safety when handling, 1-7
Messages
cool delay, 4-4
fault, 4-4
idle, 4-4
lamp delay, 4-4
lamp on, 4-4
operating, 4-4
standby, 4-4
warm up, 4-4
Lamphead, internal blower, parts, 7-4
Microwave Radiation
exposure to, 1-5
RF screen protection, 1-5
Lampheads, external blower, parts, 7-7
Moving and storage, safety, 1-8
LAMPON, message, 4-4
Lamps
operating temperature, 1-7
disposal of, 1-7
Light detector, description, 2-2
Light detector board, replacement, 6-18
Light output
displaying, 4-3
specifications, 8-3
N
Network
cable part number, 7-11
connections, 3-7
selections, 4-2
termination, 3-7
LMPDLY, message, 4-4
O
Load balancing, 3-4
Off/reset input, 3-8
Local unit, startup, 4-9
Optional Two Axis Bracket Kit, Lamphead
mounting, 3-15
M
Machine stop interlock, 3-8
connection, 3-9
Options
AirShield Ventilation System, 2-8
description, 2-8
LiteTite Shutter, 2-8
Magnetron
description, 2-1, 2-3
replacement, 6-14
Output
fault, 3-8
Ready, 3-8
Magnetrons, Description, 2-4
Ozone, definition, exposure, 1-5
Maintenance
E 2013 Nordson Corporation
Part 1105120-01
iv
Index
P
Panel lock, using, 4-3
Parts
accessories, 7-12
bulbs, 7-10
cables, 7-11
external blower lampheads, 7-7
lamphead, internal blower, 7-4
RF detector, 7-2, 7-10
system controller, 7-2
system controllers, 7-1
Personal Safety, Instructions for, 1-3
Power
connections, 3-3
load balancing, 3-4
Power setpoint, function, 4-3
Power setting, function, 4-2
Power supply
moving and storage, 1-8
repair, 6-2
Pressure ports
Description, 3-18
lamphead, external blower, 3-19
lamphead, internal blower, 3-20
switching, 3-18
Pressure sensor, description, 2-2
Q
Qualified personnel, Definition of, 1-1
Quartz plate, part number, 7-12
R
Radio interference, compliance with, 1-5
Rapid cycle, using idle mode, 3-11
Rapid startup, using, 3-10
Ready output, 3-8
Reflector, replacement, 6-7
Reflectors
2.1 Focus, 2-5
3.1 Focus, 2-6
brackets, 6-7
description, 2-5
Flood, 2-7
Regulations and Approvals, safety, 1-2, 1-5
Remote, inputs and outputs, 3-7
Remote power control input, 3-8
Remote power level control, connection, 3-10
Repair
bulb, 6-5
filament transformer, 6-15
fuses, 6-2
lamphead, 6-5
light detector board, 6-18
magnetron, 6-14
power supply, 6-2
reflectors, 6-7
starter bulb, 6-18
system controller cooling fans, 6-3
temperature sensor, 6-18
RF detector
cable part numbers, 7-11
description, 2-3
installation, 3-22
part number, 7-2
RF screen
installation, 6-6
removal, 6-5
S
Safety, 1-1
fire, 1-7
high temperatures, 1-6
high voltage, 1-6
mercury bulbs, 1-7
microwave radiation, 1-5
ozone, 1-5
safety, UV inks, 1-7
symbols, 1-9
UV inks, 1-7
Schematic
external blower, 8-5
internal blower, 8-6
Schematics, 8-4
Servicing, safety while, 1-8
Part 1105120-01
E 2013 Nordson Corporation
Index
Shutdown
fault, 4-13
Normal, 4-13
T
Shutter system, part number, 7-12
Temperature sensor
description, 2-2
replacement, 6-18
Specifications
bulb, 8-4
current draw, 8-2
DeviceNet, 10-1
environment, 8-1
light output, 8-3
power settings, master/remote, 8-3
rating, controller enclosure, 8-1
RF detector, 8-1
system controller, 8-1
Standby
function, 4-2
input, 3-8
remote, 3-10
Starter bulb
description, 2-2
replacement, 6-18
testing, 4-3
Startup
local units, 4-9
remote units, 4-12
Startup, rapid, using, 3-10
Static pressure, monitoring, 3-18
STDBY, message, 4-4
System controller
balancing, 3-4
control transformer T3 taps, 3-3
description, 2-3
fuses, 6-2
HV transformer T1, T2 taps, 3-3
maintenance, 6-1
mounting, 3-1
parts, repair, 7-2
power connections, 3-3
remote I/O, 3-7
repair, 6-2
specifications, 8-1
System controllers, part numbers, 7-1
System off, function, 4-2
System on, function, 4-2
v
Temperature, displaying, 4-3
Termination, network, 3-7
Timing sequences
with idle enabled, 4-6
without idle enabled, 4-8
Torque specifications
fasteners, lamphead, ext. blower, 7-8
Fasteners, reference to, 6-1
fasteners, lamphead, int. blower, 7-5
Transformer, taps, 3-3
Troubleshooting
bulb, 5-6
curing process, 5-7
faults, 5-2
lamphead, 5-7
U
Ultraviolet light
first aid, 1-5
Permissible exposure to, 1-4
Safety when using, 1-3
Unicable
connection, 3-21
part numbers, 7-11
UV bulb, replacement, 6-5
UV bulbs, part numbers, 7-10
UV curing, description, 2-1
V
Voltage, specifications, 8-1
W
WARMUP, message, 4-4
Wave guide, description, 2-3
Wiring, diagram, 8-5
E 2013 Nordson Corporation
Part 1105120-01
vi
Index
Part 1105120-01
E 2013 Nordson Corporation
Product: Cool Wave, Cool Wave 2 and Cool Wave 2 Plus
Models: CW-610V, CW2-610V, CW2+-610V, CW2I-610V, CW2+I-610V
CW2-410V, CW2+-410V, CW2I-410V, CW2+I-410V
Description:
Applicable Directives:
Standards Used for Compliance:
Product Certificates:
Quality System Certificate – ISO9000 through