Hernon Manufacturing

107-022 Ultracure 6

Ultracure 6 LED UV Curing System 107-022

121 Tech Drive Sanford, FL 32771 www.Hernon.com Phone: (407) 322-4000 Fax: (407) 321-9700 September 2015

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Hernon Manufacturing

107-022 Ultracure 6

About This Manual Thank you for selecting Hernon's Ultracure 6 for your application. The Ultracure 6 was developed with your needs in mind. Your Ultracure 6 has been calibrated and tested to ensure optimal performance and long life. To ensure safe and trouble-free operation, please review the procedures and warnings contained in this manual before setting up or operating your Ultracure 6. While safety is paramount, proper handling and operation of Ultracure 6 will also serve to produce quality product yield. Hernon Manufacturing designs and builds a wide range of custom manufacturing and packaging machines. Hernon Manufacturing machines are built only with high quality components of proven reliability. This Manual is published by Hernon solely as a guide for Operators, Design Engineers, OEM Customers, and Maintenance Personnel. Liability for difficulties arising from unknown or unforeseen technical limitations is disclaimed, and Hernon makes no representation as to the thoroughness of this manual. Hernon reserves the right to revise this manual at any time without notice, for any reason. If you have any problems or concerns, please contact Hernon Technical Support at (407) 322-4000. Trained Hernon professionals are standing by to serve you.

IMPORTANT These instructions are general. Specific cure times should be evaluated and recommended by Hernon’s Lab. Please contact Hernon’s Technical Department (407)322-4000 for specific instructions.

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107-022 Ultracure 6

Table of Contents Ultracure 6 .................................................................................................................................................... 1 About This Manual ........................................................................................................................................ 2 Table of Contents .......................................................................................................................................... 3 Unpacking and Inspection............................................................................................................................. 4 Safety ............................................................................................................................................................ 5 General.......................................................................................................................................................... 6 Features .................................................................................................................................................... 6 Specifications ............................................................................................................................................ 6 Mounting............................................................................................................................................... 7 Operation Guidelines .................................................................................................................................... 8 Wiring Configurations ............................................................................................................................... 8 System Status/Faults............................................................................................................................... 11 UV Output Curve ..................................................................................................................................... 11 External I/O Signals ................................................................................................................................. 12 LED Failure .............................................................................................................................................. 12 Maintenance ............................................................................................................................................... 13 Frequently Asked Questions ....................................................................................................................... 13 Replacement Parts ...................................................................................................................................... 13 Warranty ..................................................................................................................................................... 14 Notes ........................................................................................................................................................... 15

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107-022 Ultracure 6

Unpacking and Inspection Upon receipt of the unit, carefully remove the contents from the boxes and check for damage. Hernon is not responsible for damage from shipping – all claims for shipping damage should be made with carrier. Check all boxes for contents and document any serial numbers for further reference. You may wish to retain original shipping cartons in case you need to repackage any item for return. If you observe or experience any problem with your equipment, notify Hernon Customer Support, your authorized distributor, or your Hernon representative immediately. NOTE: REPORT ANY SHORTAGE TO HERNON CUSTOMER SERVICE Phone: (407) 322-4000 Fax: (407) 321-9700 Email: [email protected] Before continuing with unpacking and installation, please read the following chapters of this manual for safety recommendations and installation, running, and troubleshooting instructions. CAUTION! Always wear proper (High Intensity UV Blocking) protective goggles or face shield when working near the front of the unit which emits Ultraviolet light! Note: Reflected UV light may be harmful.

WARNING! Always observe safety requirements!

CAUTION! Risk of Electrical Shock when cover is removed! CAUTION! Cover is warm to the touch when unit is in operation! WARNING: DANGEROUS ULTRAVIOLET EMMISSION

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107-022 Ultracure 6

Safety Please, read all safety specifications before performing any procedures such as checking products on delivery, storage and transportation, installation, wiring, operation and inspection, or disposal. Be sure to observe these precautions thoroughly. GENERAL WARNINGS          

All operators and maintenance personnel are required to read this safety instruction list before attempting to operate, adjust, or repair. Never operate with electrical enclosure open. Do not operate this or any other machine without all protective guards and covers in place. Do not operate this device before reading and understanding the operator’s procedures in this manual. Any electrical servicing or adjustments requiring access to electrical enclosures on the machine should be performed only by qualified personnel with electrical power disconnected and locked out. Safety glasses must be worn by the operator and any one in the area of operation. W/ #5 Green Shade Goggles. Hands should never be placed near moving or illuminated areas. Disconnect and lock out electrical power, hydraulic power, air pressure and water before performing machine or tooling adjustment and or maintenance. Keep area around device/s clear of all debris, water, oil, etc. Use only genuine OEM Hernon replacement parts when servicing this machine tool. Ignoring this warning could cause unintended operation and possible injury.

WARNING: DANGEROUS ULTRAVIOLET EMMISSION (Hernon Part Number: 107-005)

Recommended #5 Green shade goggles for eye protection This equipment is designed to be used properly set up with components correctly connected, and operated in accordance with relevant instructions. Its design was developed to maximize operator safety.

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107-022 Ultracure 6

General Features     

Ultra Violet Energy (UVA) Curing Self-cooled 365nm High Output LED Built-in power regulation and overheating protection Compact design

Specifications Part Number Power Requirements UV Output I/O Port Cooling Dimensions (approx.) System Warranty

107-022 24VDC, 700 mA 2.5 /W cm² (max) @ 365nm 5 pin CPC Fan 6” x 2” x 1.5” 1 year from purchase

NOTE: Power Supply not included.

Figure 1- Ultracure 6 dimensions and mounting specifications.

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107-022 Ultracure 6

Mounting The Ultracure 6 has two mounting options. Four M3 x 0.5 on electrical connector end, and four M2 x 0.4 on the bottom of the device. Refer to Figure 1. When mounting the Ultracure 6, do not to mount directly onto any surface that may obstruct the fan. Hernon recommends using at least a quarter inch (0.25”, 6.35mm) clearance between the mounting surface and the surface of the device; this is to ensure that the Ultracure 6 has optimal airflow for regular operation. NOTE: M3 x 0.5 mounting holes are supplied with fasteners which act as plugs covering and protecting enclosure from dust, dirt or any other debris. 3mm Fastener should never thread in excess of 6mm distance into housing. Extra-long screws may permanently damage electronics. Mounting Examples Below are examples of how to mount the Ultracure 6.

Figure 2- Ultracure 6 back face mounting, M3 x .03

Figure 3- Ultracure 6 bottom face mounting, M2 x .04

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107-022 Ultracure 6

Operation Guidelines Wiring Configurations The Ultracure 6 can be wired with or without status feedback. Quick Install – No Feedback Connect 24VDC as shown for quick install with no feedback.

Pin #2 (Error COM)

Pin #3 (Shutter)

Pin #1 (Error NC)

Pin #4 (-) Pin #5 (+)

Upper Connector Lower Connector

Figure 4 - Ultracure 6 pin connectors, with pins labelled.

Single Unit Wiring with Feedback Status I/O Reference Drawing on next page. The Ultracure 6 unit will turn on under the following conditions: when the Power Supply (PS1) is on, the Switch (SW1) is closed, and shutter relay contacts are open. If the unit has an over temperature error or a burned out LED, the error relay will turn on, opening up the NC contacts.

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107-022 Ultracure 6

The Ultracure 6 unit will turn on/off quickly when the shutter relay contacts are opened/closed. If the shutter relay is not used, leave Pin 3 disconnected and the unit will turn on and off with SW1 only. The cooling fans will be turned off with SW1 as well. DO NOT connect Pin 3 to anything over than 24 RETURN! Status Relay Contacts in each unit are rated for 30VDC and 2A. Multi-Unit Wiring with Feedback Status I/O Reference Drawing on next page. When PS1 is on, switch SW1 is closed and shutter relay contacts are open then all the Ultracure 6 units in the Multiunit loop will turn on. The green LED on each unit will turn on when the units are on. If one of the units has an over temperature error or a burned out LED then that units’ error relay will turn on and the error loop will open. The red LED will turn on when an error is active. The Ultracure 6 units will turn on/off quickly when the shutter relay contacts are opened/closed. If the shutter relay is not used/required then leave Pin 3 disconnected and the units will turn on/off with SW1 only. The cooling fans will be turned off with the SW1 as well. DO NOT connect Pin 3 to anything other than 24 RTN of this multi-unit loop! Status Relay contacts in each unit are rated for 30VDC and 2A.

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System Status/Faults Fault LED (FLT)

Power LED (PWR)

Two status indicator LED’s are located on top of the module. Green lamp: Power on and working properly. Red lamp: Indicates one of the following Fault Conditions:  

LED failure open LED short

Pink lamp: Over temperature  If the fan fails, or the ambient temperature gets too high, an automatic shutdown will protect the LEDs. The LEDs are forced off if the unit temperature reaches 60°C, and will stay off until the substrate cools down to 55°c.

UV Output Curve The Ultracure 6 has an optimal distance for ideal curing properties. The diagram below shows the UV Intensity vs Distance Curve.

Figure 5- UV output curve.

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External I/O Signals The only output signal on the Ultracure 6 is an Error signal from port 2. Refer to Figure 4.

LED Failure In the event that the unit has experienced LED failure: 1. Open the enclosure, via six Philips-head M2 screws.

2. Flip the corresponding dipswitches one at a time, from 1 to 5, until the unit turns back on. The unit will operate properly with one or more inoperable LEDs.

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Maintenance Inspect that the fan is clean before powering up for regular operation. This will ensure a long life of the Ultracure 6. Verify the protective glass is clean.

Frequently Asked Questions Q: Why is my unit turning off by itself? A: The unit has overheated from lack of airflow. Clean the fan. If the problem persists, replace the fan. AA: LED failure, refer to next question for answer. Q: The unit no longer turns on, but the unit is not hot. What happened? A: The unit has experienced an LED failure; this is fixed by opening the driver enclosure and flipping the corresponding dipswitches one at a time (from 1 to 5) until the unit turns back on. The unit will operate properly with one or more inoperable LEDs.

Q: How often should the Ultracure 6 be cleaned? A: The unit should be cleaned prior to every start up. This will ensure a long life of the fan, and the LEDs. Q: How should I clean the fan? A: The fan should be cleaned with bursts of low pressure compressed air, and a light duty brush.

Replacement Parts Below is a list of recommended replacement parts that should be kept on hand in order to minimize machine downtime due to normal wear or unexpected failure. Part Number 102-086 106-135 102-130

Description Fan Protective Glass Connector Cover

Quantity 1 1 2

Price Call For Price Call For Price Call For Price

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107-022 Ultracure 6

Warranty CAUTION! HERNON CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES, EXPRESSED OR IMPLIED, DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON HERNON EQUIPMENT WITHOUT WRITTEN AUTHORIZATION FROM HERNON. THOSE CORRECTIVE ACTIONS LISTED BELOW ARE LIMITED TO THIS AUTHORIZATION. Hernon offers a one-year warranty against defects in material and workmanship on all system components, except the LED/Fan, with proof of purchase date. Unauthorized repair, modification, or improper use of equipment may void warranty. The use of aftermarket replacement parts not supplied or approved by Hernon will void any effective warranties and may result in damage to the equipment.

The data contained in this bulletin is furnished for information only and is believed to be reliable. We cannot assume responsibility for results obtained by others over whose methods we have no control. It is the user’s responsibility to determine suitability for the user’s purpose of any product or methods mentioned herein and to adopt such precautions as may be advisable for the protection of property and persons against any hazards that may be involved in the handling and use thereof. Nothing in this bulletin is to be interpreted as a representation of freedom from domination of patents owned by others or a license under a Hernon patent. We recommend that each prospective user test his proposed application before repetitive use, using the data as a guide.

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107-022 Ultracure 6

Notes

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