dymax 1200-EC User manual

Silver EC-Series Flood Lamp User Guide
1200-EC, 2000-EC, & 5000-EC UV Light-Curing Flood Lamps
■Instructions for Safe Use
■Setup and Operation
■Maintenance
■Ordering Spare Parts and Accessories
Clockwise from top left: 2000-EC Lamp, 5000-EC Lamp, Complete EC-Series Flood System, 1200-EC Lamp

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Dymax EC-Series Flood Lamps 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 ensure 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 EC-Series Flood Lamps User Guide
Contents
Introduction.................................................................................................................................................... 4
Introduction to the User Guide ....................................................................................................................................... 4
Where to Get Help .......................................................................................................................................................... 4
Safety.............................................................................................................................................................. 4
General Safety Considerations ........................................................................................................................................ 4
Specific Safety Considerations......................................................................................................................................... 5
Dymax UV Light-Curing System Safety Considerations ................................................................................................... 5
Product Overview ........................................................................................................................................... 7
Description of the EC Series Flood Lamps ....................................................................................................................... 7
System Components........................................................................................................................................................ 7
Assembly and Setup........................................................................................................................................ 9
Unpacking and Inspecting Your Shipment....................................................................................................................... 9
Parts Included in an EC Flood Lamp............................................................................................................................... 10
System Interconnection ................................................................................................................................ 11
Operation ..................................................................................................................................................... 13
Cleaning and Maintenance ........................................................................................................................... 13
Bulb Replacement Procedure........................................................................................................................................ 13
Lamp Base Replacement Instructions ........................................................................................................................... 15
Fuse Replacement Procedure........................................................................................................................................ 15
Cleaning......................................................................................................................................................................... 16
Troubleshooting............................................................................................................................................ 17
Spare Parts and Accessories.......................................................................................................................... 18
Replacement/Spare Parts.............................................................................................................................................. 18
Accessories .................................................................................................................................................................... 19
Specifications................................................................................................................................................ 20
General Specifications ................................................................................................................................................... 20
Electrical Specifications ................................................................................................................................................. 21
Definition of Terms ....................................................................................................................................... 22
Warranty ...................................................................................................................................................... 23
Index............................................................................................................................................................. 23

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Dymax EC-Series Flood Lamps User Guide
Introduction
Introduction to the User Guide
This guide describes how to assemble, use, and maintain a Dymax EC-series flood lamp system 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 sources and do not understand the instructions, contact Dymax Application
Engineering to answer your questions before using the equipment.
Where to Get Help
Additional resources are available to ensure a trouble-free experience with our products:
■Detailed product information on www.dymax.com
■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.
■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 a Dymax UV flood lamp system without first reading and understanding
the information in this user guide, injury can result from exposure to UV light. To reduce the risk of
injury, read and ensure you understand the information in this user guide before assembling and
operating an EC-series flood lamp.
General Safety Considerations
All users of Dymax light-curing flood lamps should read and understand this user guide before assembling and
using the system.
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.

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Dymax EC-Series Flood Lamps User Guide
Specific Safety Considerations
Dymax EC-series flood lamps are designed to maximize operator safety and minimize exposure to UV light-
curing energy. To use the unit safely, it must be set up and operated in accordance with the instructions in this
user guide. Please also read and understand the safety considerations unique to UV light-curing systems as
described below.
WARNING! Looking directly at the UV light emitted by an EC flood lamp can result in eye
injury. To prevent eye injury, never look directly at the high-intensity light and always wear
protective goggles (provided).
Dymax UV Light-Curing System Safety Considerations
Operators must understand these four concepts to use the UV light source safely:
■UV exposure
■High-temperature surfaces
■Ozone
■Bright, visible light
Each is described below.
UV Exposure
Standard Dymax UV light-curing systems and bulbs have been designed primarily to emit UVA light (Figure 1).
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 (TLVs) for ultraviolet light.
Figure 1. UV Spectrum
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/cm2limit into perspective, cloudless summer days in Connecticut regularly exceed

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Dymax EC-Series Flood Lamps User Guide
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.
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.
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:
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.
Flexible Film —Translucent 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.
Ozone
Standard Dymax bulbs (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 (0.2mg/m3).
High-Temperature Surfaces
Surfaces exposed to high-intensity curing lights will rise in temperature. The intensity, distance, exposure
time, cooling fans, and the type/color of the surface can all affect the actual 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.

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Dymax EC-Series Flood Lamps User Guide
Bright, Visible Light
The bright, visible light emitted by some UV light-curing systems can be objectionable to some workers and
can 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. Both the lower working temperature and lack of spurious frequency
transmission that this system produces make it even more user friendly. Contact your Dymax representative
for information regarding the proper use of Dymax light-curing systems.
Product Overview
Description of the EC Series Flood Lamps
Dymax EC-Series Flood Lamps are general-purpose curing units used to cure UV light-curable adhesives,
coatings, and inks. These light sources are exceptionally versatile and expandable, allowing them to be utilized
in an array of manufacturing situations and applications, including bonding, potting, sealing, and
encapsulating.
Each unit is designed and shipped in a unitized configuration for easy bench-top mounting. These flood lamps
can also be custom configured so the Lamp/Reflector Assembly Housing can be mounted in a remote curing
location away from the Power Supply. Several Lamp/Reflector Assembly Housings can be mounted side-by-
side in a linear configuration (such as on conveyor systems) or a large area array. The Power Supplies can then
be stacked and mounted remotely to provide consolidated operator control. The Lamp/Reflector Assembly
Housings are designed with clean, unobstructed surfaces making them easy to install in existing or specialized
equipment.
System Components
Flood Lamps
1200-EC
The Dymax 1200-EC is a focused-beam UV Light-Curing Lamp used for the curing of UV light-curable adhesives,
coatings, and inks. The unit’s elliptical Reflector provides an intense 1" x 6" area of UV energy 4.5" away from
the lower edge of the Lamp/Reflector Assembly Housing.
The 1200-EC employs convection cooling. An optional Fan Ventilation Kit is available to remove excessive heat
and ventilate curing vapors away from the Lamp/Reflector Assembly Housing. Refer to the spare
parts/options section of this manual for more information on the Fan Ventilation Kit.

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Dymax EC-Series Flood Lamps User Guide
2000-EC
The Dymax 2000-EC is a general purpose UV Light-Curing Flood Lamp with an effective curing area of
approximately 8" x 8", making it ideal for batch processing or curing large areas.
An optional special Glass UV Filter may be installed in the 2000-EC Reflector to reduce UV-B and UV-C spectral
emissions. When operated correctly using the Glass UV Filter, extensive shielding associated with many Lamps
can be minimized.
The 2000-EC employs convection cooling. An optional Fan Ventilation Kit is also available. This kit removes
excessive heat due to the Lamp’s possible proximity to other heat sources, or to remove vapors from under
the Lamp/Reflector Assembly Housing during curing of UV light-curable materials. Refer to the spare
parts/options section of this manual for more information on the Fan Ventilation Kit.
5000-EC
The Dymax 5000-EC is a general purpose UV Light-Curing Flood Lamp with an effective curing area of
approximately 5" x 5". It is ideal for small batch processing of UV adhesives and potting compounds.
Comparatively, it provides more than twice the output intensity of a 2000-EC Flood Lamp for faster curing
capability and the additional ability to cure conformal coating resins.
Figure 2. Lamp/Reflector Housings (Left to Right: 1200-EC, 5000-EC, & 2000-EC)

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Dymax EC-Series Flood Lamps User Guide
Solid-State Power Supply
The Solid-State Power Supply allows external electrical inputs and provides power to the Lamp. The front
panel contains the On/Off Power Switch and Hour Meter. The Power Supply also houses its own Cooling Fan
and power distribution for optional accessories. The rear panel has an integrally fused AC-Power Receptacle
and an 8-pin female Amp Connector.
The Power Supply yields reliable and stabilized Lamp voltage in virtually any electrical system in the world.
Other than ensuring a properly configured plug is employed, no other adjustment of settings is required. The
Power Supply also conditions the electrical power to the Lamp providing longer, more reliable Lamp life.
Figure 3. EC-Series Power Supply
Assembly and Setup
Unpacking and Inspecting Your Shipment
When your flood lamp arrives, inspect the boxes for damage and notify the shipper of box damage
immediately.
Open each box and check for equipment damage. If parts are damaged, notify the shipper and submit a claim
for the damaged parts. Contact Dymax so that new parts can be shipped to you immediately.
Check that the parts included in your order match those listed below. If parts are missing, contact your local
Dymax representative or Dymax Customer Support to resolve the problem.

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Dymax EC-Series Flood Lamps User Guide
Parts Included in an EC Flood Lamp
■Reflector Assembly Housing (1) –Contains lamp sockets, a high-voltage starter, three circular
connectors, and one reflector (1200, 2000, or 5000) with an UV lamp (400 Watt, metal halide. Optional
visible or mercury vapor bulbs available).
■UV Glass Filter for the 2000-EC (2) –Optional
■Solid-State Power Supply (3)
■Interconnection Cable (5) –Connects the power supply to the lamp/reflector assembly housing.
■Power Cord (4) –North American power cord shown
■UV Protection Goggles (6)
■Hex Wrench (7)
■Dymax EC-Series UV Flood Lamps User Guide (8)
Figure 4. EC Series Flood Lamp Unpacking Diagram