dymax BlueWave 200 User manual

BlueWave®200 Version 2.0 (PN 40080 - North American/PN 40075 - International) shown with 4-Pole Lightguide
BlueWave®200 Version 2.0
UV Light-Curing Spot Lamp System
with Patented Intensity Control Adjustment
Operation Manual
Marked

2DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
TABLE OF CONTENTS
Introduction .....................................................................................................................................Page 3
Unpacking and Inspection ..............................................................................................................Page 4
Safety..............................................................................................................................................Page 5-8
Description......................................................................................................................................Page 8
Specifications..................................................................................................................................Page 9
Installation and System Interconnect..............................................................................................Page 10-11
Settings and Adjustments...............................................................................................................Page 11-14
Operation ........................................................................................................................................Page 14-16
Maintenance ...................................................................................................................................Page 17
Troubleshooting ..............................................................................................................................Page 18
Frequently Asked Questions...........................................................................................................Page 19-20
Spare Parts List ..............................................................................................................................Page 21
Definition of Terms..........................................................................................................................Page 22
Warranty .........................................................................................................................................Page 23

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 3
INTRODUCTION
The enclosed BlueWave® 200 UV Light-Curing Spot Lamp System was developed and manufactured by the
DYMAX team, driven by a desire to best serve your needs. Before shipping, your BlueWave 200 was thoroughly
checked and tested for trouble-free performance.
The proper set up and operation of this Spot Lamp System will maximize safety and user-friendly performance,
providing optimum yield of your technological process.
THEREFORE, WE ENCOURAGE YOU TO READ, UNDERSTAND, AND FOLLOW ALL SAFETY AND
OPERATING INSTRUCTIONS AND RECOMMENDATIONS COMPILED IN THIS AND OTHER RELATED
MANUALS prior to setting up and operating this new Spot Lamp System or its individual components.
Par conséquent, nous vous encouragez a lire, comprend, et suivre tout sécurité et instructions
d’opération et conseillations rédiger dans cette et autre manuels etablir un lien avant de mettre en place et
de faire marcher cette nouveau système de lampe de tache ou cettes composants individuel.
If you encounter a problem, have any questions, or would like to help us with your suggestions or recom-
mendations, please contact our Applications Engineering or Customer Service Departments. Trained DYMAX
professionals are standing by to serve you.
Si vous rencontrez un problème, avait n’importe de questions, ou si vous voudrez de nous aider avec tes
suggestions ou conseillations, s’il vous plait contacte notre departements technique ou service client. DYMAX
formé professionals attendre a vous servir.

4DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
UNPACKING AND INSPECTION
Upon receipt of the unit, carefully remove the contents from the boxes and check for damage. DYMAXis not
responsible for damage from shipping –all claims for shipping damage should be made with the carrier.
Check all boxes for contents and write down any serial numbers for further reference. You may wish to retain the
original shipping cartons in case you need to repackage any item for return.
If you observe or experience any problem with your equipment, notify DYMAX Customer Service, your authorized
distributor, or your DYMAX representative immediately.
Figure 1. BlueWave®200 (PN 40075 & PN 40080) Unpacking Diagram
NOTE: Lamps are shipped with the Bulb/Reflector installed.
NOTE: Report any shortage to DYMAX Customer Service.

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 5
Before continuing with unpacking and installation, please read the following chapters of this manual for safety
recommendations, installation, operating, and troubleshooting instructions.
CAUTION! Always wear protective goggles or face shield when working near the front of the unit,
which emits UV light! The rear of the unit also emits stray UV light.
WARNING! Always observe safety requirements!
CAUTION! Risk of electrical shock if cover is removed!
CAUTION! Cover is warm to the touch when unit is in operation!
PRÉ-CAUTION! Toujours faisez de l’usage des lunettes de protection ou protéger de visage
marche près du devant d’élément!
AVERTISSEMENT! Remmarquez toujours besoin de sécurité!
PRÉ-CAUTION! Risque de décharge électrique quand le couvert est enlever!
PRÉ-CAUTION! Le couvert est chaud a le touche quand l’élément est en opération!
ACHTUNG! Tragen Sie immer eine Sicherheitsbrille oder einen Gesichtsschutz, wenn Sie nahe an
der UV Lichtquelle arbeiten. Die Rückseite des Gerätes emittiert gestreutes UV Licht!
WARNHINWEIS! Bitte beachten Sie immer die Sicherheitshinweise!
ACHTUNG! Gefahr eines Stromschlages bei geöffnetem Gehäuse!
ACHTUNG! Gehäuse erwärmt sich während des Betriebs: Vorsicht bei Berührung!
SAFETY
Equipment is designed to be used properly set up, with components correctly connected, and operated in
accordance with relevant instructions. The system's design was developed to maximize operator safety and
minimize exposure to UV.
SAFETY RECOMMENDATIONS:
Use the goggles provided or a face shield approved for UV protection to protect your eyes.
Long-sleeved shirts or a lab coat are recommended to protect the arms and use of UV-opaque gloves will
protect the hands.
NOTE:With the internal Filter installed, the BlueWave®200 emits UVA and visible light. Never look directly at the
light source while the unit is on.
SÉCURITÉ
L’équipment ètre concu pour ètre utilisé correctement constituer, avec composants brancher correctement, et
marché en conformément avec instructions important. Le plan étais developer pour render au maxime opérateur
sécurité et minimiser exposition à ultraviolette.

6DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
RECOMMANDER DE SÉCURITÉ:
Emploi lunettes ou un protéger de visage pour protection de ultraviolet pour protéger vous oeux.
Chemises à manche long ou manteau de labo sont recommander pour protéger les bras, et utilisation de
ultraviolette gants opague vais protéger les mains.
REMARQUER: avec le filtre intérieur installé, l’Onde Bleu émettre UVA et lumière visible. Ne jamais regardez
directement à la source de lumière pendant que l’élément est en opération.
SICHERHEITSHINWEISE
Dieses Gerät wurde so entwickelt, dass es nur vollständig, alle Komponenten korrekt miteinander verbunden, in
Übereinstimmung mit relevanten Instruktionen betrieben wird. Bei der Entwicklung wurde weiterhin großen Wert
auf die Benutzersicherheit und minimale UV Belastung gelegt.
SICHERHEITSHINWEISE:
Tragen Sie immer die mitgelieferten Sicherheitsbrille oder speziellen Gesichtsschutz, der Ihre Augen vor UV
Licht schützt.
Wir empfehlen Langarm - Hemden oder einen Laborkittel zu tragen, um die Arme zu schützen. Für die Hände
empfehlen wir UV- geblockte Handschuhe.
BITTE BEACHTEN SIE: Durch den installierten inneren Filter strahlt die BlueWave 200 UVA und sichtbares Licht
aus. Schauen Sie deshalb niemals direkt in die Lichtquelle, wenn das Gerät angeschaltet ist.
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. There are four common questions/concerns related to UV light-curing
systems: UV exposure, high-temperature surfaces, ozone, and bright, visible light.
UV EXPOSURE
Standard DYMAX UV light-curing systems and bulbs have been designed to primarily emit UVA light(as shown in
Chart 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 (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/cm2limit 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 tans, sun burns, and
skin cancer) as well.
The human eye can not 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.
UV light-curing of adhesives 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.

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 7
Chart 1. Light Spectrum
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 –Aluminum, steel, stainless steel, etc. Sheet metal should be coated black or black
anodized to minimize reflection of UV and visible light toward operators.
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.
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.
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 a more moderate surface temperature or appropriate protection and
training for operators.
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).

8DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
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. Contact your DYMAX representative for information regarding the proper use
of DYMAX UV light-curing systems.
DESCRIPTION
The BlueWave®200 is a high-intensity UV light-curing Spot Lamp System used for small area curing of
adhesives, coatings, and potting materials. It emits up to an 8-mm diameter spot of UV light from a liquid
Lightguide (sold separately). The Lightguide is hand-held for complete mobility or can be clamped into position
on assembly equipment or workstations for repetitive operations.
WARNING: Engage the Lightguide in the Bezel before the light is turned on, and remove the Lightguide from the
Bezel only after the light is turned off to avoid the possibility of exposure to the light. Lightly tighten the setscrew
for safety.
AVERTISSEMENT: Engager le guide de lumière dans le biseau avant la lumière est allumer, et enlève le guide
de lumière de le biseau seulement après la lumière est fermer pour éviter la possiblité d’exposition à la lumière.
Reserrer doucement la vis pour sécurité,
The system consists of an anodized aluminum housing containing an electronic Power Supply, Circuit Protection,
Bulb/Reflector Assembly, Internal Light Filter for extended Lightguide life, thermostatically-controlled Cooling Fan,
Lightguide Mount, Bulb and Unit Status Indicator Lights, combination resettable and non-resettable Hour-Meter,
and Shutter. The Shutter is supplied with a timed and manual operation mode.
The Power Supply operates on line voltages between 100 and 240 VAC, and frequency between 50 and 60 Hz.
The Power Supply is auto-ranging and is specially designed to provide proper rated voltage and current to the
200 Watt Lamp.
A Cooling Fan with a control loop is provided to keep the Lamp Housing and internal components of the Power
Supply at the optimum operating temperature. The Cooling Fan must not be covered or otherwise blocked.
The UV source is a 200-Watt, medium-pressure arc metal halide Bulb mounted in a Reflector and focused to
provide optimum light output. The unit is rated for continuous operation. The Bulbs used to power all high-intensity
UV light-curing Spot Lamps degrade with use. Intensity, therefore, decreases as the Bulb ages. Using the Blue
Wave 200’s intensity control feature, users can eliminate this variation by manually increasing intensity to offset
this degradation. During operation a user can adjust the output intensity using a tool or removable knob. The
Blue Indicator Light, above the Bezel, lights when the Bulb is operating. If the Bulb extinguishes due to a
momentary power failure, the unit must be turned off, allowed to cool, and then restarted to re-ignite the Bulb. A
Change Bulb Indicating Light turns on when Bulb replacement is required.
A Thermal Shutdown Sensor is provided for internal temperature control of the unit. A Cover-Closed Switch and
Lightguide Sensing Switch add to the safety of the unit. Fan Filters should be changed or cleaned frequently to
prevent blockage and reduced ventilation airflow. Electric Shutters are supplied with timed and manual Shutter
operating modes.

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 9
SPECIFICATIONS
Part Number
PN 40080 –North American Version (with 115V standard plug)
PN 40075 –International Version (with no plug)
Intensities
Total (280-450) 40+ W/cm2
Visible (400-450 nm) 17+ W/cm2
UVA¹ (320-395 nm) 17+ W/cm2
UVB (280-320 nm) 7 W/cm2
Power Requirements
100 to 240 VAC, 50 to 60 Hz, 2.5 Amps
Power Supply
Solid State, 200 Watt
Bulb
200 Watt mercury Bulb included; replacement in less than a minute
Reflector
Elliptical; glass with diachronic coating to reflect UV and minimize IR
Shutter Timer
Digital LCD timer up to 99.99 seconds; manual or timed shutter
Shutter Activation
Footswitch or PLC
I/O Port
15-Pin D –sub-miniature connector
Signals
(PLC Integration)
Inputs Shutter activate, Shutter de-activate, Lamp turn on
Outputs Unit in warm-up, Lamp Lit, Unit Over Temperature, 1,950 hours,
Bulb Replace 2,000 hours, Shutter Status
Cooling
Filtered, single fan arrangement; thermally controlled to maintain proper lamp
temperature
Operating Conditions
Temperature range: 0 –40°C humidity limit –non-condensing
Hour Meter
Digital LCD; Total unit operating hours (non re-settable)
Total Bulb hours (re-settable)
Housing Dimensions
12.0" x 12.25" X 6.5" (30.5 cm X 31.1 cm X 16.5 cm)
Weight
14 lbs. (6.0 kg)
System Warranty
1 year from purchase
Bulb Warranty
2,000 hours (no intensity warranty during 2,000 hours, only lighting)
Replacement Bulb
PN 38465
¹ Measured with an EIT Spotcure Radiometer or an ACCU-CAL™ 50 Radiometer using a Lightguide Simulator and standard internal “Cool Blue” Filter.
UV Spectral Output
0
1
2
3
4
5
6
282 305 328 352 375 398 421 444 467 489 512 535 558 580 603 625 647
Wavelength
Intensity
Dual Filter
No Filter
Black Light
Standard Filter
Figure 2. 200W Bulb Spectral Chart

10 DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
INSTALLATION AND SYSTEM INTERCONNECT
1. Connect the Power Cord to the Power Receptacle on the rear
of the unit and plug the Power Cord into a grounded wall
outlet.
2. Connect the Footswitch to the Footswitch Connection
(Figure 3) in the rear of the unit. A ground stud is provided on
the back of the unit if additional grounding is desired.
3. Remove the protective cover from the BlueWave®200’s
Lightguide Mount (Figure 4).
NOTE: Always have a Lightguide or the protective cap
engaged in the Lightguide Mount. UV light can escape when
the Shutter is activated.
4. Remove the protective end caps from the Lightguide.
Visually inspect the two ends of the Lightguide to verify that
no foreign material is present. The ends of a DYMAX liquid-
filled Lightguide can be cleaned with isopropyl alcohol as
required to remove foreign material and deposition from
outgassing.
5. Insert the large end of the Lightguide into the Lightguide
Mount until it snaps into place (Figure 5). A Blue Lightguide
Seated Indicator Light illuminates when the Lightguide is
properly installed and the unit is turned on.
6. If desired, the Lightguide may be fastened into place by lightly
tightening the securing setscrew installed in the Lightguide
Mount (Figure 6). A hex wrench is provided with the
BlueWave 200 for this purpose. The setscrew should be
tightened gently to prevent damaging the Lightguide.
NOTE: Multi-leg Lightguides should be balanced by rotating
the Lightguide to obtain the desired UV intensity of each leg
before tightening the setscrew.
4. Turn the BlueWave 200's Power Switch on.
5. Allow the Bulb to warm up. The unit is warmed-up when the
blue Unit Ready Indicating Light is illuminated. Two beeps will
sound. The Shutter is inoperable until the warm-up is complete
and a Lightguide is installed.
CAUTION: This is an arc, not a filament Bulb. Once ignited, it
must be left on for a minimum of 10 minutes to fully vaporize
elements in the Bulb. If not, the Bulb may be difficult to re-
ignite. Each re-ignition increases the rate of Bulb degradation.
NOTE: The Bulb must cool before it can be re-ignited. Turn
the unit off and allow 5 to 10 minutes for it to cool down. If the
Bulb fails to ignite, refer to the Troubleshooting Section of this
manual. Bulb life is reduced each time the unit is switched on
and off. Avoid repeated cycles that shorten Bulb life by leaving
unit on through breaks.
Figure 3. Cable Connection,
BlueWave 200 Rear Panel
Figure 4. Lightguide Mount
Protective Cover Installed (left);
Protective Cover Removed (right)
Figure 5. Insert Lightguide into
Lightguide Mount
Figure 6. Tighten Setscrew on Lightguide
Mount with Hex Wrench
Power Cord
Footswitch
Connection
Power
Receptacle

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 11
6. Operate the Shutter by pressing the Footswitch. With the Shutter Selector Switch in the manual position, the
Shutter operates directly from the Footswitch. In the timed position, the Shutter opening is determined by the
setting on the electronic Timer. Simply push the Timer Setting Buttons to enter the desired number of
seconds the Shutter is to remain open.
7. With the Shutter open, adjust the Intensity Adjustment Screw as required to achieve the desired output
intensity (Figure 7).
SETTINGS AND ADJUSTMENTS
INTENSITY ADJUSTMENT
The Bulbs used to power all high-intensity UV light-curing spot lamps degrade with use. Intensity, therefore,
decreases as the Bulb ages. Using the BlueWave®200’s patented Intensity Adjustment feature, users can
eliminate this variation by manually increasing output intensity to offset this degradation.
The intensity can be adjusted with a tool (Figure 7) or a removable knob (Figure 8). This feature is useful for both
validation and control.
Figure 7. Intensity Adjustment Figure 8. Intensity Adjustment with Knob
with Tool
INTENSITY VALIDATION
Prior to production, DYMAX advises customers to conduct testing to determine the time and intensity required to
fully cure their resin in their specific application. Typically, users validate by one of the following methods:
Set Exposure Time, Determine Intensity - Users can specify a cure time and through empirical testing,
determine the intensity required to achieve full cure. As with any manufacturing process, it is advisable to
incorporate a safety factor.
Set Intensity, Determine Exposure Time - Users can specify intensity and through empirical testing,
determine the exposure time required to achieve full cure. As with any manufacturing process, it is
advisable to incorporate a safety factor.
INTENSITY CONTROL
Process validation confirms a minimum acceptable intensity. Users can then
choose to operate at full intensity (using the excess intensity as an additional
safety factor) or maintain a constant intensity through periodic manual
adjustments. BlueWave 200 Bulbs will typically vary less than 1% over eight
hours of normal use and so daily or weekly adjustments are adequate to
maintain a tightly controlled process. A Change Bulb Indicator Light
(Figure 9) is provided to alert the operator to check Bulb operation or to
change the Bulb if required.
Figure 9. Indicator Lights

12 DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
SETTING THE CYCLE DURATION
The Shutter Timer located on the front panel of the BlueWave® 200 is factory set to the most common operating
mode and recommended operation of the Timer with the BlueWave 200. Some modes available on the Timer
may not operate correctly with the BlueWave 200 unit.
The Shutter Timer contains an LCD Display and Keypad. The LCD Display has a reset indicator, key protect
indicator, output indicator, preset timing value, set value, and timing operation indicator. Below is a brief
description of each display and location:
Figure 10. Shutter Timer
RST [Reset Indicator] –Active when the Shutter Timer is reset by pressing the “RST” button on the lower left
face of Shutter Timer.
K/P [Key Protect] –Will always be lit as the function of the Shutter Timer is programmed at the factory and
locked before shipment.
OUT [Output Indicator] - Displayed when relay is switched on; is not displayed when relay is switched to off.
Timing Value –Four-digit segmented display in center of the Shutter Timer. Shows current status of time.
Set Value –Four-digit segmented display in lower right corner of the Shutter Timer. Shows set length of time.
In addition to the indicators, the Shutter Timer contains six buttons with their functions described as follows:
MODE –Disabled at the factory and locked before shipment.
Reset Indicator (RST) –Used to cancel out of a timed cycle. If a cycle is initiated and counting down, pressing
this button will close the Shutter and reset the counter to the current preset.
Digit Increment 1-4: Pressing these buttons up or down will increment or decrement that digit by one. The
timer digits are formatted MM:SS for a maximum Shutter time of 99 minutes and 0.99 seconds. Consult
DYMAX for information on changing the format of this Timer.
To select the time, press the appropriate up key until the corresponding digit increments in the set value. By
pressing the up key labeled (1, Figure 10), it will increment the left most digit on the set value. By pressing the up
key (2, Figure 10), it will increment the second digit of the set value. The same will happen with the up key
Timing Value
Set Value
Digital Increment 1-4
Press top half to
increment digit up
Digital Increment 1-4
Press bottom half to
increment digit down
Reset Button
Reset Indicator
Key Protect
Output Indicator

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 13
(3, Figure 10) and the third digit of the set display, and up key (4, Figure 10) and the fourth digit of the set display.
The Timer will increment from 9 back to 0. The Timer comes programmed for a range of 00.01 seconds to 99.99
seconds. Consult factory for other time ranges and functions.
To operate the Timer, select the "TIMER" option on the switch on the front panel (large rocker switch left of the
Timer module). Program the time into the Timer as described above and depress the Footswitch. The Shutter
will open and the preset value will begin to count backward. When the Timer reaches 00.00, it will reset the value
to the set value and close the Shutter. The Timer can be stopped once started by pressing the Reset Button on
the lower left face of the Timer. If power is removed from unit, the Timer will reset to the set value.
LAMP DUAL-HOUR METER
The Lamp Dual-Hour Meter (Figure 11) provides elapsed time of
unit operation (top display), as well as Lamp usage (bottom
display). The top display of the Lamp Dual-Hour Meter continues
to count hours of operation on the unit and cannot be reset. The
lower display reflects the total number of hours on the Bulb; Bulb
hours should only be reset when a new Bulb is installed.
Instructions for Bulb replacement may be found in this manual as
well as being located on the sticker under the unit cover next to
where the Bulb is located.
When the lower display on the Dual-Hour Meter reaches 2,000
hours, the Bulb will turn off and Hour Meter will alternate
between “CHANGE BULB” and "2000.0". The unit will not
operate until a new Bulb is installed.
WARNING: Operating the Lamp beyond 2,000 hours may result
in non-passive failure of the Lamp!
BULB REPLACEMENT PROCEDURE
Bulb replacement is easily accomplished by following the steps below. Refer to the labeled diagrams under the
light source cover.
1. Ensure that the Power Cord is unplugged from the rear of the unit.
2. Remove the top cover from the BlueWave®200 by loosening the four cover fasteners.
3. Unplug the Bulb and Lift the Bulb Mounting Bracket (Figure 13) from it. Remove the Bulb from the Bulb Mount
(Figure 14).
Figure 12.Bulb Installed in Figure 13.Lift Bulb Mounting Bracket Figure 14.Remove Bulb from
Bulb Mount Bulb Mount
Figure 11.Lamp Dual-Hour Meter

14 DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
4. Unpack the new Bulb. Take care not to bend the flat Electrode in the center of the Bulb.
Figure 15.Bulb Package (Closed) Figure 16.Bulb Package (Open) Figure 17.Remove Bulb from Box Figure 18.Bulb
5. Install the new Bulb into the unit (Figure 19), plug the Bulb in (Figure 20), and tighten the two Mounting
Bracket Thumbscrews (Figure 21). Re-install the BlueWave®200's cover. Make sure that the center
Electrode is positioned as shown in Figure 21.
Figure 19.Install Bulb Figure 20.Plug in Bulb Figure 21.Bulb Electrode Figure 22.Reset Button
6. Plug in and turn on the BlueWave 200. Press and release the red Reset Button on the back of the unit
(Figure 22).This completes Bulb installation. When the unit is turned on, the Bulb will now ignite and is now
reset to operate for 2,000 hours.
NOTE: If the Bulb does not light, repeat instruction 5 to verify all steps were done correctly.
7. Allow the Bulb to warm up. The unit's warm-up is complete when the Unit Ready Indicator Light illuminates.
The unit will also sound a double beep when the warm-up is complete.
NOTE: The Shutter is inoperable until the warm-up is complete and a Lightguide is installed.
8. The unit is ready for use.
OPERATION
The BlueWave 200 will arrive almost fully assembled. Please refer
to the Installation and Interconnection Section for instructions on
installation of the Lightguide, Power Cord, and Footswitch. The
system should be positioned in a dry location that does not obstruct
airflow from the rear of the unit.
IMPORTANT: To ensure proper operation of the Shutter, be sure to
completely insert the Lightguide into the Lightguide Mount prior to
This metal Electrode connecting the Bulb
to the wire from the Reflector should be
parallel to the bottom of the unit.
Figure 23. BlueWave Front Plate
Mounting Bracket Thumbscrews

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 15
tightening the setscrew. Be sure to lightly tighten the setscrew to
ensure the Lightguide remains in place during use.
To energize the system turn the Power Switch from the “O” position
to the “l” position; Fan, Hour Meter, Timer, and 200 Watt Lamp
should begin to function. This can be confirmed by viewing the
illuminated “200” nameplate above the Lightguide Mount (Figure 24).
Before operating unit, allow the 200 Watt Lamp to complete the
warm-up cycle.
CAUTION: Always wear protective goggles or face shield when
working near UV light. Never look directly at the light exiting the
Lightguide.
PRE-CAUTION: Toujours porte lunettes de protection ou protéger
de visage en travaillant près lumière ultraviolette. J’amais regarde
directement à lumière sortie de le guide de lumière.
Position the Lightguide end no closer than ¼" from material being
cured. Locating the Lightguide end too close can cause the
Lightguide end to become cloudy from vapors coming off of curing
material. This cloudiness can reduce UV output by as much as 50%.
Bulb life is reduced each time it is started. To avoid premature Bulb
deterioration, leave the unit on through breaks, short shutdowns, and
lunch hours. These UV light sources are designed for continuous
operation. If the power is momentarily lost, shut the unit “off” and let
it cool down for 5 to 10 minutes then switch back “ON” and wait for
warm-up.
As the Bulb degrades, some adjustment may be needed to the Lamp
intensity. To use the patented Lamp Intensity Adjustment, the
Intensity Adjustment Knob must be installed. This knob installs into
the Intensity Adjustment Screw as shown in Figure 25.
15-PIN CONNECTOR I/O SIGNALS
The BlueWave®200 is equipped with a 15-Pin D-Subminiature
Connector (Figure 26) that provides interface between the BlueWave 200
and PLC and similar factory control equipment. The following discussion
will describe inputs and outputs, their properties and how to use them.
Input signals:
Pin 1 –User Supplied +24 VDC
Pin 2 –User Supplied 24 Volt Common
Pin 3 –Remote Shutter Activate (activate low): This signal line may be used to remotely open the BlueWave
200's Shutter. When it is being used, the local Shutter Enable Jack on the rear of the BlueWave 200 is still
capable of opening the Shutter. The Shutter will stay open for the duration of the remote Shutter activate signal.
The Shutter is opened when Pin 3 of the DSUB15 connector is low (0 VDC). When Pin 3 is high, the Shutter is
closed. The position of the timed/manual mode has no effect on this input. The Timer will not be activated by this
input.
Pin 4 –Remote Shutter De-Activate (active low): This signal line may be used to remotely prevent the Shutter
of the BlueWave 200 from being open under any circumstances. Bringing Pin 4 low (0 VDC) will deactivate the
Shutter. The unit will not respond to the Footswitch.
Figure 26. 15-Pin I/O Signals
Figure 24. 200 Nameplate (Not illuminated)
Figure 25. Intensity Adjustment Knob

16 DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
Pin 5 –Remote UV Lamp Turn On (active low): With the main AC switched on and the PLC (Pin 6) enabled,
this input is used to remotely power up the Bulb Supply. Until this input is grounded, the unit will be in “standby”
mode –indicated by the Unit Ready Indicator Light.
Pin 6 –Remote PLC Enable: The user must supply 0 VDC to enable remote UV Lamp turn on.
Output signals:
The output signals are all opto-isolated signals; active low
Pin 7 –Unit Ready (active low) Indicates unit ready for operation.
Pin 8 –Indicates Lamp Lit (active low when lamp lit)
Pin 9 –Indicates Shutter Fault (low) during fault
Pin 10 –Indicates Temperature Fault (low during fault)
Pin 11 –Indicates 1,950 Hours (active low)
Pin 12 –Bulb Replace. Indicates 2,000 hours (active low).
Pin 13 –AC Power ON (active low)
Pin 14 –Lightguide Inserted (active low)
Pin 15 –Shutter Status: Shutter open is indicated by an active low signal.
Figure 27 shows the suggested relationship for both inputs and outputs between the BlueWave®200 and a PLC
system. The component values shown are appropriate for a 24 VDC PLC power supply to limit current flow to
safe levels for the opto-coupler devices within the BlueWave 200.
Figure 27. 15-Pin I/O Signals

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 17
MAINTENANCE
The BlueWave®200 was designed to operate with minimum maintenance. Follow the schedule below to assure
top performance from the unit.
LIGHTGUIDE
Clean the ends of the Lightguide monthly or as required. The ends of the Lightguide should be kept clean to
transmit as much light as possible. Cured adhesive can be removed with a razor blade. Avoid sharp bends with
the Lightguide since this reduces light output and damages guide.
FAN FILTERS
The external Fan Filters should be inspected and cleaned periodically to prevent dust buildup from affecting airflow
through the unit. Spare Fan Filters are provided with each unit and with replacement Bulbs. The Fan Filters are
washable and may be reused. Remove the Fan Filter by removing the snap-on cover from the rear of each grill.
Figure 28.Exhaust Fans with Fan Filters Removed Figure 29.Disassembled Fan Filter
FUSE REPLACEMENT
The unit has two Fuses that are installed in the Power Receptacle. To remove the Fuses, unplug the unit and
remove the Fuse Holder with a small screwdriver. Remove the Fuses from the Fuse Holder and install new
Fuses. Replace the Fuse Holder into the Power Receptacle. The correct Fuses are DYMAX PN 37869, 4.0 Amp
fast-acting type.
Figure 30.Power Receptacle Figure 31.Fuse Holder Figure 32. Fuses Removed from Holder

18 DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
TROUBLESHOOTING
WARNING: Only qualified maintenance personnel should attempt the following procedures:
AVERTISSEMENT: Seulement personnel d’entretien diplomé devrais essayer les procedures suivant.
Problem
Possible Cause
Testing
Corrective Action
Bulb Will Not
Ignite
Improper connections
Visually inspect all input/output
connections (i.e. Power Cord,
Bulb).
Secure all connections.
Bulb beyond useful life of
2,000 hours
Replace with a new Bulb/
Reflector Assembly. Reset the
Bulb Hour Meter and re-test unit.
Replace the Bulb/Reflector
Assembly if required
(typical life = 2,000 hours).
Main line Fuse blown
(nothing in unit operates)
Remove the Fuse from the
Power Receptacle and check it
with an Ohmmeter.
Replace the Fuse if defective.
Low Output
Intensity
or
Fails To Cure
Adhesive In
Allotted Time
Bulb beyond useful life
Use a Radiometer (DYMAX
ACCU-CAL™ 50 or equivalent)
to measure output intensity.
Replace the Bulb/reflector
assembly if beyond useful life
(typical = 2,000 hours).
Transmission loss in
Lightguide too great
Compare Lightguide output
against new Lightguide (or use
the DYMAX Lightguide
Simulator) to determine
transmission loss.
Replace the Lightguide.
Contaminants on
Lightguide
Visually examine ends of
Lightguide for contaminants.
Clean with isopropyl alcohol
(or equivalent). Heavy
deposits on liquid Lightguides
may be removed with a razor
blade. Replace Lightguide if it
can not be cleaned.
Bulb/Reflector Assembly
not installed properly
Visually check to make sure the
Bulb/Reflector Assembly is
seated flush in the Bulb Mount
Assembly (any error in
installation could cause a low
output).
Properly install Bulb/Reflector
Assembly.

DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System 19
FREQENTLY ASKED QUESTIONS
Q.) My BlueWave®200 will not turn on.
A.) Check the Power Cord connection.
B.) Check the Fuses located where the Power Cord plugs into the unit.
Q.) The blue lens on the front panel does not light.
A.) This signifies the Bulb has not ignited. Check that the Power Cord and Bulb connections are secure.
Q.) The Bulb will not ignite; it only “flickers”.
A.) Replace the Bulb. Excessive power cycling will shorten the life expectancy of the Bulb. This is an arc,
not a filament Bulb. Once ignited, it must be left on for a minimum of 10 minutes to fully vaporize
elements in the Bulb. If not, the Bulb may be difficult to re-ignite. Each re-ignition increases the rate of
Bulb degradation.
Q.) I installed a new Bulb, and it still will not ignite.
A.) The BlueWave 200 has a safety shutdown feature at 2,000 hours. If the equipment has reached the
safety shutdown point, the Hour Meter will alternate between "CHANGE BULB" and "2000.0" and the
Bulb will not light. When this happens, the BlueWave 200 will no longer supply an ignition voltage until
a new Bulb is installed and the Reset Switch is pressed on the back of the unit. The power must be on
for this reset to be performed. The Reset Switch should always be pressed whenever a new Bulb is
installed and a Bulb should never be operated after it reaches the 2,000 hour life expectancy.
B.) Check and make sure the Bulb Connector is fully seated into the Igniter.
Q.) Why do I have low intensity, even with a new Bulb?
A.) Standard BlueWave 200 units have a Filter Lens installed, which filters the light before it reaches the
Lightguide. The light intensity will be decreased as the light that passes through the filter is restricted by
dust and debris.
B.) The intensity is being checked too early. The 200 Watt Bulb will not reach full intensity until five
minutes after initial power up.
C.) The Lightguide may not be fully seated into the Lightguide Mount.
D.) The end of the Lightguide may have a build-up of adhesive. Carefully remove with isopropyl alcohol or
use a razor blade for heavier deposits.
E.) The condition of the Lightguide will also affect the intensity. All Lightguides degrade with time, but
intensity will also drop if the Lightguide is bent or compressed. The intensity reading from the
Lightguide should be compared to the intensity reading from a Lightguide Simulator to determine the
efficiency.
F.) Incorrect installation of the Bulb. Bulb orientation is vital during the installation of the Bulb. Refer to the
Bulb installation instructions supplied with all new 200 Watt Bulbs for the proper installation procedure.
Q.) My Footswitch is not operating.
A.) Check the connection of the Footswitch into the unit.
B.) Check that the Lightguide is fully installed and that the Lightguide Seated Indicating Light is on.

20 DYMAX BlueWave®200 Version 2.0 UV Light-Curing Spot Lamp System
Q.) What causes my Shutter to hesitate to open when I activate my Footswitch?
A.) Maintaining clean equipment and a clean working environment will help prevent the build up of dust and
other debris from collecting on the mechanical parts of the BlueWave®200.Debris that settles in the
piston well (adjustment screw) can hinder the movement of the Shutter Solenoid Piston.
B.) Shutter alignment to Reflector Mount incorrect.
C.) The Shutter is a mechanical part which may wear after extended use.
D.) Incorrect alignment of the Shutter to the Bulb Mount Assembly.
Q.) Why does my shutter sometimes hesitate to close?
A.) This problem may also relate to the cleanliness of the working environment. Dust and debris can
collect and cause the Shutter to work improperly.
B.) Shutter alignment to Reflector Mount incorrect.
C.) The Shutter is a mechanical part which may wear after extended use.
D.) Incorrect alignment of the Shutter to the Bulb Mount Assembly.
Q.) Why does my BlueWave 200 seem to run very hot?
A.) Replace the Fan Filter Media on the Exhaust Fan and vent located in the back of the equipment. This
is your first line of defense against airborne dust and debris. The Fan Filter Media is supplied with new
Bulbs and should be changed regularly.
B.) Idea operation of this equipment suggests at least 12" of clearance behind the unit for proper
ventilation. Confirm that the Intake Fan is not feeding from the exhaust of other equipment.
C.) Confirm both Intake and Exhausts Fans are operating.
D.) Equipment may already be full of dust and debris; over heating the internal electronics.