dymax BlueWave 200 User manual

BlueWave
®
200 Version 1.1
UV Light-Curing Spot Lamp System
with Patented Intensity Control Adjustment
Marked
BlueWave®200 Version 1.1 (PN 38905 – North American / PN 38605 – International) shown with 4-pole lightguide
Operation Manual

TABLE OF CONTENTS
Unpacking and Inspection ..............................................................................................................Page 4-5
Safety..............................................................................................................................................Page 5-7
General Information........................................................................................................................Page 8
Specifications..................................................................................................................................Page 9
Installation and System Interconnect..............................................................................................Page 10
Settings & Adjustments...................................................................................................................Page 11-14
Intensity Adjustment...................................................................................................................Page 11
Intensity Validation.....................................................................................................................Page 11
Intensity Control.........................................................................................................................Page 11
Setting the Cycle Duration.........................................................................................................Page 11-12
Lamp Dual-Hour Meter ..............................................................................................................Page 13
Bulb Replacement Procedure....................................................................................................Page 13-14
Operation........................................................................................................................................Page 15-17
Maintenance ...................................................................................................................................Page 18
Troubleshooting..............................................................................................................................Page 19
Frequently Asked Questions...........................................................................................................Page 19-20
Spare Parts List ..............................................................................................................................Page 21
Definition of Terms..........................................................................................................................Page 22
Warranty .........................................................................................................................................Page 23
2DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

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 recommendations,
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.
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 3

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 (PN38905 & PN38605) Unpacking Diagram
NOTE: Units are shipped with the Bulb/Reflector installed.
NOTE: Report any shortage to DYMAX Customer Service.
4DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

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.
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 5

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/cm2of UVA light and also include the more dangerous
UVB light (primarily responsible for sun tans, sun burns, and skin cancer) as well.
Chart 1. Light Spectrum
6DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

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.
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/ 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 O2
to create ozone O3. The current, long-term ozone concentration limit recommended by ACGIH, NIOSH, and OSHA is
0.1 ppm (0.2mg/m3).
BRIGHT, VISIBLE LIGHT
The bright, visible light emitted by some UV light-curing systems 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.
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 7

GENERAL INFORMATION
The BlueWave®200 is a high-intensity, UV light-curing spot lamp used for the curing of adhesives, coatings, and potting
materials. It emits UV light from a Lightguide, which is sold separately. The Lightguide can be hand-held for complete
mobility, clamped into position for repetitive operations, or in automated equipment.
The unit 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 Fans,
Lightguide Mount, Bulb Status Indicator Light, combination resetable and non-resetable Hour-Meter, and Shutter
system. A Thermal Shutdown Sensor is provided for internal temperature control 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. The Lightguide is separate and plugs into the Lightguide Mount.
A patented Intensity Control Feature allows operators to manually adjust output intensity during process validation and
production. Users can now manually adjust intensity to compensate for bulb degradation.
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 Blue Indicator Light above the Bezel lights when the Bulb is operating. The Power Supply operates on line
voltages of either 115 or 230 Vac, 50/60 Hz. If the Bulb extinguishes due to a momentary power failure, the unit must
be turned off, allowed to cool, and then turned on again to re-ignite the Bulb.
A Cooling Fan is provided to keep the Bulb 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
short-arc mercury-vapor Bulb mounted in a Reflector and pre-focused to provide optimum light output. The unit is rated
for continuous operation.
8DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

SPECIFICATIONS
Part Number PN 38905 – North American Version (with 115V standard plug)
PN 38605 – International Version (with no plug)
Intensities
Total (280-450) 40+ W/cm2
Visible (400-450nm) 17+ W/cm2
UVA¹ (320-395nm) 17+ W/cm2
UVB (280-320nm) 7 W/cm2
Power Requirements 90-265, 47-63 Hz
Power Supply Solid State, 200 Watt
Bulb 200-Watt mercury bulb included; replacement in less than a minute
Reflector Elliptical; glass with dichroic coating to reflect UV and minimize IR
Shutter Timer Digital LCD timer up to 99.99 seconds; manual or timed shutter
Shutter Activation Foot switch or PLC
I/O Port 9-pin D – sub-miniature connector
Signals (PLC Integration)
Inputs Shutter activate, Shutter de-activate
Outputs Lamp on, lamp off, replace lamp
Shutter opened, shutter closed, shutter fault
Cooling Filtered, dual-fan arrangement; thermally controlled to maintain proper lamp
temperature
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" (30.5cm x 31.1cm x 16.5cm)
Weight 14 lbs. (6.0 kg)
System Warranty 1 year from purchase
Bulb Warranty 2,000 hours (no intensity warranty, only Bulb ignition)
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
DualFilter
No Filter
Black Light
Standard Filter
Figure 2. 200W Bulb Spectral Chart
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 9

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.
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. Adjust the Intensity Adjustment
Screw
Footswitch
Connection
Power
Receptacle
Power Cord
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).
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.
7. Turn the BlueWave 200's Power Switch on.
8. Allow the Bulb to warm up 4-5 minutes to obtain the maximum
light output.
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.
9. 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.
10. With the Shutter open, adjust the Intensity Adjustment Screw as
required to achieve the desired output intensity (Figure 6).
10 DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

SETTINGS AND ADJUSTMENTS
PATENTED 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 Control 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 with Tool Figure 8. Intensity Adjustment with Knob Figure 9. Intensity Adjustment (Interior View)
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 is provided to
alert the operator to check Bulb operation or to change the Bulb if required.
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 Shutter Timer with the BlueWave 200. Some modes available on this Shutter Timer
may not operate correctly with the BlueWave 200 unit and have been disabled.
The front panel of the Shutter Timer contains a LCD Display and Keypad. The LCD Display has a Power Indicator,
Signal Input Indicator, Reset Indicator, Gate Input Indicator, Key Protect Indicator, Output Indicator, present value, set
value, and Timing Operation Indicator.
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 11

A brief description of each display and location:
•PW [Power Indicator] – Upper left corner of Timer Display. Displayed when external power for operation is present.
•SIG [Signal Input Indicator] – Upper left corner of Timer Display, located to right of Power Indicator. Displayed
when activate signal is present.
•OUT [Output Indicator] - Displayed when relay is switched on; is not displayed when relay is switched to off.
•Present Value – Four digits segmented display in center of Timer. Shows current status of time.
•Timing Operation Indicator – Displays RUN in upper right corner to the left of Output Indicator. Displayed when
Timer is active.
•Set Value – Four-digit segmented display in lower right corner of the Shutter Timer. Shows set length of time.
•K/P [Key Protect] –Will always be lit as the function of the Shutter Timer is programmed at the factory and locked
before shipment.
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.
•RST [Reset Indicator] – Active when the Shutter Timer is reset by pressing the “RST” button on the lower left face
of Shutter Timer.
•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.
Present Value
Set Value
Press top half to
increment digit up
Reset Button Press bottom half to
increment digit down
Figure 10. Shutter Timer
To set the Shutter open duration, press the appropriate up/down button until the corresponding digit increments in
the set value. By pressing the key labeled (1), it will increment the left most digit on the set value. By pressing the
key labeled (2), it will increment the second digit of the set value and similar for digits 3 and 4. The small grey
buttons are “rocker” style so pressing the top half increments the digit up while pressing the bottom half will
increment down. The Timer will increment from 9 back to 0. If the Timer is not operating, the Timer should
12 DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

periodically update the present value with the set value. If the Timer does not, press the Reset Button. Reset
value will become the present value. 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 Operation Mode on the front panel (large Rocker Switch left of the Timer).
Program the time into the Timer as described above and depress the Footswitch. Factory settings will open the
Shutter and the present 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 cannot be stopped once started. If power is removed from unit,
the Timer will reset to set value.
LAMP DUAL-HOUR METER
The Lamp Dual-Hour Meter (Figure 11) provides elapsed time
of unit operation (top display), as well as Bulb usage (bottom
display). The top display (Elapsed-Time Meter) continues to
count hours of operation on the unit and cannot be reset. The
lower display reflects the number of hours on the Bulb. Bulb
hours should only be reset when a new Bulb is installed.
Figure 11. Lamp Dual-Hour Meter
When the Total Bulb Hours Line of the Lamp Dual-Hour Meter
reaches 2,000 hours, the display will alternate between
“CHANGE BULB” and "2000.0". This indicates that the Bulb
has reached the end of its useful life and needs replacement.
Instructions for Bulb replacement are found in the Bulb
replacement section of this manual as well as being located on
the sticker under the unit cover next to where the Bulb is
located.
WARNING: Operating a BlueWave®200 Lamp beyond 2,000
hours will result in a non-passive failure of the Bulb! Do not
reset the Lamp Dual-Hour Meter without replacing the Bulb.
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 Bulb Mount Figure 13. Lift Bulb Mounting Bracket Figure 14. Remove Bulb from
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 13

Bulb Mount
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).
6. Make sure that the center Electrode is positioned as shown in Figure 22.
Mounting Bracket Thumbscrews
This metal Electrode connecting the Bulb
to the wire from the Reflector should be
parallel to the bottom of the unit.
Figure 19. Install Bulb Figure 20. Plug in Bulb Figure 21. Tighten Mounting Figure 22. Bulb Electrode
Bracket Thumbscrews
7. Press Hour Meter Reset Switch (Figure 23).
8. Re-install the BlueWave®200's cover.
Figure 23. Hour Meter Reset Button
9. This completes Bulb installation. The Bulb will now ignite. If the Bulb does not light, repeat instruction 5. The unit is
now reset to operate for 2,000 hours.
14 DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

10. Allow the Bulb to warm up for five minutes and then the unit is ready for use.
Figure 24. BlueWave 200 Front Plate
Figure 25. Illuminated Blue Lens
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
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 blue lens above the Lightguide Mount (Figure 25).
Before operating unit, allow the 200 Watt Lamp to warm-up for
approximately 5 minutes.
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.
Figure 26. 9-Pin I/O Signals
9-PIN CONNECTOR I/O SIGNALS
The BlueWave 200 is equipped with a 9-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 – Shutter Activate
This signal line may be used to remotely open the BlueWave 200 Shutter. When it is being used, the local Shutter
Enable Jack on the rear of the BlueWave is still capable of opening the Shutter. Similar to the local Shutter
Enable, if the Timer/Manual Switch is in timer mode, the Shutter will stay open for the time set on the Timer. In the
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 15

manual mode, the Shutter will stay open for the duration of the remote Shutter Activate Signal. The Shutter is
opened when Pin 1 of the DSUB9 Connector is connected to Pin 2. When the connection between DSUB9
Connector Pins 1 & 2 is broken, the Shutter is closed.
Pin 7 – Shutter De-Activate
This signal line may be used to remotely prevent the Shutter of the BlueWave®from being open under any
circumstances. If the operator wishes to use the Shutter deactivate feature they must first remove both Outer and
Inner Cover Assemblies and remove Jumper JP-2 from the Communications Board.
200 Watt units are shipped from the factory with Jumper JP-2 installed on the Communications Board. This board
is located on the rear of the OMRON Timer and can be accessed only by removing the Outer and Inner Cover
Assemblies.
Once JP-2 is removed, this will allow the operator to remotely enable or disable the Shutter deployment from any
input.
If using a PLC to control this signal, an isolated relay contact (normally open) will provide the proper sense in the
event a disable of Shutter is required. Closing the contact, connecting Pin 7 to Pin 2 of the DSUB9 Connector will
provide normal Shutter operation. Opening the connection between Pins 7 and 2 of the DSUB9 Connector will
disable Shutter operation and leave the Shutter closed. Under this condition, the Shutter may not be operated
locally or remotely.
In summary, both input signals are said to be enabled when there is electrical contact between their pin and Pin 2
of the 9-Pin D-Subminiature Connector. Closure can be supplied either by dry contacts or by Opto-Coupler output
as shown in Figure 27.
Output Signals:
The output signals are all opto-isolated signals. Each signal has an NPN Output Transistor. The emitters of all
Output Transistors are tied together and connected to the PLC common on DSUB9 Pin 4. Each individual Output
Signal Line is connected to the collector of each Transistor. When the Transistor is turned on, this provides a
ground to the PLC system that can be used to enable a relay coil or an enable signal to an Opto-Coupler. The
Conducting Transistor can also function as a set of contacts that can initiate actions within the PLC. When the
Transistor is on, the signal is said to be enabled or asserted. When the Transistor is off, the signal is said to be
disabled or unasserted. The Transistors have a max current rating of 30 mA, and a max power rating of 150mW.
Only positive voltages with respect to the PLC common should be used to a maximum of 24 V. D. C. Series
Limiting Resistors should be used to insure that the max conditions are not exceeded.
Pin 3 - Shutter Fault
Pin 6 - Shutter Open
Shutter fault and Shutter open are gated by two Photocells monitoring the position of the Shutter. When the
Shutter is closed, both Photocells will be conducting due to their exposure to Lamp intensity. When the Shutter
begins to deploy to an open position, first Shutter fault, then Shutter open will be blocked from Lamp intensity by
the Shutter Assembly itself. Should the Shutter get stuck, one of these signals will indicate the wrong sense, and
will flag the problem.
When the Shutter is off, Pins 3 and 6 will be shorted to Pin 4. When the Shutter opens, both Pins will be open with
respect to Pin 4. Since a shorted condition would be used to indicate a failure, these signals should only be polled
45 milliseconds after the Shutter closes. By this time they will be open with respect to Pin 4 in normal operation.
Should either of these lines remain shorted to Pin 4 after the 45 millisecond delay, the operator should conclude
that a Shutter fault condition exists.
Pin 8 – Lamp Lit
Pin 8 will be shorted to Pin 4 when the Bulb is lit. Pin 8 will be open with respect to Pin 4, during startup prior to
the Bulb lighting, or if the Bulb has failed.
16 DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System

Pin 9 – Lamp Replace
When the Elapsed Time Meter reaches 2000 hours, it disables the Lamp from lighting. At this point in time, Pin 9
becomes shorted to Pin 4. Pin 8 will no longer be shorted to Pin 4 indicating that the Lamp is no longer lit.
Otherwise, Pin 9 will be open with respect to Pin 4.
Pin 5 of the DSUB9 Connector is not used at this time.
Figure 10 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. 9-Pin I/O Signals
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 17

MAINTENANCE
The BlueWave®200 was designed to operate with a minimal amount of 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 1.1 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
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).
Bulb Will Not
Ignite
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.
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.
Low Output
Intensity
or
Fails To Cure
Adhesive In
Allotted Time
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.
FREQUENTLY ASKED QUESTIONS
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.
DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System 19

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 lower display on 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 for five minutes.
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.
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: Ideal 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.
20 DYMAX BlueWave®200 Version 1.1 UV Light-Curing Spot Lamp System