AMERICAN ULTRAVIOLET LESCO SUPERSPOT MAX Product manual

SUPERSPOT™
MAX / MAX HP
Model: VSM3002
UV SPOTCURE SYSTEM
100 / 200 WATT
TECHNICAL REFERENCE
MANUAL
AUV\LESCO
A DIVISION OF AMERICAN ULTRAVIOLET COMPANY
WWW.LESCOUV.COM
23555 Telo Avenue
Torrance, CA 90505
1/26/10
This product conforms to
CE Standards
See Appendix B for details
REV.
F

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KMD1042F.DOC 2

KMD1042F.DOC 3

KMD1042F.DOC 4
AUV\LESCO FIBER OPTIC LIGHTGUIDES
WARRANTY POLICY
WARRANTY :
Fiber optic lightguides sold by AUV\LESCO are warranted to be free from defects in material and
workmanship under normal and proper use for 60 days from date of original shipment. This warranty
applies solely to defects in material and workmanship. AUV\LESCO will repair or replace at its option,
any defective fiber optic lightguides when returned to AUV\LESCO by the purchaser, all transportation
paid by the purchaser, within 60 days from date of original shipment. Said lightguides may not be
returned, whether for warranty or other purposes, without a RMA (Return Material Authorization) number.
AUV\LESCO will assume no expense or liability for repairs made outside its plant without written consent
by AUV\LESCO, nor for any labor costs, which are so incurred.
AUV\LESCO will not be liable for any consequential costs or damages of any kind.
CONDITIONS OF WARRANTY:
For above warranty on AUV\LESCO fiber optic lightguides to be enforceable, the purchaser must:
1. Return any lightguides claimed to be defective for inspection and action by AUV\LESCO. All
returns must be pre-authorized, correctly packaged and shipped, accompanied by a RMA
(Returned Material Authorization) number.
2. Keep accurate records of elapsed time, time of installation or removal in sufficient detail, to
determine the running time and environment of the lightguide in question. The purchaser will
allow AUV\LESCO to verify such records if necessary.
The following will void AUV\LESCO’s warranty:
1. Chemical and/or mechanical damage of any kind, damage caused by excessive radiation,
scratching, or damage caused by using the lightguides outside their intended service or their
operating parameters,
2. Defects resulting from improper installation, storage or use,
3. Tampering with equipment,
4. Lack of maintenance,
5. Service not in accordance with AUV\LESCO Technical Reference Manual, or
6. Acts of God.
There are no warranties, expressed or implied, except as stated above or provided in writing by an
authorized AUV\LESCO representative.

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Table of Contents
1.0 General Information ...........................................................................................7
1.1 Scope of Manual.......................................................................................7
1.2 System Description...................................................................................8
2.0 Safety.................................................................................................................9
2.1 Ultraviolet Radiation..................................................................................9
2.2 Power up ................................................................................................10
3.0 Component Descriptions..................................................................................11
3.1 Front Panel .............................................................................................11
3.2 Back Panel..............................................................................................13
3.3 Housing...................................................................................................15
3.4 Special Features.....................................................................................18
3.5 Interior Control Components...................................................................19
4.0 Installation/Start Up..........................................................................................21
4.1 System Components ..............................................................................21
4.2 Bulb Installation ......................................................................................21
4.3 Voltage Setting .......................................................................................23
5.0 Operation .........................................................................................................25
5.1 Max Power Alert Functionality ................................................................25
5.2 Alarm Latching (Al) .................................................................................26
6.0 Calibration ........................................................................................................26
6.1 User Calibration Procedure ....................................................................26
6.2 Calibration Error......................................................................................27
6.3 Terminating Procedure ...........................................................................27
7.0 Serial Communication DataMAX......................................................................28
7.1 Serial Communication.............................................................................28
7.2 Data MAX Interface ................................................................................29
8.0 Maintenance.....................................................................................................30
8.1 Housing...................................................................................................30

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8.2 Optical Components ...............................................................................31
9.0 Drawings/Schematics.......................................................................................34
9.1 Main Schematic ......................................................................................34
9.2 I/O Connector - Parallel Interface ...........................................................41
9.3 Serial Communication.............................................................................43
10.0 Accessories ......................................................................................................46
10.1 Standard Replacement Parts..................................................................46
10.2 Optional Liquid-Filled Lightguides...........................................................46
10.3 Fiber Optic Lightguides...........................................................................46
10.4 Recommended Spare Parts Kit ..............................................................47
11.0 Troubleshooting.................................................................................................49

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Super Spot MAX
1.0 General Information
1.1 Scope of Manual
This manual provides information necessary for operating and maintaining the
AUV\LESCO SUPERSPOT MAX UV spot curing system (the MAX). It also includes safety
requirements and references to pertinent mechanical and electrical drawings.
Throughout this manual, precautions necessary to prevent injury to personnel are
preceded by the heading WARNING; precautions necessary to prevent damage to
equipment are preceded by the heading CAUTION. See examples below.
** WARNING **
(Precautions necessary to prevent injury to personnel)
** CAUTION **
(Precautions necessary to prevent damage to equipment)

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1.2 System Description
The AUV\LESCO SUPERSPOT MAX curing systems are ultraviolet (UV) light sources that
provide an intense concentration of UV light for the purpose of spot curing UV sensitive
materials (photo polymerization).
The MAX is the most powerful UV spot curing system that utilizes a lightguide delivery
method (liquid filled or fiber type). The MAX provides intensities that allow for increased
production speeds unobtainable from other units.
The MAX also incorporates a microprocessor based control platform in addition to other
standard features such as a membrane keypad with digital readout, optical feedback, I/O,
and RS-485 communications capability.
The microprocessor provides many additional benefits for process control and flexibility.
One benefit is to statistically track and time stamp all of the process parameters related to
the UV spot cure process. Some examples of this benefit include: set point intensities,
duration of cure, electrical power to the lamp, and date / time stamp. It also indicates if a
USER CALIBRATION was performed in the system.
The curing information is stored in the battery backup built-in memory and can be
accessed through the serial communications ports, in real time (while the machine is in
operation) and from up to 4,000 feet of CAT5 cable when using the RS485 interface. The
available data can be used for FDA and ISO type certifications, software data logging or
statistical process control.
The communications capability also allows all variable set points to be manipulated through
the AUV\LESCO software interface or a custom written application. When using the
RS485 interface, one remote computer can communicate with up to 99 MAX systems
allowing for easy large-scale production process changes.
The shutter cycle is activated by either a footswitch, a membrane keypad switch or an
automation process control connected to the I/O port. One of the unit’s built in
microprocessors controls the duration of the UV exposure, as well as the time between
exposures and the total number of cure cycles.
The MAX is an intelligent control system designed for clean room operation requiring high
UV output, high-speed operation and high accuracy production applications for worldwide
manufacturing.

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The AUV\LESCO SUPERSPOT MAX features:
•UV intensity for 100 Watt MAX up to 25 Watts in UVA, up to 30 Watts
or more total intensity (Traceable to NIST)
•UV intensity for 200 Watt MAX HP up to 30 Watts in UVA, up to 45 Watts or
more total intensity (Traceable to NIST)
•Optical Feedback for constant intensity and process control
•RS-485 and RS-232 Serial communication ports
•Membrane keypad with digital readouts
•I/O connectors for automation applications
•Distal UV sensor connection port
•Stainless steel housing
•Solid state bi-level power supply
•Liquid filled 1 Meter flexible light-guide with 5mm tip diameter (100W MAX
only)
•Large selection of standard size fiber optic light-guides available, as well as
custom designs.
•Remote footswitch included for automatic operation
•Air-cooled lamp and power supply with ventilation protection
•IR filter for reduced heat transmission
•DataMAX Process Validation software
•Special rubber feet designed for use in clean rooms
2.0 Safety
The AUV\LESCO UV spotcure system has been designed to operate safely. They are
being used in a wide variety of industrial environments worldwide without any worker safety
problems or health hazards. However, this equipment can present worker safety problems
if care is not taken to install and operate correctly.
**WARNING**
It is important that all personnel operating this equipment become familiar with
this safety information.
The following information is provided concerning various aspects of worker safety with this
equipment. All personnel should read this manual to understand the safety issues and
government regulations pertaining to this equipment.
With care in installation and operation, coupled with adequate worker training, no unusual
safety problems should arise.
2.1 Ultraviolet Radiation
Ultraviolet radiation (UV), which is emitted during normal operation of AUV\LESCO
spotcure systems, can be dangerous to the eyes and skin. All personnel within close
vicinity of direct UV light should be required to wear goggles with UV certified lenses or
remain behind UV blocking light shielding. Personnel should also be prevented from

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allowing any skin surface from coming within close proximity of the high intensity light
output(s).
Additionally, it is never advisable to stare directly at any high intensity light source whether
visible or ultraviolet for prolonged periods unless precautions have been taken to reduce both
visible and ultraviolet light to safe levels. Discomfort from excessive eye exposure to UV light
typically occurs about six hours after exposure. Personnel who experience eye pain after
possible exposure to direct UV light should see a doctor immediately. Highly focused
radiation, whether UV or visible light, can ignite paper and similar combustible materials. Care
should be taken to avoid this.
There is no present US government standard on worker exposure to UV light. However,
there is a NIOSH (National Institute for Occupational Safety and Health) document,
"Criteria for a Recommended Standard - Occupational Exposure to Ultraviolet Radiation"
(No. HSM 73-11009), and several useful publications are available from the Bureau of
Radiological Health of the Food and Drug Administration.
2.2 Power up
Always verify the correct voltage setting of the unit before applying power. Damage to the
power supply can occur if wrong voltage is applied even momentarily. The UV bulb may also
be affected. Verify the proper setting following Section 4.3.
** CAUTION **
Disconnect power from system, or unplug system from wall or
VAC power source, before connecting the footswitch adapter.

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3.0 Component Descriptions
3.1 Front Panel
The front panel is a membrane control pad with digital displays and LED indicators. The
keypad controls all the major operating features of the MAX.
3.1.1 Intensity
The digital display and LED’s on the panel’s left side are used to view system intensity in
watts per square centimeter, Joules (total energy, or the value of the process intensity
multiplied by total cure time) and electrical power in watts applied to the bulb.
Lightguide Port/Receptacle
Timer digital display
Shutter activate
Timer select button
ON time
Number of cure
cycles
OFF time
UV digital display
Alarm Reset
Intensity W/cm2
Dosage J/cm2
Power to the bulb in watts
Distal UV sensor
Connector
UV Output Select
Button

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The electric power displayed is the necessary excitation applied to the bulb to achieve the
required intensity. It is a useful indicator to monitor the status of the bulb or its
performance.
The SELECT button is used to change modes. Each time the SELECT button is pressed, a
different LED illuminates the specified mode. The illuminated LED digital readout displays
stored and calculated values of UV output. The directional arrow keys are for adjusting
intensity values.
3.1.2 Time Functions
The digital readout and LED’s on the panel’s right side are used to view the system’s time
functions and settings. The LED’s indicate ON, CURE CYCLES, and OFF selections. The
SELECT button is used to change modes. Each time the SELECT button is pressed, a
different LED will illuminate the specified mode. Using the arrow keys, set your required
value. Holding the arrow keys allows for faster speed.
3.1.3 ON Time
The ON TIME indicates how long the shutter will remain open once activated. The ON
TIME variable can be set by using the directional arrow keys. The presence of three bars (-
- -) in the timer display indicates that the unit is currently in the manual mode, following the
shutter command’s duration.
3.1.4 OFF Time
The OFF TIME is used in conjunction with the cycle timer function and is used to control
the dwell part of the cycle, meaning it controls how long the shutter should wait before it
can re-cycle. The Off time can be changed with the directional arrow keys.
3.1.5 Cycles
CYCLES are used in conjunction with the ON and OFF time. CYCLES is the number of
times that the ON and OFF times will repeat. This mode is very useful in automation and
multiple curing applications where heat is a critical factor. Using the directional arrow keys
can change the cycles. If set below 1, the letters CON in the display indicates continuous
cycling. The unit will repeat the cure cycle continuously. The Alarm reset will stop the
curing cycles.
3.1.6 Lamp Hour Display
Press both Timers UP and DOWN arrow keys simultaneously to display Lamp hours used.
After two seconds, the MAX returns to normal operation.
3.1.7 Alarm Reset
The power alarm gives an audible alert and a flashing LED signal if there are any system
performance problems. The reset button silences the alarm buzzer if the alarm-latching
mode is enabled. It also terminates the calibration procedure (see section 5.0).
3.1.8 Shutter Button
The shutter ACTIVATE button in the lower right corner triggers the shutter or a curing
cycle. It will cancel an operating cycle, if pressed for more than one (1) second.

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3.2 Back Panel
The MAX housing is made of stainless steel, making it ideal for clean room applications. The
following parts and connections are located on the rear of the system.
** CAUTION **
Do not cover chassis ventilation slots.
** CAUTION **
Disconnect power from system or unplug system from wall or
VAC power source before connecting the footswitch adapter.
3.2.1 Cooling Fans
The fan system is used to maintain the optimum temperature of the Lamp while cooling the
optics and electronics. The bottom fan is used for intake and the upper fan is used for
exhaust.
Power Control Switch
I/O Connector
Cooling Fan
Footswitch Connector
RS-485 Connector
RS-232 Connector

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3.2.2 Power Entry Module
It contains the power switch, power cord socket (IEC type), main fuse, and EMI filter.
** WARNING **
For continued protection against risk of fire,
replace only with the same type and rating of fuse.
Input volts Fuse rating
115-120 4A T, 250 VAC, Slow Blow
220-250 2A T, 250 VAC, Slow Blow
3.2.3 Footswitch Connector
A standard stereo phone jack connector is used for the foot pedal plug.
** CAUTION **
Disconnect power from system or unplug system from wall or
VAC power source before connecting the footswitch adapter.
3.2.4 Nine Pin Shielded RS-232 and RS-485 Connectors
Each Nine Pin DB-9 Connector is used for RS-232 and RS-485 interface. Pin connections
can be found in the schematic section.
3.2.5 Seven Pin I/O Connector
The I/O connector is used to monitor the shutter status (open or close), the optical
feedback alert status, bulb ignition status and to trigger the shutter

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3.3 Housing
The MAX housing is made of stainless steel, making the equipment suitable for clean room
operations and allowing for easy cleaning. The housing consists of 3 main sections:
Chassis - The vertical design allows for more efficient use of counter-top space. The
optical assembly is located in the upper compartment. The top cover is secured by four
quarter-turn, captive Phillips head fasteners. The power supply and all the controls and
accessories are located in the bottom housing.
Lamp Housing - The top cover is secured by four quarter-turn, captive Phillips head
fasteners. Removing it allows access to the bulb, reflector, and the IR filter assemblies.
Bottom Cabinet - The bottom side cover is fastened by six Allen head screws. Removing it
allows access to the power supply for voltage setting. There are no serviceable parts
inside.
The housing compartment features a recessed rear panel with air vents on the top and
sides. These vents provide air access to the cooling fans even if the MAX is operated
while pushed all the way against a wall.

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3.3.1 Lamp Housing Compartment
This area contains the optical transmission assembly, bulb, reflector, optical feedback
sensor and electrical lamp connections. The function and relationship of each component
in the lamp housing is described below:
3.3.2 Shutter Assembly
The Shutter Assembly is a shutter plate that is connected to a positive open, spring return,
rotary solenoid for efficient control and safety. The shutter is also connected to an interlock
switch located on the lightguide receptacle where the proximal end of the lightguide is
inserted.
This switch disables the shutter to ensure there is no unintentional exposure if the
lightguide is missing or improperly inserted into the MAX.
Bulb Reflector Sub-Assembly
UV Bulb
UV Bulb Connector Block
Lightguide
Receptacle

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3.3.3 Bulb
The MAX uses a proprietary high-pressure short arc mercury vapor bulb designed for long
life at very high intensity.
3.3.4 Reflector
The reflector is a high precision, first surface elliptical reflector used to gather and focus the
highest concentration of the available energy from the bulb.
3.3.5 Bulb Reflector Sub-Assembly
The Bulb Reflector Sub-Assembly is detachable, and it consists of the bulb holder and an
elliptical metal-formed reflector. The Bulb is optically aligned within the reflector to reflect
the energy through the IR filter to the end of the lightguide.
3.3.6 Bulb Connection
The black lead wire coming from the bulb and the red lead wire from the reflector holder
assembly correspond to the same colored sockets located in the reflector support block.
Please ensure that the black lead wire runs through the access hole on the bottom of the
reflector holder, as pictured below.
Bulb Connection
3.3.7 Optical Feedback Sensor
The optical feedback sensor is located on the bottom of the lightguide receptacle and
operates in a standby mode until the shutter is triggered. This signal is sent to the power
supply located in the lower housing (refer to Section 3.4), which internally monitors the
intensity set point. The power supply will make minor adjustments to maintain that intensity
set point.

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3.3.8 Lightguide Receptacle
The Lightguide Receptacle is a precision mechanical assembly that aligns the bulb, bulb
reflector assembly, and lightguide for optimal focal point location. It also supports the
shutter assembly, optical feedback sensor, lightguide safety switch, and infrared filter.
3.4 Special Features
Here are several special features that can be accessed via the front panel.
3.4.1 Lamp Hours
The current amount of hours the bulb has been running can be displayed and reset to zero.
In order to display the Lamp hours perform the following steps:
a. Press both Timer Up-Down arrow keys at the same time.
b. The Right hand display will show the current running time in hours.
c. To reset the lamp hours to zero press both Timer Up-Down arrow keys at the same
time for approximately 5 seconds.
3.4.2 Front Panel Lockout
The front panel keys can be locked out, inhibiting the user from changing the settings.
There are two ways to achieve this lockout:
1. Through the Front Panel:
a. Press both select keys and the reset key at the same time.
b. When the front panel is locked, the front panel displays LOC for 1 second.
c. When the front panel is unlocked, the front panel displays UL for 1 second.
2. Through the Serial Port Communication:
There are two levels of restriction and must be programmed using the serial interface.
Please see Section 7.1 for further explanation. In order to lock and unlock the front
panel perform the following:
a. Send a Serial command of the form Uaa,L <ENTER> (aa being the address of the
unit) to inhibit the UV and Timer setting functions.
b. Send a command Uaa,A <ENTER> (aa being the address of the unit) to inhibit only
the SHUTTER ACTIVATE button.
c. Send a command Uaa,U <ENTER> to unlock the front panel from either level previously selected.

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3.4.3 Alarm Latching
The High Limit Alarm indicator can be latched on. If an alarm is latched on, it will remain
set on until power is turned off. The Alarm Reset button will silence the beeper sound only.
When the non-latching mode is selected, the Alarm indication (both visual and audible) will
extinguish upon shutter closure. The Alarm Latching mode must be programmed using the
serial interface. In order to latch or unlatch the power alarm performs the following steps:
a. Send a serial command of the form Saa,Y<ENTER> (aa being the unit address)
to set the Alarm Latch Mode.
b. Send a command Saa,N<ENTER> to cancel the Alarm Latching Mode.
Please see section 7.1 for further explanation.
3.4.4 Setting RS485 Address
This serially programmable value sets the unit’s address to allow it to be accessed on an
RS485 network or RS232 interface. The address is a unique number from 0 to 99 (Default
= 0). In order to set the RS485 address performs the following steps:
a. Send a Serial command of the form Eaa,XX <ENTER> aa being the current address of
the unit and XX the new address wishing to program.
b. If the command is sent without a new address, the unit will respond with its current
address to help define its proper location.
The unit will display its current address upon power momentarily during boot up before
turning the lamp on. This parameter will also be available via the serial interface. The initial
print out is an automatic broadcast feature that includes all programmed parameters in
memory.
3.4.5 Display Firmware version Number
This parameter is available via the serial interface, as part of the initial automatic broadcast
feature that includes all programmed parameters in memory.
This simply displays the current version of the firmware. Please consult the factory for
available upgrades or latest releases of firmware.
3.5 Interior Control Components
The interior control system contains the following 3 sub-systems.
3.5.1 Display/CPU Board
The Display/CPU board is located directly behind the front membrane switch panel. It is
protected from direct UV light and EMI by a magnetic stainless steel shield on the back.
The Display/CPU board is connected to the membrane switch panel and provides the
external interface.