Guide to Selecting and Using DYMAX UV Light Curing Systems

Table of Contents
Benefits of Light Curing ......................................................................................................................................................2
Overview of Light-Curing Systems ................................................................................................................................. 3-4
Fundamentals of Light-Curing ............................................................................................................................................5
Designing a Light-Curing Process .......................................................................................................................................6
Light-Curing Spot-Lamp Systems .................................................................................................................................. 7-10
BlueWave® 75 ................................................................................................................................................................7
BlueWave® 200 ..............................................................................................................................................................8
BlueWave® LED Prime UVA ...........................................................................................................................................9
BlueWave® LED VisiCure™ ...........................................................................................................................................10
Light-Curing Spot/Flood-Lamp Systems ..................................................................................................................... 11-12
BlueWave® LED DX-1000 .............................................................................................................................................11
BlueWave® LED DX-1000 VisiCure™ ............................................................................................................................12
Lightguides for Spot Lamp Systems .................................................................................................................................13
Accessories for Spot Lamp Systems .................................................................................................................................14
Light-Curing Flood Lamps ........................................................................................................................................... 15-17
EC-Series Flood Lamp Systems.....................................................................................................................................15
ECE-Series Flood Lamp Systems ...................................................................................................................................16
BlueWave® LED Flood Lamps .......................................................................................................................................17
Accessories for Flood Lamp Systems ......................................................................................................................... 18-19
Light-Curing Conveyor Systems .................................................................................................................................. 20-24
UVCS UV Light-Curing Conveyors ................................................................................................................................20
UVCS SideCure Conveyor Systems ...............................................................................................................................21
Specialty UV-Curing Conveyors (Edge-Cure & WIDECURE) ................................................................................... 22-23
UVCS LED Light-Curing Conveyors ...............................................................................................................................24
Radiometers for Light-Curing Systems ....................................................................................................................... 25-26
Light-Curing Safety ...........................................................................................................................................................27
Setting Up & Monitoring a Light-Curing Process ............................................................................................................28
Maximizing Light-Curing Lamp Performance ...................................................................................................................29
1
Benefits of Light Curing
Light-curing technology has allowed manufacturers to lower
processing costs, produce higher quality products, and
eliminate the use of harmful chemicals from the workplace for
over 30 years. Although each manufacturer will perceive and
realize a unique set of benefits from light curing, there are a
few features/benefits that Dymax customers consistently cite:
Light-Curing
Features
Light-Curing Benefits
■
■
■
■
Fast Light Cures
“On Demand”
■
■
■
■
■
■
■
■
■
One Component
■
No hazardous waste due to
purging/poor mixing
■
No static mixers
■
Easier to operate/maintain
dispensing systems
Better work acceptance
No explosion-proof equipment
Fewer health issues
Reduced regulatory costs
Reduced disposal costs
■
■
Environmentally
& Worker Friendly
Reduced labor costs
Simplified automation
Easier alignment of parts before
cure
Improved
in-line inspection
Reduced work-in-progress
Shorter cycle times
Shorter lead times to customers
Fewer assembly stations required
No racking during cure
No ovens/heat curing
No mixing
No pot life issues, less waste
Less expensive dispensing
equipment
■
■
■
As the only major manufacturer of both light-curable
adhesives and light-curing equipment, we are acutely aware of
the need to match the curing system with the curing
chemistry.
Adhesive samples and light-curing equipment trials allow our
customers to fully evaluate Dymax products prior to purchase.
In addition, our Application Engineering Team is available to
help recommend a light-curable material, a curing system, and
a curing process for your specific application. Whenever
possible our Application Engineers will conduct testing on your
specific parts. If testing indicates our standard formulations or
complete line of light-curing systems are not suitable, we can
help you search for a solution for your assembly process.
This “Guide to Selecting and Using Dymax Light-Curing
Systems” will assist you in selecting the best light-curing
system for your application. It will also help you set up an
efficient and controlled light-curing process. For more
information on Dymax light-curing equipment and adhesives,
please contact our Application Engineers by phone at
860.482.1010 or visit us on the web at www.dymax.com. Your
complete and on-going satisfaction with your light-curing
process is our commitment and our mission.
MAKING MANUFACTURERS MORE EFFICIENT
Realizing the tremendous opportunity for cost savings,
expanded design capabilities, and environmentally “friendly”
bonding and sealing solutions, Dymax introduced UV lightcurable adhesives and coatings to manufacturers in the early
1980’s. Since that time the company has specialized in lightcuring assembly solutions and now offers the broadest range
of light-curable materials available and a complete line of lightcuring equipment. Our materials and curing equipment are
used in a wide range of medical, electronic, industrial,
aerospace, optical, auto-motive, packaging, and appliance
applications.
Visit the Dymax Web site at www.dymax.com to learn more
about our light-curing systems and compatible adhesives.
2
Overview of Light-Curing Systems
SPOT-LAMP SYSTEMS
Dymax spot-lamp systems provide high intensity (up to 17,000
mW/cm2 (320-395 nm)) curing over a small area (typically <½",
5 mm diameter). These intensities usually result in a
0.5-5 second cure time. Available in both UV, visible, and LED
light-curing models, Dymax spot-curing systems utilize an
integral timed/manual shutter and typically require little
external shielding. An intensity adjustment feature aids users
in both validating and controlling a light-curing process.
Spot-lamp systems are ideal for curing small areas quickly and
can be easily integrated into an automated assembly process
or used as a turnkey bench-top systems. Learn more about
Dymax spot-curing lamps on pages 7-10.
BlueWave® 200 Spot-Curing System with
Intensity Adjustment
SPOT/FLOOD-LAMP SYSTEMS
Dymax offers flexible LED light-curing systems which can be
easily configured as a spot lamp or a flood lamp. These units
provides all the benefits of Dymax’s advanced LED light-curing
technology in a flexible system design that can adapt to meet
changing business and application needs. Learn more about
Dymax spot/flood curing systems on pages 11-12.
BlueWave® LED DX-1000 Spot/Flood Lamp System
LIGHT-CURING FLOOD-LAMP SYSTEMS
Dymax light-curing flood-lamp systems offer moderate to high
intensity (75-225 mW/cm2) over a larger area (typically 5" x 5"
or 8" x 8" (127 mm x 127 mm or 203 mm x 203 mm)). UV,
visible, and LED light-curing models are available. These lamps
are ideal for curing areas larger than ½" (12.7 mm) in diameter
or curing many small parts simultaneously.
Dymax light-curing flood-lamp systems can be incorporated
into conveyors, automated assembly systems, or used as
turnkey bench-top units. Learn more about Dymax light-curing
flood-lamp systems on pages 15-17 of this guide.
3
ECE 2000 Flood Lamp with Light Shield and Shutter
Overview of Light-Curing Systems
CONVEYORS
Dymax conveyors incorporate either flood or focused-beam
curing systems. The benefits of light-curing conveyors include
consistent cure times and the ability to cure larger parts.
Conveyors also completely shield operators from UV light.
Dymax conveyors have 12" wide belts, and can be configured
for 6" and 12" width curing with UV flood lamps or 5" and 10"
with LED flood arrays. Conveyor speed is tightly controlled and
typically ranges from 1-32 feet per minute. Dymax light-curing
conveyors can be outfitted with different types of lamps and
up to four lamps on a single conveyor. Learn more about
Dymax light-curing conveyors on pages 20-24.
RADIOMETERS
A radiometer is a device that measures the intensity and/or
dose associated with light of specified wavelengths. UV light is,
by definition, not visible and so a radiometer is required to
determine UV intensity. Dymax’s ACCU-CAL™ radiometers are
ideal for measuring the intensity of spot lamps, flood lamps,
and conveyors. These radiometers measures intensity and
dose in the UVA (320-395 nm) range. The ability to measure
light intensity is useful for three reasons: maintaining a
controlled light-curing process, providing a “worker friendly”
light-curing process, and measuring light-transmission rates
through substrates. Learn more about Dymax radiometers on
pages 25-26 of this guide.
UVCS 12" Wide UV Light-Curing Conveyor with
Two Dymax 5000-EC Flood Lamps
ADDITIONAL CUSTOM EQUIPMENT
This guide contains the most popular Dymax light-curing
systems and radiometers. Additional turnkey equipment and
accessories are available including additional conveyors
(wider, shorter, faster, or higher clearance), dispensing
systems (time/pressure syringe dispensers, and valve/
pressure pot systems), dispensing needles, and more. In some
cases, Dymax will custom design a light-curing system to fit
your specific needs. Contact Dymax directly for more
information regarding custom equipment or additional
equipment not contained in this guide.
ACCU-CAL™ 50 Radiometer
30" Wide UV Light-Curing Conveyor
4
Fundamentals of Light Curing
Developing a successful light-curing process requires
knowledge of the following key concepts.
Higher Intensity = Faster Cures – Intensity is the light energy
reaching a surface per time and it is often measured in
mW/cm2. Higher intensity light (of the proper wavelengths)
will generally provide faster cure.
Shortwave and Longwave Bulbs – Dymax UV light-curing
systems can be outfitted with either shortwave bulbs
(emphasizing UVB and UVC) or longwave bulbs (emphasizing
UVA and visible light). Longwave bulbs are recommended for
curing most Dymax (and similar) light-curing materials due to
their superior depth of cure and substantial visible-light
intensity. The chart at the bottom of this page describes the
portion of the electromagnetic spectrum emitted by standard
Dymax longwave bulbs.
Distance and Substrates Affect Intensity – Distance from a
light-curing lamp always affects intensity. Intensity decreases
with increasing distance from both spot lamps and floodcuring systems, especially spot lamps. Intensity decreases with
increasing distance from the focal point for focused-beam
systems. Intensity is also reduced when curing through
substrates that transmit less than 100% of the light used for
curing. Advances in light-curable adhesive technology now
allow curing through most translucent substrates, even those
that block UV completely.
that curing is complete when further light exposure no longer
improves product properties. Quantitative testing of cured
specimens can be used to determine the minimum exposure
time and/or minimum intensity required for complete cure.
The graph on page 28 shows how this method could be used
in a bonding application.
Shadows – Light-curable materials will not cure unless
exposed to light of appropriate wavelength, intensity, and
duration. For applications where shadowed areas may be an
issue, Dymax offers a line of light-curable materials that are
formulated to also cure over time with heat or moisture.
Oxygen Inhibition – In some cases, light-curable adhesive
surfaces exposed to oxygen during curing may remain tacky
after cure. This is caused by oxygen inhibition. Oxygen in the
air actually slows the cure at the top-most layer of an airexposed coating surface. This tackiness does not necessarily
indicate incomplete cure and can be observed with some
materials, even after complete cure. In general, there are four
ways to minimize or eliminate the tackiness associated with
oxygen inhibition:
■
Longer and/or Higher Intensity Cure – In many cases, curing
longer or with higher intensity will minimize or eliminate a tacky
surface.
■
Use of “Shortwave” Bulb – Use of a UVB (shortwave) bulb instead
of a UVA (longwave) bulb may also help to eliminate surface
tack. A UVB bulb may, however, result in a limited depth of cure.
Limited Depth of Cure – Since light-curable materials themselves absorb light, each has a maximum depth of cure. For
most Dymax products, this depth is between ¼" (6.35 mm) and
½" (12.7 mm).
■
Choose an Alternate Dymax Material – An alternate formulation
may cure “tack free” more readily.
■
Blanket with Inert Gas – Blanketing exposed resin surfaces with
inert gas (like nitrogen or argon) during cure can often eliminate
the problem of oxygen inhibition completely.
Determining Complete Cure – Changing from a liquid to a solid
is a simple definition of cure. A more complete definition is
5
Designing a Light-Curing Process
There are several factors to consider when designing a lightcuring process.
beneath three separate lamps. Brief interruptions during cure
are acceptable.
Intensity – A well-designed light-curing process incorporates a
curing system with excess intensity. Excess intensity provides
both a safety margin and long bulb life. See page 28 “Setting
Up and Monitoring a Light-Curing Process” for specific
intensity and safety margin guidelines.
Safety – Proper equipment set-up and operator training are
the keys to developing a safe light-curing process. Always
follow the operation manual to ensure safe installation. Proper
shielding, protective equipment, and eye protection are
required to ensure a safe light-curing process.
Spectral Output – It is important to match the spectral output
of the lamp to the material and application. Dymax supplies
both shortwave bulbs (also called Mercury or “H”) and
longwave bulbs (also called Metal Halide or “D” bulbs). In
general, longwave bulbs emit primarily UVA providing superior
depth of cure, while shortwave bulbs emit primarily UVB/UVC
providing superior surface cure for coatings and inks.
Longwave bulbs are recommended for most applications
involving Dymax materials.
Controls – Unless exposed to light of sufficient wavelength,
intensity, and duration, most light-curing materials will remain
uncured. To insure a consistent exposure time, timed shutters
are standard on spot lamps and available for most flood and
focused-beam systems. A digital speed controller on Dymax
conveyors insures consistent exposure times.
Curing Area – The size of the area to be cured may dictate
which type of lamp is appropriate. Spot lamps are typically
used to cure areas less than ½" (12 mm) in diameter. Flood or
focused-beam lamps are used when curing large areas (up to
8" x 8" (203 mm x 203 mm)). Multiple flood lamps or
conveyors can be used to cure even larger areas.
Avoid Creating a “Bottleneck” – Ideally, the light-curing
process is designed to be faster than the limiting or
“bottleneck” step in the overall manufacturing process.
Dispensing, assembling, testing, or packaging parts while other
parts are curing will maximize efficiency.
Lamp intensity should be regularly monitored with a
radiometer. Bulb replacement and/or appropriate lamp
maintenance should be conducted when intensity dips below
a pre-determined minimum value.
Bulb Life – The cost of replacement parts can be an important
consideration when selecting a light-curing system. Generally,
low bulb-replacement costs are achieved by selecting a lamp
with intensity to spare, thereby extending allowable bulb life.
Price Per Bulb x Frequency = Bulb Replacement Cost
Curing Multiple Parts Simultaneously – In some cases, it is
more efficient to cure many small parts simultaneously using a
flood or conveyor than to cure each part individually. For
example, a spot lamp may cure one small part every three
seconds (or 20 parts-per-minute) whereas a flood lamp may
cure 20 small parts every 15 seconds (or 80 parts-per-minute).
Multiple Cure Stations – On an automated production line
where the required cure time exceeds the index/cycle time,
multiple cure stations can be used. For example, if a part
requires nine seconds to cure and the index/cycle time is only
three seconds, each part can be cured for three seconds
Dymax Light-Curing Spot Lamps are
Ideal for Automation!
6
Light-Curing Spot-Lamp Systems
BLUEWAVE® 75 WITH INTENSITY ADJUSTMENT
The BlueWave® 75 UV light-curing spot lamp is simple to
operate and is designed for use with light-curable adhesives,
coatings, and encapsulants. The BlueWave 75 is compatible
with a wide array of lightguide options (see Table 1 on page
13). With over 9 W/cm2 in initial UV curing intensity, 1-10
second cures are typical.
Bulbs used in UV light-curing spot lamps degrade with use,
emitting less and less intensity. Prior to production, the
intensity adjustment feature aids users in determining an
acceptable intensity range. Once in production, this feature
can be used to maintain the intensity within the acceptable
range. The BlueWave 75 has a typical bulb life of 2,000 hours.
Intensity Adjustment Options:
BlueWave® 75 UV Light-Curing Spot-Lamp System
This UV light-curing spot lamp includes an integral shutter that
can be actuated by foot pedal. A solid-state power supply
insures consistent operation despite fluctuations in input
voltage. Please refer to Dymax literature #Lit238 for more
information on the BlueWave 75 UV light-curing spot lamp.
BlueWave® 75 UV Light-Curing Spot Lamp Features
Part Number
Intensity adjustment knob
Intensity adjustment, with knob for
fingertip adjustment removed,
performed with adjustment tool
Intensity measurement is easily accomplished with the Dymax
ACCU-CAL™ 50 radiometer. Scheduled intensity measurements taken during the production process will indicate
whether additional intensity adjustments are required. This
method of measurement provides the most accurate readings
as they are taken through the lightguide in the actual
production setting. Please refer to page 25 for more
information on the ACCU-CAL 50 radiometer.
7
North American Version, 120V Plug
40077
Asian Version, Type G Plug
40183
Unit With No Power Cord1
Peak Intensity2
>9,000 mW/cm2
Intensity Adjustment
Manual, 1-100%
Lightguides
See Table 1. on page 14
Curing Area
<½" (12.7 mm)
Shutter
Timed and manual modes; foot pedal
Bulb Warranty
2,000 hours (ignition)
Power Requirements
Auto-switching 90-264V, 47-63 Hz
1 Contains
2
40078
the appropriate power cord for Europe
As measured through a 5-mm liquid lightguide with a Dymax ACCU-CAL™ 50
(320-395 nm)
Light-Curing Spot-Lamp Systems
BLUEWAVE® 200 3.0 WITH INTENSITY ADJUSTMENT
The BlueWave® 200 3.0 UV light-curing spot lamp offers the
highest intensity and most user-friendly operation in the
industry. The BlueWave 200 3.0 spot lamp primarily emits UVA
and blue visible light (300-450 nm) and is designed for UV lightcuring of adhesives, coatings, and encapsulants. With over 17
W/cm2 in initial bulb UVA curing intensity, 0.5-5 second cures
are typical.
Bulbs used in UV light-curing spot lamps degrade with use,
emitting less and less intensity (see Chart 1). Prior to
production, the intensity adjustment feature aids users in
determining an acceptable intensity range. Once in
production, this feature can be used to maintain the intensity
within the acceptable range.
BlueWave® 200 3.0 Spot-Curing System with Intensity Adjustment
BlueWave® 200 UV Light-Curing Spot Lamp Features
Peak Intensity2
41015 North American Version, 120V Plug
41014 Asian Verison, Type G Plug
41013 Unit With No Power Cord1
>17,000 mW/cm2
Intensity Adjustment
Manual, 1-100%
Lightguides
See Table 1. on page 14
Curing Area
<½" (12.7 mm)
Shutter
Bulb Warranty
Timed and manual modes; foot pedal or
PLC controlled
2,000 hours (ignition)
Power Requirements
Auto-switching 90-264V, 47-63 Hz
Part Numbers
Intensity Adjustment Options:
1 Contains
the appropriate power cord for Europe
2 As
Intensity measurement is easily accomplished with the Dymax
ACCU-CAL™ 50 radiometer. Scheduled intensity measurements taken during the production process will indicate
whether additional intensity adjustments are required. This
method of measurement provides the most accurate readings
as they are taken through the lightguide in the actual
production setting. Please refer to page 25 for more
information on the ACCU-CAL 50 radiometer.
The BlueWave 200 3.0 contains an integral shutter which can
be actuated by a foot pedal or PLC making it ideal for both
manual and automated processes. A universal power input
provides consistent performance at any voltage (100-240V, 5060 Hz). For more information on the BlueWave 200 3.0, please
see Dymax literature #PB035.
Dymax also offers a wide range of long-lasting lightguides and
the BlueWave 200's high intensity makes the lamp ideal for use
with multi-pole lightguides (see Table 1. on page 13).
New Intensity Adjustment Feature
Typical bulb degradation curve
Intensity
Intensity can be adjusted with the adjustment knob or with a screwdriver
measured through a 5-mm liquid lightguide with a Dymax ACCU-CAL™ 50
radiometer (320-395 nm)
New Intensity Control Feature
Users are now able to maintain a constant Intensity by manually controlling how
much light is transmitted through the lightguide.
0
500
1000
Bulb Life (Hours)
1500
2000
8
Light-Curing Spot-Lamp Systems
BLUEWAVE® LED PRIME UVA
The BlueWave® LED Prime UVA high-intensity spot-curing lamp
is designed for rapid curing of various coatings as well as
adhesive bonding of metal, glass, polycarbonate, PVC, PET, and
many other substrates. This simple-to-operate spot lamp
emits over 15 W/cm2 of UV curing intensity and features an
intensity adjustment control from 0-100%. The BlueWave LED
Prime UVA is compatible with a wide array of lightguide
options (see Table 1 on page 13).
The BlueWave LED Prime UVA spot-curing lamp includes an
electronic exposure control circuit that can be actuated by foot
pedal or PLC. A solid-state power supply ensures consistent
operation despite fluctuations in input voltage. Low initial
cost, long-lasting lightguides, and over 20,000-hour LED life
makes the BlueWave LED Prime UVA an extremely economical
spot-curing system. Please refer to Dymax literature Lit267 for
more information on the BlueWave LED Prime UVA spot-curing
system.
BlueWave® LED Prime UVA Spot-Curing Lamp Features
Part Numbers
North American Version, 120V Plug
40950
Asian Version, Type G Plug
40960
Unit With No Power Cord1
Peak Intensity2
>15 W/cm2
Intensity Adjustment
Manual, 0-100%
Lightguides
See Table 1. on page 14
<½” diameter (12.7 mm)
Curing Area
LED Life
Timed and manual modes; foot pedal or
PLC controlled
Up to 20,000 hours
Power Requirements
Auto-switching, 100-240 VAC, 47-63 Hz
Shutter
1 Contains
2
40322
CURING WITH LIGHT EMITTING DIODES (LEDS)
The BlueWave® LED Prime UVA spot-curing lamp generates
curing energy using high-intensity LEDs. LEDs offer many
advantages over conventional bulbs including constant
intensity, no required warm-up time, and a life span of over
20,000 hours. The relatively narrow frequency band produced
by LEDs also generates cooler curing temperatures making this
unit ideal for use with thermally sensitive substrates.
the appropriate power cord for Europe
As measured through a 5-mm liquid lightguide with a Dymax ACCU-CAL™ 50
LED radiometer
9
BlueWave® LED Prime UVA Spot-Curing Lamp System
BlueWave® LED Prime UVA Spectral Distribution
Light-Curing Spot-Lamp Systems
BLUEWAVE® LED VISICURE™
The BlueWave® LED VisiCure™ high-intensity spot-curing
system generates curing energy using high-intensity LEDs. The
LEDs produce visible light energy in a relatively narrow
wavelength band centered at 405 nm, as contrasted to a
typical broad band, high-pressure UV bulb (300-500 nm). This
system emits maximum light intensity output through a 5-mm
diameter lightguide, and allows users to adjust intensity
output from 0% to 100%.
BlueWave® LED VisiCure™ Spot-Curing Lamp Features
Part Numbers
41062
North American Version, 120V Plug
41063
Asian Version, Type G Plug
41064
Unit With No Power Cord1
Peak Intensity2
>15 W/cm2
Intensity Adjustment
Manual, 0-100%
Lightguides
See Table 1. on page 14
Curing Area
<½” diameter (12.7 mm)
Shutter
Timed and manual modes; foot pedal or
PLC controlled
LED Life
Up to 20,000 hours
Power Requirements
Auto-switching, 100-240 VAC, 50-60 Hz
1 Contains
2
the appropriate power cord for Europe
As measured with an ACCU-CAL™ 50-LED Radiometer and lightguide
simulator.
BlueWave® LED VisiCure™ Spot-Curing Lamp System
CURING WITH LIGHT EMITTING DIODES (LEDS)
The BlueWave LED VisiCure spot-curing lamp generates curing
energy using high-intensity LEDs. LEDs offer many advantages
over conventional bulbs including constant intensity, no
required warm-up time, and a life span of up to 20,000 hours.
The relatively narrow frequency band produced by LEDs also
generates cooler curing temperatures making this unit ideal
for use with thermally sensitive substrates.
Relative Intensity
The BlueWave LED VisiCure lamp includes an electronic
exposure control circuit that can be actuated by foot pedal or
PLC. A solid-state power supply ensures consistent operation
despite fluctuations in input voltage. Low initial cost, longlasting lightguides, and up to 20,000-hour LED life makes the
BlueWave LED VisiCure an extremely economical spot-curing
system. Please refer to Dymax literature #PB038 for more
information on the BlueWave LED VisiCure spot-curing system.
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
300 320 340 360 380 400 420 440 460 480 500
Wavelength in nm
BlueWave® LED VisiCure™ Spectral Distribution
10
Light-Curing Spot/Flood-Lamp Systems
BLUEWAVE® LED DX-1000
The Dymax BlueWave® LED DX-1000 is a flexible LED lightcuring system that utilizes liquid-filled or fiber-optic quartz
lightguides to deliver up to 15 W/cm2 of curing energy in a
spot-cure configuration. The flexibility of the DX-1000 also
allows it to be configured to deliver up to 1 W/cm2 of energy
over a 1" x 1.5" (2.5 cm x 3.8 cm) area for applications that
require larger exposure area.
The BlueWave LED DX-1000 provides all the benefits of
Dymax’s advanced LED light-curing technology in a flexible
system design that can adapt to meet changing business and
application needs. Please refer to Dymax literature #Lit284 for
more information on the BlueWave LED DX-1000 curing
system.
BlueWave® LED DX-1000 Curing System Features
Flood
Mode
Spot
Mode
Lab
Developer
Base
System
North American Version,
120V Plug
40760
40990
41020
-
Asian Version, Type G
Plug
40580
40590
41010
-
40750
40980
41000
40560
Unit with No Power
Cord1
Output2
Power Requirements
1 Contains
2
Flood Mode: 1.0
emission
[W/cm2]
Flood Mode Package - includes controller, irradiator head,
collimating optic #1, bench-top stand with silicone pad,
magnetic shielding, footswitch, and interface cable.
at 1.0" in direct
Spot Mode: 15.0 [W/cm2] at 0.5" with 5
mm x 1 M liquid lightguide
100-240V, 47-63 Hz (auto ranging); 100
Watts maximum
the appropriate power cord for Europe
As measured by a Dymax ACCU-CAL™ 50 LED radiometer
Base System - includes irradiator head with collimating optic
#1, controller, footswitch, and magnetic shielding.
11
Lab Developer Package - includes controller, irradiator head,
2 interface cables, lightguide adapter, collimating optic #1,
bench-top stand with silicone pad, bench-top base, 5-mm
lightguide, footswitch, and magnetic shielding.
Spot Mode Package - includes controller, irradiator head, 5mm lightguide, lightguide stand, lightguide adapter,
footswitch, interface cable, lightguide mounting stand, and
bench-top base.
Light-Curing Spot/Flood-Lamp Systems
BLUEWAVE® LED DX-1000 VISICURE™
The BlueWave LED DX-1000 VisiCure is a flexible LED lightcuring system which produces visible light energy in a
relatively narrow wavelength band centered at 405 nm. This
system utilizes liquid-filled or fiber-optic quartz lightguides to
deliver up to 15 W/cm2 of curing energy in a spot-cure
configuration. It can also be configured to deliver up to
1 W/cm2* of energy over a 1" x 1.5" (2.5 cm x 3.8 cm) area for
applications that require larger exposure area.
The BlueWave LED DX-1000 VisiCure provides all the benefits
of Dymax’s advanced LED light-curing technology in a flexible
system design that can adapt to meet changing business and
application needs. Please refer to Dymax literature #PB039 for
more information on the BlueWave LED DX-1000 VisiCure
curing system.
Lab Developer Package - includes controller, irradiator head,
2 interface cables, lightguide adapter, collimating optic #1,
bench-top stand with silicone pad, bench-top base, 5-mm
lightguide, footswitch, and magnetic shielding
Flood Mode Package - includes controller, irradiator head,
collimating optic #1, bench-top stand with silicone pad,
magnetic shielding, footswitch, and interface cable
BlueWave® LED DX-1000 VisiCure™ Curing System
North American Version,
120V Plug
Asian Version, Type G Plug
Flood
Mode
Spot
Mode
Lab
Developer
Base
System
41049
41053
41057
-
41048
41052
41056
-
41047
41051
41055
41046
1
Unit with No Power Cord
Output2
Flood Mode: 1.2
direct emission
[W/cm2]
at 1.0" in
Spot Mode: 15.0 [W/cm2] at 0.5" with
5 mm x 1 M liquid lightguide
Power Requirements
1 Contains
2 As
100-240V, 47-63 Hz (auto ranging);
100 Watts maximum
the appropriate power cord for Europe
Spot Mode Package - includes controller, irradiator head,
5-mm lightguide, lightguide stand, lightguide adapter,
footswitch, interface cable, lightguide mounting stand, and
bench-top base
measured by a Dymax ACCU-CAL™ 50 LED radiometer
Base System - includes irradiator head with collimating optic
#1, controller, footswitch, and magnetic shielding
12
Lightguides for Spot Lamp Systems
LIGHTGUIDES
Lightguides transmit UV and visible light from a source
mounted inside of a spot-curing unit to the curing area. There
are several factors to consider when choosing a lightguide.
Length – Lightguides are commonly one meter long although
other lengths are available.
Curing Area/Intensity vs. Distance – The UV and visible light
emitted from a lightguide diverges. As a result, intensity
decreases and curing area increases with distance from the
end of the light guide. The chart below describes this
relationship clearly for the 5-mm liquid lightguide.
Diameter – Single-pole lightguides are available with 3-mm,
5-mm, or 8-mm inside diameters. Although the 5-mm
lightguide will register a higher intensity, the 8-mm lightguide
provides more curing power (intensity x area) because a larger
lightguide opening captures more of the light emitted from the
bulb. Each pole of a multi-pole lightguide has an inside
diameter of 3 mm.
Multiple Poles – Light emitting from a spot lamp can be
channeled through a single lightguide (single pole) or split
between multiple lightguides (multiple poles). Each pole of a
multi-pole lightguide emits equal intensity (typically  10% for
liquid-filled lightguides) and all share a common shutter. Both
liquid-filled and quartz-fiber multi-pole lightguides are
available from Dymax.
Connection – There are basically two types of connectors used
in the spot lamp industry, “Wolf” and “D” connectors. Dymax
provides lightguides with both connector types, although “D”
connectors are an industry standard and compatible with
current Dymax lamp designs (older Dymax designs utilized
“Wolf” connectors).
Table 1 – Lightguides Compatible with BlueWave ® 75/200/LED Prime UVA /LED VisiCure™/DX-1000/DX-1000 VisiCure™
Part Number
Lightguide Description
(all noted are liquid filled; quartz fiber are also available)
5720
Single pole
5 mm x 1 Meter
5721
5722
38476
38477
38478
Single pole
Single pole
Two pole
Three pole
Four pole
5 mm x 1.5 Meters
8 mm x 1 Meter
3 mm x 1 Meter
3 mm x 1 Meter
3 mm x 1 Meter
13
Accessories for Spot Lamp Systems
SPOT ACCESSORIES
PROTECTIVE EYEWEAR
There are a number of accessories available for the Dymax
BlueWave® spot-curing systems. Please contact Dymax
Application Engineering for more information on the
accessories featured below.
Dymax recommends that operators using Dymax equipment
wear UV protective eyewear. All Dymax eye protection blocks
>99.9% of UV.
Description
ACCU-CAL™ RADIOMETERS – See pages 25-26
LIGHTGUIDES – See page 13
Part Number
Clear
Dark
35284
35286
Tinted
35285
LIGHTGUIDE MOUNTING STANDS
Dymax’s lightguide mounting
stand utilizes a 24" flexible
arm for mounting 3-mm, 5mm, and 8-mm lightguides.
This stand offers a 5" x 5"
(127 mm x 127 mm) working
area and allows repeatable,
hands-free spot curing.
PN 39700
Also available is Dymax’s
acrylic lightguide mounting
stand. Multiple lightguides
can be securely mounted on
this stand for repeatable,
hand-free spot curing.
PN 41325
LIGHTGUIDE TERMINATORS
ROD LENSES
Turn a spot into a flood lamp
with shutter! A rod lens refocuses the UV light emitted
from a spot lamp so as to
create a very uniform (<5%
variation) 2" x 2" (50.8 mm x
50.8 mm) or 5" x 5" (127 mm x 127 mm) curing area. These
rod lenses attach to the UV light-curing spot system using an
8mm lightguide (sold separately). Intensities listed are those
associated with the BlueWave® 200 UV light-curing spot lamp.
Description
Part Number
2" x 2" (50.8 x 50.8 mm) Area (100 W/cm2)
38699
5" x 5" (127 x 127 mm) Area (30 mW/cm2)
38698
Lightguide terminators can be attached to the end of a
lightguide to help users get UV light to those difficult-to-reach
locations.
Description
Part Number
3 mm/60
3 mm/90
5 mm/60
5 mm/90
8 mm/60
39029
8 mm/90
39030
38042
38049
39334
39333
14
Light-Curing Flood-Lamp Systems
EC-SERIES FLOOD LAMP SYSTEMS
Dymax UV light-curing flood-lamp systems are ideal for light
curing large parts or curing many small parts simultaneously.
With intensities ranging from 75-225 mW/cm2, Dymax flood
lamps are capable of curing most UV light-curable adhesives,
sealants, and coatings, tack free in 30 seconds or less. These
flood lamps can be incorporated into automated assembly
systems or mounted onto conveyors. Dymax flood units can
also be used as turnkey bench-top units (with optional
shutters). Please refer to Dymax literature #Lit206 for more
information on UV light-curing flood-lamp systems.
5000-EC Flood Lamp System
(Shown with ZIP™ Shutter & EC Light Shield)
Part Number for Various Lamp/Shutter/Shielding Combinations
2000 EC
Description
5000 EC
North American
Power Cord with 120V Plug
2000-EC Flood Lamp Modular
2000-EC
Modular (No Shielding or Shutter)
38105
38100
With Mounting Stand
39730
39830
With EC Light Shield
39720
39820
With EC Light Shield & Manual Shutter
39723
39823
With EC Light Shield & ZIP™ Shutter
39721
39821
5000-EC
Typical Initial
Intensity Output1
75 mW/cm2
225 mW/cm2
Curing Area
8" x 8"
(20.3 cm x 20.3 cm)
5" x 5"
(12.7 cm x 12.7 cm)
Working Distance
2" - 6" (5.08 cm – 15.24 cm)
Typical Degradation
< 20% over 2,000 hours
Power Requirements
90-265V, 50-60 Hz
1 At
UVA (365 nm). Intensity readings vary widely depending on the make and
model of the radiometer. These intensities were measured with the ACCUCAL™ 50 radiometer.
The intensity generated by Dymax flood systems is very consistent.
Bulb degradation of less than 10% over the first 1,000 hours is typical
(on/off every eight hours). More frequent on/off cycles will accelerate
bulb degradation.
2000-EC and 5000-EC UV light-curing flood lamps spectral
distribution using a standard metal halide bulb (PN 38560)
15
Light-Curing Flood-Lamp Systems
ECE FLOOD LAMP SYSTEMS
Dymax UV light-curing flood-lamp systems are ideal for light
curing large parts or curing many small parts simultaneously.
With intensities ranging from 105-225 mW/cm2, Dymax flood
lamps are capable of curing most UV light-curable adhesives,
sealants, and coatings, tack free in 30 seconds or less. These
flood lamps can be incorporated into automated assembly
systems or mounted onto conveyors. Dymax flood units can
also be used as turnkey benchtop units (with optional
shutters). Please refer to Dymax literature #PB024 for more
information on UV light-curing flood-lamp systems.
Typical Initial
Intensity Output1
ECE 2000
ECE 5000
105 mW/cm2
225 mW/cm2
8" x 8"
(20.3 cm x 20.3 cm)
Curing Area
ECE 2000 Flood Lamp System
(Shown with ZIP™ Shutter & ECE Light Shield)
5" x 5"
(12.7 cm x 12.7 cm)
Working Distance
2" - 6" (5.08 cm – 15.24 cm)
Typical Degradation
< 20% over 2,000 hours
Power
Requirements
100 - 240 VAC +/-10% Single Phase
47 – 63 Hz
1 At
UVA (365 nm). Intensity readings vary widely depending on the make
and model of the radiometer. These intensities were measured with the
ACCU-CAL™ 50 radiometer.
Part Number for Various Lamp/Shutter/Shielding Combinations
ECE 2000
Description
No Power
Cord*
ECE 5000
Asian
Version,
North
American,
Type G
Power Cord
Power Cord
with 120V Plug
No Power
Cord*
Asian
Version,
North
American,
Type G
Power Cord
Power Cord
with 120V Plug
Modular (No Shielding or Shutter)
40965
40995
40985
40915
40935
40925
With Mounting Stand
40920
41180
41170
40970
41140
41130
With ECE Light Shield
40870
41200
41190
40900
41160
41150
With ECE Light Shield & Manual Shutter
40790
40860
40810
40850
41100
40940
With ECE Light Shield & ECE ZIP™ Shutter
40830
41060
41040
40840
41050
41030
* For customers in Europe, the appropriate power cord is added.
16
Light-Curing Flood-Lamp Systems
DYMAX BLUEWAVE® LED FLOOD CURING SYSTEM
The BlueWave® LED Flood System offers high-intensity curing
energy over a 5" x 5" (12.7 cm x 12.7 cm) area. Cure times in
the 5-30 second range are typical when using Dymax lightcurable materials. This unit is simple to operate and can be
used as a stand-alone system or easily integrated into
automated assembly systems. Dymax offers the system with
three different wavelength arrays (365, 385, and 405 nm) so
users can fully optimize the curing process between their lightcurable material and the curing system.
The BlueWave® LED Flood System offers all the benefits of LED
light-curing technology including more consistent intensity,
less energy consumption, a shutter-free design, instant on/off,
and cooler curing temperatures. Please refer to Dymax
literature #PB041 for more information on the BlueWave LED
Flood.
SYSTEM UNIFORMITY
BlueWave® LED Flood Lamp Features
Part Numbers
PrimeCure™
385 nm
VisiCure™
405 nm
RediCure™
365 nm
No Power Cord
41261
41260
41262
Asian/Type G Cord
41290
41291
41289
Noorth America/
Cord with 120V Plug
41287
41288
41292
850 mW/cm2
950 mW/cm2
TBD
Typical Initial
Output Intensity2
Curing Area
Power
Requirements
5” x 5” (127 mm x 127 mm)
100 – 240 VAC 50/60Hz (Auto-Ranging)
1
Contains the appropriate power cord for Europe
2
When measured at 25mm distance with an ACCU-CAL™ 50 LED radiometer
in Flood mode
CURING WITH LIGHT EMITTING DIODES (LEDS)
The BlueWave® LED flood lamp generates curing energy using
high-intensity LEDs. LEDs offer many advantages over
conventional bulbs including constant intensity, no required
warm-up time, and a life span of over 20,000 hours. The
relatively narrow frequency band produced by LEDs also
generates cooler curing temperatures making this unit ideal
for use with thermally sensitive substrates.
17
BlueWave® LED Flood Lamp System Shown with VisiCure™
Array and Standard Mounting Stand
When compared to other LED units, the BlueWave® LED Flood
provides much higher intensity and more overall uniformity
across the active area. These benefits allow shorter cure times,
and in turn, faster manufacturing throughput.
The following graph illustrates the Dymax BlueWave® LED
Flood’s high uniformity when multiple arrays are positioned
next to each other. This is especially important in conveyor
applications to ensure a consistent cure across the entire
substrate.
BlueWave® LED Flood with
Two VisiCure™ Arrays (Mounted Face-to-Face)
Accessories for Flood Lamp Systems
Dymax light-curing flood lamps can be outfitted with the
shutters and shielding shown below. Additional shutters,
enclosures, and accessories may be available.
SHUTTERS
MOUNTING STANDS
Standard Mounting Stand Kit – A simple and cost effective
mounting stand with adjustable height. For use with the
BlueWave® LED Flood. PN 41268
Turning a bulb off and on between cycles is not practical since
each off/on cycle shortens bulb life and requires a 5-minute
warm-up period. A shutter, however, can be used to shield a
flood system between cycles. Shutters control exposure time,
reduce heat on the work surface, and shield operators from
exposure to UV light. There are two types of shutters pictured
below. Both ZIP™ and manual shutters are compatible with
Dymax flood lamps.
ZIP™ Shutter – Timed and manual modes. Foot pedal or PLC
controlled.
PN 37863 – Compatible with EC Floods
PN 40885 – Compatible with ECE Floods
Premium Mounting Stand Kit – Easily adjustable, self-locking
mounting stand. For use with the BlueWave® LED Flood.
PN 41294
Mounting Stand Kits – Cost-effective, mounting stand and 3sided shielding. Not compatible with Dymax shutters. For use
with Dymax EC- and ECE-series flood lamps.
Manual Shutter – Most cost-effective shutter system.
Compatible with both EC and ECE flood lamp systems.
PN 35572
PN 38290 – Mounting Stand Kit, 2000 EC or ECE
PN 38289 – Mounting Stand Kit, 5000 EC or ECE
18
Accessories for Flood Lamp Systems
SHIELDING
Dymax offers several standard shielding options for flood
lamps. All shields are 100% UVA blocking and visibly tinted.
Light Shield – 360 shielding with lifting door and sliding curing
shelf. Compatible with Dymax shutters.
PN 41175 – Light Shield (EC Systems)
PN 40785 – ECE Light Shield
Acrylic Shield – A simple and cost effective 3-sided shield that
is removed manually. Compatible with the BlueWave® LED
Flood. PN 41395
19
Light-Curing Conveyor Systems
UVCS UV LIGHT-CURING CONVEYORS
The standard Dymax conveyor platform, the UVCS series, has
a belt width of 12" (304.8 mm) and can be outfitted with a
number of different UV light-curing systems (as shown below).
Belt speed is accurately measured using an optical encoder
and displayed on a digital LCD. The UVCS series conveyors are
completely shielded. The Dymax 5000-EC and Fusion® F300S
curing systems listed below are described in more detail on
pages 12 and 14, respectively. Please refer to Dymax literature
#Lit051A for more information on UV light-curing conveyor
systems.
Advantages of Dymax UV Light-Curing Conveyors
■
■
■
■
■
Multiple flood or focused-beam configurations
available
12" belt width (wider conveyors are also available)
Up to 10" clearance available (with optional risers)
Accurate belt speed (using an optical encoder)
1-27 fpm (faster conveyors are available)
Two Dymax 5000-ECs mounted on a
Dymax UVCS 12" conveyor platform
Overall Dimensions for All UVCS Conveyors
■
■
■
50.5" (128 cm) long
16.4" (42 cm) tall
29.8" (76 cm) wide (from control panel to rear of
blower)
5000-EC Lamps
Part Number
One
5000-EC1
Two 5000-ECs
(Series)1
Two 5000-ECs
(Parallel)
Four 5000-ECs
(Parallel)
One Fusion
F300S1
Two Fusion
F300S (Parallel)
390602
390702
390802
391002
39150
39160
Belt Width
12"
Width of Illuminated Area
Maximum UVA Intensity
(320-390 nm)
Maximum UVA Energy
(320-390 nm @ 5 fpm (J/cm2)
Shipping Weight with Crates (lbs.)
Belt Speeds (feet per minute)
1These
2These
Fusion F300S Lamps
12"
6"
12"
6"
225 mW/cm2
1.5
390
3
1.5
410
12"
2,500 mW/cm2
3
450
5
475
1-27 fpm
580
1-27 fpm
conveyors have center-mounted lamps and are supplied with removable guides to channel parts into the middle 6" of conveyor.
conveyors require 120 volts. 230 volt conveyors are also available.
20
Light-Curing Conveyor Systems
UVCS SIDECURE CONVEYOR SYSTEMS
The Dymax UVCS SideCure conveyor system is designed for the
UV curing of Dymax adhesives and coatings from the left, right,
and/or top. The SideCure conveyor can be outfitted with up to
eight 5000-EC UV curing flood lamps that offer complete
shielding from UV light and consistent exposure times. The
conveyor’s 12" wide belt and 5" high side-curing capability
makes the SideCure a very versatile UV curing solution. The
SideCure conveyor is ideal for masking, medical, and electronic
applications where 180° UV curing is required. Please refer to
Dymax literature #Lit201 for more information on SideCure
conveyor systems.
Advantages of SideCure Conveyors
■
■
■
■
Dymax UVCS SideCure conveyor system
Left, right, and top curing capability
12" belt width (guides available to channel parts into
center 6")
Adjustable top lamp height and side lamp position
Accepts parts up to 36" x 12" x 7" (L x W x H)
UVCS SideCure with TWO Side Lamps
(lamps sold separately)
Part Number
39767
39766
39939
39941
Voltage (VAC)
120V
220/230V
120V
220/230V
Amperage (Not including lamps)
1.6A
0.8A
1.6A
0.8A
Lamps (SideCure 5000-ECs PN 39798)
Up to six (sold separately)
Width of Area Illuminated From Top
5000-EC Maximum UVA Intensity1
(320-390 nm)
6" or 12" (depending upon # and orientation of lamps) (15 cm to 30 cm)
Up to eight (sold separately)
225 mW/cm2
Side Lamp Adjustment
From 3.5" to 6" off center (9 cm to 15 cm)
Top Lamp Adjustment
From 6.25" to 9" off the belt (16 cm to 23 cm)
Maximum Parts Height
7" (17.8 cm)
Belt Speeds (feet per minute)
Belt Width
Overall Dimensions (L x W x H)
(Not including lamps)
1
21
UVCS SideCure with FOUR Side
Lamps (lamps sold separately)
Measured using an ACCU-CAL™ 150 radiometer
1-27 fpm
12" (30.5 cm)
51" x 30" x 21.5" (130 cm x 76 cm x 55 cm)
Light-Curing Conveyor Systems
SPECIALTY UV-CURING CONVEYORS
Edge-Carry Conveyor Systems
Dymax Edge-Carry conveyors are designed for efficient curing
of UV and/or visible light-sensitive adhesives, inks, and
coatings. These conveyors can be outfitted with a variety of
lamp configurations to address a variety of application specific
requirements. They offer complete shielding from UV light and
consistent cure times. Configuration options allow flexibility
when defining intensity requirements to keep operating costs
to a minimum. Standard height clearance is 0.75" across the
entire 18" width, which is ideal for low profile parts such as
PCBs, and up to 6 inches across a 13.75" width, which can be
increased to either 8" or 12" with optional risers installed.
Please refer to Dymax literature #PB023 for more information
on Edge-Carry conveyor systems.
Dymax Edge-Carry Conveyor
Advantages of Edge-Carry Conveyors
Multiple flood or focused-beam configurations
available
Chain rail width is easily adjusted to accommodate
parts widths up to 18”
Adjustable lamp-to-part distance
Adjustable speed of 1-32 fpm
■
■
■
■
2000/1200
EC LAMPS
5000-EC LAMPS
Part Number
40324
40328
40325
40329
Maximum Chain Spacing
Width of Illuminated Area
2
40334
40332
40335
40333
11
40336
40280
11
11
2
FW
CM
CM
CM
FW
6"
12"
9"
9"
6"
12"
100
400
2,500
0.1
0.4
2
1.25
2.50
Belt Speeds (feet per min.)
2
4
200
Maximum UVA Energy
(320-390 nm) @ 5 fpm
(J/cm2)
Amperage
40331
CM
Maximum UVA Intensity
(320-390 nm), mW/cm2
1These
40327
18"
21
Orientation2
Voltage (VAC)
40275
18"
11
Number of Lamps
Lamp
40326
FUSION F300
LAMPS
115V
208240V
115V
9.6
4.8
17.6
1.25
1-32 fpm
208115V
240V
8.8
17.6
2.50
208240V
115V
208240V
8.8
33.6
16.8
1-32 fpm
1-32 fpm
115 or 208-240V
208-240V
16
32.6
conveyors have center-mounted lamps and are supplied with removable guides to channel parts into the middle 6" of conveyor.
CM = center mounted, FW = full width
22
Light-Curing Conveyor Systems
SPECIALTY UV-CURING CONVEYORS
WIDECURE Conveyor
18" and 25" WIDECURE UV light-curing conveyors offer fast,
consistent UV curing of large parts. Dymax WIDECURE
conveyors run 4-50 feet per minute and can be outfitted with
either a longwave bulb (for most Dymax materials) or a
shortwave bulb (for inks). No stray UV light, durable
construction, tightly controlled line speed, and 5" to 12"
adjustable lamp heights make these conveyors very
production friendly.
Advantages of WIDECURE Conveyors
WIDECURE Conveyor
■
■
■
■
■
■
Powerful UV-curing lamps with two bulb options
(shortwave or longwave)
Curing widths of 18” or 25”
Line speeds from 4-50 fpm
Easily adjustable lamp-to-belt distance (5”-12”)
Integral vacuum hold-down and cooling system
Complete light containment
SPECIFICATIONS
Custom Conveyors
Looking for a wider conveyor, shorter conveyor, or one with
more clearance? Dymax can custom design a conveyor to your
specifications. Contact Dymax for more information on
customized conveyors.
18" CONVEYOR
25" CONVEYOR
39380
39381
Part Number
Bulb Curing Length
18" (45.7 cm)
25" (63.5 cm)
Peak Intensity
900
Bulb Degradation
<20% degradation over 750 hours
UV Lamp Type
400 Watts per inch (metal halide (standard) or mercury)2
Reflector Type
Non-focused; 4" (10.2 cm) curing width
Belt Width
25-⅞" (65.7 cm)
Adjustable from 35" to 41" (88.9 cm to 104.1 cm)
Belt Material / Speed
Teflon-coated fiberglass / Adjustable 4-50 fpm
Digital readout; 0.1 fpm increments; 2% accuracy
Maximum Belt Load
Overall Dimensions (L x W x H)
30 lbs. (13.61 kg)
126" x 38" x 71"
(320 cm x 97 cm x 180 cm)
Clearance and Lamp Height
UV Lamp Electrical Requirements
Conveyor Electrical Requirements
3
32-⅞" (83.5 cm)
Belt Working Height
Speed Control
2
nominal1
4.0 J/cm2 nominal1
Energy @ 5 fpm
1
mW/cm2
Adjustable from 5" to 12" (12.7 cm to 30.5 cm)
VAC3,
220
60 Hz, 50 Amps,
Single phase plus ground
110 VAC, 60 Hz, 15 Amps
Measured with an EIT Power Puck (320-395 nm) radiometer at a lamp height of 5"
Can also be outfitted with mercury bulbs (shortwave, UVB, "H" type) for UV inks
Other UV lamp voltages are available upon request (208V, 420V, 460V)
23
126" x 45" x 71"
(320 cm x 114 cm x 180 cm)
220 VAC3, 60 Hz, 80 Amps,
Single phase plus ground
Light-Curing Conveyor Systems
UVCS LED LIGHT-CURING CONVEYORS
Dymax LED light-curing conveyor systems offer consistent,
fast, safe, and efficient LED curing of widths up to 10" in a 12"
wide parts width platform. These conveyors are designed for
curing LED-curable adhesives, coatings, and inks that react in
the UVA and/or UVV spectral ranges.
Consistent line speed, lamp height, and intensity together
provide a consistent curing process. These conveyors do not
emit stray light and can be outfitted with one or two 365, 385,
or 405 nm lamps positioned in either in-line or side-by-side
configurations as required by the application.
Two BlueWave LED flood arrays mounted on a
Dymax UVCS 12" conveyor platform
Features of Dymax LED Light-Curing Conveyors
■
Consistent LED curing
■
Complete LED shielding
■
Adjustable lamp-to-belt distance
■
Conveyor speeds of 1-32 fpm
■
Integral cooling and vacuum hold-down
RediCure™ 365 nm Array
PrimeCure™ 385 nm Array
VisiCure™ 405 nm Array
Part Numbers
Power Cord w/120 V Plug
Asia Type G Power Cord
41343
41345
41344
41346
41353
41355
41354
41356
41363
41364
41465
41366
-
41347
-
41348
-
41357
-
41358
-
41367
-
41368
Technical Specifications
LED Array Voltage
Conveyor Voltage
120V
230V
90V to 260V
120V
230V
120V
230V
90V to 260V
120V
230V
120V
230V
120V
230V
# of Lamps
1
2
1
2
1
2
Width of Illuminated
Area1
5"
CM – 5"
FW – 10"
5"
CM – 5"
FW – 10"
5"
CM – 5"
FW – 10"
Belt Speeds
1-32 feet per minute
Belt Width
12"
Vertical Clearance
4" (Standard), 6" (with 2" riser, PN 39218), 10" (with 6" riser, PN 39280)
Overall Dimensions
(L x W x H)
50.5" x 29.8" x 16.4" (128 cm x 76 cm x 72 cm)
Maximum Intensity2
1
90V to 260V
TBD
850 mW/cm2
950 mW/cm2
CM = center mounted, FW = full width
readings vary widely depending on the make and model of the radiometer. These are typical output intensities measured with the ACCU-CAL™ 50-LED
Radiometer.
2 Intensity
24
Radiometers for Light-Curing Systems
A radiometer is a device that measures the intensity and/or
energy associated with light of specified wavelengths. UV light
is, by definition, not visible and so a radiometer is required to
determine UV intensity. Dymax offers the ACCU-CAL™ 50 for
spots, floods, and conveyors. The ability to measure light
intensity is useful for three reasons:
1.
2.
3.
Maintaining a light-curing process – A radiometer can
measure whether a light-curing system is providing
intensity above the “bulb change” intensity. A radiometer
is to a light-curing process what a thermometer is to a
heat-curing process.
Providing a worker-friendly light-curing process – A
radiometer is required to determine if any UV light is
reaching operators or bystanders.
Measuring transmission rates through substrates – A
radiometer can be used to measure the transmission rates
of various wavelengths through substrates that absorb UV
and/or visible light. To assure an effective curing process
it is critical to measure the light intensity reaching the
light-curable material below the intervening substrate.
ACCU-CAL™ 50 RADIOMETER
Dymax’s ACCU-CAL 50 is capable of measuring both the UV
intensity (mW/cm2) and dose (J/cm2) emitted from spot
lamps*, flood lamps, and conveyors. This easy-to-use
radiometer is compatible with 3-mm, 5-mm and 8-mm
lightguides and only requires re-calibration once per year.
Please refer to Dymax literature #Lit159 for more information.
ACCU-CAL™ 50 RADIOMETER
Part
Number
Measures
Intensity
Resolution
Battery Life
39561 – UVA; compatible with all lamps
except spot lamps*
ACCU-CAL™ 50 Radiometer
ACCU-CAL™ 50-LED RADIOMETER
Dymax’s ACCU-CAL 50-LED can measure energy levels emitted
from 3-mm, 5-mm, and 8-mm lightguides and LED flood lamps.
This radiometer has a spectral sensitivity range of 350-450 nm
and an intensity measurement from 1 W/cm2 to 40 W/cm2,
making it ideal for measuring LED curing-source energy levels.
A specially designed photo-sensor assembly provides
repeatable measurements and protection from high
temperatures associated with some LED systems on the
market. Please refer to Dymax literature #Lit276 for more
information.
ACCU-CAL™ 50-LED RADIOMETER
Part
Number
Measures
Intensity
Resolution
Battery Life
40505 –compatible with LED spot and
flood units
40519 – compatible with LED flood and
conveyor units
Intensity (mW/cm2); 350-450 nm (UVA)
1-40 W/cm2
0.001 W/cm2 or 3 significant figures
250 Hours
39560 – UVA; compatible with all lamps;
includes lightguide simulator and
attachments*
Intensity (mW/cm2); 320-395 nm (UVA)
0-35 W/cm2
0.001 W/cm2 or 3 significant figures
100 Hours
*Part #39560 includes lightguide attachments, part #39561 does not.
ACCU-CAL™ 50-LED Radiometer
25
Radiometers for Light-Curing Systems
ACCU-CAL™ 50-V RADIOMETER
ACCU-CAL™ 150 RADIOMETER
The ACCU-CAL 50V radiometer is simple to operate and offers
repeatable measurement of visible light. The ACCU-CAL 50V
can measure visible light energy emitted from lightguides
(3 mm, 5 mm, and 8 mm), flood systems, and conveyors. With
a spectral sensitivity from 395 to 465 nm (blue portion of the
visible spectrum), the ACCU-CAL 50V measures intensities
from 1 mW/cm2 to 40 W/cm2. A specially designed photo
sensor assembly protects the photo sensor from the high
temperatures sometimes associated with today’s highintensity spot lamps. Please refer to Dymax literature #Lit236
for more information.
Dymax’s ACCU-CAL 150 can measure UV light up to 10 W/cm2
emitted from stationary light-curing flood lamps or lamps used
in conveyorized processes. This radiometer can be used to
determine intensity (mW/cm2) or total energy as derived from
intensity and exposure time (mJ/cm2). Calibration is
recommended every six months to ensure proper operation of
the radiometer. Please refer to Dymax literature #Lit290 for
more information.
ACCU-CAL™ 50V RADIOMETER
Part Number
40044 – Visible; for measuring floods
and conveyors
40043 – Visible; compatible with all
lamps; includes lightguide simulator and
attachments
Measures
Intensity
Resolution
Calibration
Period
Intensity (mW/cm2); 395-465 nm
1 mW/cm2 - 40 W/cm2
1 mW/cm2 or 3 significant figures
Battery Life
250 hours (automatic shutoff after 1 hour)
12 months
ACCU-CAL™ 150 Radiometer
ACCU-CAL™ 150 RADIOMETER
Part Number
40550 – compatible with UV light-curing
flood lamps and conveyor systems
40629 – Optional Data Download Kit1
Measures
Intensity
Resolution
Accuracy
Calibration
Period
Intensity (mW/cm2); 320-390 nm (UVA)
0.01 W/cm2 - 10 W/cm2
0.001 W/cm2 or 3 significant figures
± 10%, ± 5% typical
Battery Life
20 hours with display on
(automatic shutoff after 2 minutes)
1
6 months
Allows data capture and download to PC
ACCU-CAL 50V Radiometer
26
Light-Curing Safety
Dymax ultraviolet light-curing technology has been used
successfully for over 30 years. The fast cure, one-component
nature of our UV light-curing technology has made it the
process of choice for many manufacturers requiring a “Cure on
Demand” assembly process. There are three common
questions/concerns related to UV light-curing systems: UV
exposure, ozone, and bright visible light.
SHIELDING THE SOURCE OF UV
Any substrate that blocks UV light can be used as a shield to
protect workers from stray UV light. The following materials
can be used to create simple shielding structures or blind
corners:
■
Sheet Metal – Aluminum, steel, stainless steel, etc.
Sheet metal should be coated black or black anodized to
minimize reflection of UV and visible light.
■
Rigid Plastic Film – Transparent, UV-blocking plastics
(typically polycarbonate or acrylic) are commonly used
to create shielding where transparency is also desired.
These rigid plastic films are available either water-clear
or tinted, (to reduce visible light glare).
■
Flexible Film – UV-blocking, flexible urethane films can
be used to quickly create workstation shielding. This UVblocking, flexible urethane film is available from Dymax.
UV EXPOSURE
Standard Dymax UV light-curing systems and bulbs have been
designed to primarily emit UVA light1. UVA light is generally
considered the safest of the three UV ranges: UVA, UVB, and
UVC. Although OSHA does not currently regulate ultraviolet
light exposure in the workplace, the American Conference of
Governmental Industrial Hygienists (ACGIH) does recommend
Threshold Limit Values (TLVs) for ultraviolet light. The
strictest interpretation of the TLV (over the UVA range) for
workers’ eyes and skin is 1 mW/cm2 (intensity), continuous
exposure. Unless workers are placing bare hands into the
curing area, it is unusual to exceed these limits. To put
1 mW/cm2 limit into perspective, cloudless summer days in
Connecticut regularly exceed 3 mW/cm2 of UVA light and also
include the more dangerous UVB light (primarily responsible
for sun burns) as well.
The human eye cannot detect “pure” UV light, only visible
light. A radiometer should be used to measure stray UV light
to confirm the safety of a UV light-curing process. A
workstation that exposes an operator to more than 1 mW/cm2
of UVA continuously should be redesigned. UV adhesive light
curing can be a regulatory-compliant, “worker-friendly”
manufacturing process when the proper safety equipment and
operator training is utilized. There are two ways to protect
operators from UV exposure: Shield the operator and/or
shield the source.
SHIELDING THE OPERATOR
■
UV-Blocking Eye Protection – UV-blocking eye protection
is recommended when operating UV light-curing systems.
Both clear and tinted UV-blocking eye protection is
available from Dymax.
■
UV-Blocking Skin Protection – Where the potential exists
for UV exposure upon skin, opaque, UV-blocking clothing,
gloves, and full face shields are recommended.
27
OZONE
Standard Dymax bulbs (UVA type) generate an insignificant
amount of UVC and therefore essentially no ozone1. Some UV
light-curing systems, like those used to cure UV inks, emit
primarily “shortwave” (UVB and UVC) energy. Upon exposure
to UVC light (specifically <240 nm), oxygen molecules (O 2) split
into oxygen atoms (O) and recombine with O2 to create Ozone
(O3). The current, long-term ozone concentration limit
recommended by ACGIH, NIOSH, and OSHA is 0.1 ppm
(0.2mg/m3).
BRIGHT, VISIBLE LIGHT
The bright, visible light emitted by some UV light-curing
systems may be objectionable to some workers and may cause
eyestrain. Tinted eye protection and/or opaque/tinted
shielding can be utilized to address this concern.
SUMMARY
UV light sources can be more “worker friendly” than many
commonly accepted industrial processes, provided the
potential concerns are addressed. Contact your Dymax
representative for information regarding the proper use of
Dymax UV light-curing systems.
1Dymax
also provides special order “shortwave” bulbs that emit primarily UVB and UVC
light. Contact Dymax directly for information regarding the use of “shortwave” bulbs.
Setting Up & Monitoring a Light-Curing Process
There are two parameters that must be considered to ensure
a successful light-curing process, 1) intensity at the curing
location and 2) cure time. Dymax recommends setting up and
monitoring a UV light-curing process as follows:
1.
Choose a Light-Curing Material (LCM) – Select an LCM
that satisfies the performance requirements of the
application.
2.
Determine available light-cure time – Determine the cure
time available so that the UV curing process is not a
“bottleneck” in the manufacturing process. For example,
if dispensing and assembly requires 12 seconds per part in
a one piece flow process, the maximum available cure
time is 12 seconds. For a light-curing conveyor, determine
the minimum line speed required.
3.
Choose a light-curing system – Choose the appropriate
light-curing system that will fully cure the LCM within the
cure time available. Dymax Applications Engineering can
help you identify the best light-curing system for a specific
application.
4.
Determine the lowest acceptable intensity – The lowest
acceptable intensity is that which fully cures the LCM in
the available cure time (determined above). The lowest
acceptable intensity can be determined through
quantitative testing of parts cured at various intensities as
shown in the diagram to the right. In the case of a
focused-beam lamp on a conveyor, determine the lowest
acceptable dose‡, not intensity.
5.
Monitor and maintain intensity – Using a radiometer,
monitor the UV light intensity at the bond line. If the
intensity reaches the “bulb change” intensity, install a new
bulb or conduct appropriate maintenance (see page 29
“Maximizing Lamp Performance”). In the case of a
conveyor, dose (not intensity) should be monitored.
If the resulting cure process is causing heat damage, a
cooling fan or shorter cure time is recommended. If the
resulting bulb life is too short, a longer cure time or higher
intensity lamp is recommended.
‡Both
residence time and intensity varies with lamp height on conveyors with
focused-beam lamps. For this reason, it is better to monitor dose (J/cm2) on
these systems rather than intensity. The most practical way to artificially
lower the dose on these systems is to adjust the line speed.
The following techniques may be used to artificially
modify intensity to facilitate determining the lowest
acceptable intensity.
■
Increase distance – Since light emitting from lightcuring lamps diverges, the intensity decreases as the
distance from the lamp increases. This is especially
useful for flood lamps.
■
Adjust Intensity – Some UV light-curing systems (like
the BlueWave® 200 with intensity adjustment
feature) allow users to adjust intensity.
Note: As with any manufacturing process, it is advisable
to operate with a safety factor. Dymax recommends a
“bulb change” intensity that is 50-100% higher than the
“lowest acceptable intensity”.
28
Maximizing Light-Curing Lamp Performance
There are three ways to maximize lamp performance:
1.
Proper Set-Up – The first key to maximizing lamp
performance is proper set-up. Reference the operation
manual provided with each Dymax lamp for instructions
on proper set-up. After ignition, wait five (5) minutes
before use to allow the lamp to reach full intensity. Then,
use the following techniques to maximize intensity at the
curing location.
■
Spot-Cure Systems – Maximize curing intensity by
minimizing distance from the end of the lightguide to
the light-curable material, while still covering the
curing area. Positive airflow can prevent those vapors
commonly emitted during cure from condensing on
the end of a lightguide. Be aware that excessive
bending, clamping, or set-screw tightening can
damage lightguides. The minimum bend radii for
standard lightguide diameters are as follows:
■
■
■
2.
3-mm lightguides – 40-mm bend radius
5-mm lightguides – 60-mm bend radius
8-mm lightguides – 100-mm bend radius
■
Flood Lamps – Minimize distance from the bottom of
the flood housing to the light-curable material. Note
that distances 3" (76.2 mm) or more from the lamp
housing provide the most uniform intensity across the
curing area.
■
Focused-Beam Lamps – Place light-curable material
at the focal point of the focused-beam lamp for
maximum intensity. The focal distance for the
Fusion® F300S is 2.1" (53.34 mm) below the lamp
housing.
Optimizing Bulb Life – The intensity of light being emitted
from UV bulbs gradually decreases with usage (except in
the Fusion F300S). This degradation cannot be avoided,
but it can be minimized through proper operation.
The longest bulb life is obtained by simply using the lamp
continuously (not turning it off). The more often the lamp
is cycled on and off, the more quickly the bulb degrades.
The general rule of thumb is to leave the lamp on if it will
be used again within an hour.
29
Once ignited, do not turn the lamp off for at least five
minutes. Turning the lamp off before it has reached its
operating temperature can damage the bulb. In addition,
do not attempt to re-start a UV light-curing system until it
has been allowed to cool for five (5) minutes.
3.
Proper Maintenance – As with all production equipment,
routine maintenance will optimize performance. In the
case of a spot lamp, keep the end of the lightguide clean
and replace it if it no longer transmits enough light (a
lightguide simulator is available from Dymax to help
determine lightguide transmission).
See Lit#069
Lightguide Simulator for more information on lightguide
and bulb maintenance. In the case of a flood lamp, the
reflector and lamp base (sockets that the bulb fit into)
should be cleaned and/or replaced as necessary. Please
refer to the user guide for each light-curing system for
further guidance on proper maintenance.
30
FREE DYMAX EQUIPMENT EVALUATION
Contact your Dymax representative to initiate rental of Dymax UV light-curing
equipment. The highlights of the Dymax Trial Rental/Lease program are:
■
■
■
■
Two (2) weeks free evaluation and 3% per week thereafter
Eight (8) weeks of rental fees are deducted from the price at purchase
50% of additional rental fees are deducted
Customer pays shipping both ways
© 2005-2014 Dymax Corporation. All rights reserved. All trademarks in this guide, except where noted, are the property of, or used under license by Dymax Corporation, U.S.A.
Please note that most dispensing and curing system applications are unique. Dymax does not warrant the fitness of the product for the intended application. Any warranty applicable to the product, its application and use is strictly limited to that contained in
Dymax’s standard Conditions of Sale. Dymax recommends that any intended application be evaluated and tested by the user to insure that desired performance criteria are satisfied. Dymax is willing to assist users in their performance testing and evaluation by
offering equipment trial rental and leasing programs to assist in such testing and evaluations. Data sheets are available for valve controllers or pressure pots upon request.
LIT010A 7/102014
Dymax Corporation
860.482.1010 | [email protected] | www.dymax.com
Dymax Oligomers & Coatings
860.626.7006 | [email protected] | www.dymax-oc.com
Dymax Asia (H.K.) Limited
+852.2460.7038 | [email protected] | www.dymax.com.cn
Dymax Europe GmbH
+49 (0) 611.962.7900 | [email protected] | www.dymax.de
Dymax UV Adhesives & Equipment (Shanghai) Co. Ltd.
+86.21.37285759 | [email protected] | www.dymax.com.cn
Dymax Asia Pacific Pte. Ltd.
+65.6752.2887 | [email protected] | www.dymax-ap.com
Dymax Engineering Adhesives Ireland Ltd.
+353.1.231 4696 | [email protected] | www.dymax.ie
Dymax UV Adhesives & Equipment (Shenzhen) Co. Ltd.
+86.755.83485759 | [email protected] | www.dymax.com.cn
Dymax Korea LLC
+82.2.784.3434 | [email protected] | www.dymax.com/kr