dymax Edge-Carry User manual

Dymax Edge-Carry Conveyor User Guide
UV Light-Curing Conveyor System
▪Instructions for Safe Use
▪Setup and Operation
▪Maintenance
▪Ordering Spare Parts and Accessories

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Dymax Edge-Carry Conveyor User Guide
About Dymax
UV/Visible light-curable adhesives. Systems for light curing, fluid dispensing, and fluid packaging.
Dymax manufactures industrial adhesives, light-curable adhesives, epoxy resins, cyanoacrylates, and activator-cured adhesives.
We also manufacture a complete line of manual fluid dispensing systems, automatic fluid dispensing systems, and light-curing systems.
Light-curing systems include LED light sources, spot, flood, and conveyor systems designed for compatibility and high performance
with Dymax adhesives
Dymax adhesives and light-curing systems optimize the speed of automated assembly, allow for 100% in-line inspection, and increase
throughput. System designs enable stand-alone configuration or integration into your existing assembly line.
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 the Dymax
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.

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Dymax Edge-Carry Conveyor User Guide
Contents
Introduction....................................................................................................................................................4
Introduction to the User Guide ....................................................................................................................................... 4
Where to Get Help .......................................................................................................................................................... 4
Safety..............................................................................................................................................................4
General Safety Considerations ........................................................................................................................................ 4
Dymax UV Light-Curing System Safety Considerations ................................................................................................... 5
Product Overview ...........................................................................................................................................7
Description of the Edge-Carry Conveyor ......................................................................................................................... 7
Specifications..................................................................................................................................................8
General............................................................................................................................................................................ 8
Electrical Specifications ................................................................................................................................................... 9
Physical Specifications..................................................................................................................................................... 9
Unpacking..................................................................................................................................................... 12
Unpacking and Inspecting Your Shipment..................................................................................................................... 12
Parts Included in the Edge-Carry Conveyor................................................................................................................... 12
Setup and Interconnect................................................................................................................................. 12
Conveyors Using Dymax EC-Series Flood Lamps ........................................................................................................... 12
Conveyors Using Fusion Flood Lamps............................................................................................................................ 15
Belt Speed Adjustment.................................................................................................................................................. 18
Conveyor Configurations............................................................................................................................... 19
2A Lamp Configuration: Two 5000-EC Lamps In-Line.................................................................................................... 19
2B Lamp Configuration: Two 5000-EC Lamps Side-By-Side........................................................................................... 19
Four 5000-EC Lamp Configuration................................................................................................................................. 20
Single 2000-EC or 1200-EC Lamp Configuration............................................................................................................ 20
Dual Fusion Lamp Configuration ................................................................................................................................... 20
Single Fusion Lamp Configuration ................................................................................................................................. 21
Conveyor Operation...................................................................................................................................... 22
Operating Instructions for Conveyors Using Dymax 5000-, 2000-, Or 1200-EC Lamp Systems..................................... 22
Operating Instructions for Conveyors Using Fusion Lamp Systems .............................................................................. 25
Maintenance................................................................................................................................................. 26
Chain Carrier Position Adjustment ................................................................................................................................ 26
Chain Tension Adjustment ............................................................................................................................................ 26
Troubleshooting............................................................................................................................................27
Spare Parts and Accessories.......................................................................................................................... 28
EC-Series Flood Lamp Replacement Parts ..................................................................................................................... 28
Fusion Lamp Replacement Parts ................................................................................................................................... 29
Conveyor Replacement Parts/Accessories .................................................................................................................... 29
Definition of Terms....................................................................................................................................... 30
Warranty ...................................................................................................................................................... 31
Index............................................................................................................................................................. 31

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Dymax Edge-Carry Conveyor User Guide
Introduction
Introduction to the User Guide
This guide describes how to use the Dymax Edge-Carry Conveyor. Sections in this guide describe how to
assemble, use, and maintain the conveyor safely and efficiently.
Intended Audience
Dymax prepared this user guide for experienced process engineers, technicians, and manufacturing personnel.
If you are new to UV light curing and do not understand the instructions, contact Dymax Application
Engineering to answer your questions before using the equipment.
Where to Get Help
Dymax Customer Support and Application Engineering teams are available in the United States, Monday
through Friday, from 8:00 a.m. to 5:30 p.m. Eastern Standard Time. You can also email Dymax at
[email protected]. Contact information for additional Dymax locations can be found on the back cover of this
user guide.
Additional resources are available to ensure a trouble-free experience with our products:
◼Detailed product information on www.dymax.com
◼Dymax adhesive Product Data Sheets (PDS) on our website
◼Material Safety Data Sheets (MSDS) provided with shipments of Dymax adhesives
Safety
WARNING! If you use this light-curing system without first reading and understanding the
information in this user guide, injury can result from exposure to high-intensity light. To reduce
the risk of injury, read and ensure you understand the information in this user guide before
assembling and operating a Dymax UV conveyor system.
To use this conveyor system safely, it must be set up and operated in accordance with the
instructions given by Dymax. Using the system in any other manner will impair the protection of
the system. Dymax assumes no liability for any changes that may impair the protection of the
system.
General Safety Considerations
The Edge-Carry conveyor is designed to maximize operator safety and minimize exposure to light-curing
energy. To use the unit safely, it must be set up and operated in accordance with the instructions in this user
guide. All users of Dymax equipment should read and understand this user guide before assembling and using
the equipment.
!

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Dymax Edge-Carry Conveyor User Guide
To learn about the safe handling and use of light-curable formulations, obtain and read the MSDS for each
product. Dymax includes an MSDS with each adhesive sold. In addition, fluid product MSDS can be requested
through the Dymax website.
Dymax UV Light-Curing System Safety Considerations
Dymax UV 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. Operators must understand these four concepts to use the UV light
source safely: UV exposure, high-temperature surfaces, ozone, and bright, visible light. Each is described
below.
UV Exposure
Standard Dymax UV light-curing systems have been designed primarily to emit UVA energy (Figure 1). UVA
energy is generally considered the safest of the three UV ranges: UVA, UVB, and UVC. Although OSHA does not
currently regulate UV light exposure in the workplace, the American Conference of Governmental Industrial
Hygienists (ACGIH) does recommend Threshold Limit Values (TLVs) for ultraviolet light.
The strictest interpretation of the TLV (over the UVA range) for workers’ eyes and skin allows continuous
exposure up to 1 mW/cm2(intensity). Unless you are placing bare hands into the curing area, it is unusual to
exceed these limits. To put 1 mW/cm2limit into perspective, a cloudless summer day will typically exceed
3 mW/cm2of UVA light, and also include the more dangerous UVB light (primarily responsible for sun tans,
sun burns, and skin cancer) as well.
Figure 1. UV Spectrum
Checking the Workstation
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/cm2of UVA continuously should be redesigned.
Protecting Operators
Light-curing technology 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.

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Dymax Edge-Carry Conveyor User Guide
Shield 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.
Shield 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 —Sheet metal (aluminum, steel, stainless steel, etc) should be coated black or black anodized to
minimize reflection of UV and visible light toward operators.
Rigid Plastic Film —Transparent or translucent/UV-blocking plastics (typically polycarbonate or acrylic) are
commonly used to create shielding where some level of transparency is also desired. These rigid plastic films
are available wither water clear or tinted.
Flexible Film —UV-blocking, flexible urethane films can be used to quickly create workstation shielding. This
UV-blocking, flexible urethane film is available from Dymax, call for assistance.
High-Temperature Surfaces
Surfaces exposed to high-intensity curing lights may rise in temperature. The intensity, distance, exposure
time, cooling fans, and composition of the surface can all affect the rise in surface temperature. In some cases,
exposed surfaces can reach temperatures capable of producing a burn or causing damage to a substrate. In
these cases, care must be taken to ensure either a more moderate surface temperature or appropriate
protection/training for operators.
Ozone
Standard Dymax lamps (UVA type) generate an insignificant amount of UVC and therefore essentially no
ozone. 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 (O2) split into oxygen
atoms (O) and recombine with O2to create ozone O3. The current, long-term ozone concentration limit
recommended by ACGIH, NIOSH, and OSHA is 0.1 ppm (0.2 mg/m3).
Bright, Visible Light
The bright, visible light energy emitted by UV light-curing systems can cause eye strain if proper eye protection
or shielding is not used. The proper use of tinted eye protection and/or opaque/tinted shielding can be utilized
to reduce eye strain and 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.

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Dymax Edge-Carry Conveyor User Guide
Product Overview
Description of the Edge-Carry Conveyor
The Edge-Carry UV light-curing conveyor system is designed to provide reliable and consistent processing of
UV/Visible light-reactive adhesives and coatings. The conveyor is available in a 120 or 200-240 volt model.
Dymax 5000-EC, 2000-EC, 1200-EC Series or Fusion microwave lamps may be installed on either voltage
model. Standard features include a direct drive motor, an integrated adjustable cooling system, and an
adjustable chain carrier. The conveyor is designed for bench- or table-top operations. The self-contained
cooling system and integral UV light shielding allow it to be placed virtually anywhere space permits.
Dymax UV light sources are capable of curing a wide variety of UV-curable adhesives, coatings, and inks. They
have extensive use in a variety of applications such as bonding, potting, sealing, and encapsulating. These light
sources offer exceptional versatility and expandability to accommodate most process demands.
A large number of accessories are available for the base conveyor. These items address safety as well as
functional flexibility which is depicted and discussed in this manual.
Figure 2. Conveyor with Dymax Lamps Installed
Figure 3. Conveyor with Fusion Lamps Installed

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Dymax Edge-Carry Conveyor User Guide
Specifications
General
For Systems Using Dymax EC-Series Flood Lamps
▪A solid-state lamp power supply that allows external electrical inputs and provides power to the lamp
located in the lamp/reflector assembly housing. The power supply contains the on/off power switch and
hour meter that are located on the left side of the front panel. The power supply also houses its own
cooling fans and power distribution for optional accessories. The rear panel has an integrally fused AC
Power Receptacle, and a 14-pin female amp connector.
▪The solid-state lamp power supply yields reliable and stabilized lamp voltage in virtually any electrical
system in the world. No other adjustment or settings are required other than ensuring a properly wire
configured plug is employed to the system. The power supply also conditions the electrical power to the
lamp providing longer, more reliable lamp life.
▪A lamp/reflector assembly housing (refer to drawing on specific models) which contains the reflector, UV
lamp, lamp bases, high-voltage starter, and one circular connector.
▪Connection cable between the power supply and lamp/reflector assembly housing.
▪A power cord.
▪400 Watt metal halide UV lamp, optional mercury vapor (PN 36970), or visible-spectrum lamps
(PN 36658) are available upon request.
For Systems Using Fusion Lamps
▪A transformer-based lamp power supply that allows external electrical inputs and provides power to the
microwave lamp located in the reflector assembly housing. The power supply contains the on/off power
switch, control, and interlock circuitry. The power supply also houses its own cooling fans. The rear panel
has an AC power receptacle and connections for the lamp, conveyor interlocks, and slave unit control.
▪The lamp power supply allows adjustment for different voltage and frequency conditions suitable for
virtually any electrical system in the world. Switching between 50 and 60 HZ frequency operation requires
movement of capacitor jumpers in the power supplies. See the fusion lamp technical manual for specific
instructions.
▪A power cord.
▪Fusion “D” lamps (PN 36399) are standard. “H” lamps (PN 36441) and “V” lamps (PN 38146) are available
upon request.

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Dymax Edge-Carry Conveyor User Guide
Electrical Specifications
Table 1. Electrical Requirements
Property
Specification
Conveyor Voltage
Requirements
115 or 220 VAC, 50 or 60 HZ
Conveyor Current
Requirements
See Table 5
Lamp/Power Supply Input
Voltage
100-240 VAC (continuous) Dymax lamp systems
208-240 VAC Fusion lamp systems
Input Current
See Table 6 for individual model numbers
Conveyor & Lamp Total Input
Current
See Table 7
Physical Specifications
Table 2. Physical Requirements
Property
Specification
Model*
UVCS Edge Carry
Cure Width
Up to 12 inches (305 mm)
Number of Lamps
One Dymax 1200-EC or 2000-EC lamps; Up to four Dymax 5000-EC lamps
Up to two Fusion F300 series lamps
Motor Drive
Direct
Chain Speed
1.0 –32.0 FPM (0.304 –9.73 m/min.)
Chain Speed (Special Order)
0.5 FPM –32 FPM (0.15 –9.73 m/min)
Chain Speed Display
Red digits, 1 decimal place
Lamp Focus Adjustment
4.0" - 7.5" (102 -191 mm)
Maximum Part Height
6 inches ( 152 mm)**
Exhaust System
1 integral centrifugal blower
*Sixteen different configurations of conveyor are available. Table 3 and Table 4 show all of the possible choices.
** Larger part heights are achievable with the installation of optional riser kits.
The Edge-Carry Conveyor has an adjustable chain width. Different lamp installations can irradiate between 6"
and 12" of that width.

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Dymax Edge-Carry Conveyor User Guide
Table 3. Model Number Structure
Conveyor Model
Lamp Mfg.
Lamp Model
Lamp Quantity
Power
Edge Carry (EC)
Dymax (D)
5 (5000-EC)
1-4
115 / 200
2 (2000-EC)
1 (1200-EC)
Fusion (F)
F300
1 to 2
208 through 240
There are 16 distinct model numbers (not including special models) and Table 4 indicates what components
are used in each model.
Table 4. Lamp Configurations
Lamp Choices
Blower Motor
Lamp Quantity
5000-EC
2000-EC
1200-EC
Fusion
115V
200-
230V
Item
Part Number
Model Number
1
2
4
1
1
1
2
1
40324
EC-D-5-1-120
v
v
2*
40325
EC-D-5-2A-120
v
v
3
40326
EC-D-5-2B-120
v
v
4
40327
EC-D-5-4-120
v
v
5
40328
EC-D-5-1-220
v
v
6
40329
EC-D-5-2A-220
v
v
7
40275
EC-D-5-2B-220
v
v
8
40331
EC-D-5-4-220
v
v
9
40332
EC-D-2-1-120
v
v
10
40333
EC-D-2-1-220
v
v
11
40334
EC-D-1-1-120
v
v
12
40335
EC-D-1-1-220
v
v
13
40336
EC-F-1-220
v
v
14
40280
EC-F-2-220
v
v
15
40338
EC-0-0-120
v
16
40339
EC-0-0-220
v
Legend: EC –D–2 –1–120
Voltage
Lamp Quantity (1-4)
Lamp Model (5 = 5000-EC, 2 = 2000-EC, 1= 1200-EC)
Lamp Manufacturer (D = DYMAX, F = Fusion)
Model Number (EC = Edge Carry)