dymax BlueWave AX-550 User manual

BlueWave® AX-550
All-in-One, Large-Area LED
Flood System User Guide

2 U S E R G UI D E |B L U E W A V E ®AX-550
About Dymax
UV/Visible light-curable adhesives. Systems for light
curing, fluid dispensing, and fluid packaging.
Dymax manufactures industrial, light-curable, epoxy, 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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Contents
Introduction ..................................................................................4
Where to Get Help.................................................................................. 4
Safety ............................................................................................4
Product Overview......................................................................... 5
Unpacking .....................................................................................6
Unpacking and Inspecting Your Shipment ......................................... 6
Parts Included......................................................................................... 6
System Installation .......................................................................7
System Assembly................................................................................... 7
System Cooling ...................................................................................... 7
Wiring and Connections ........................................................................ 8
Connections ............................................................................................ 9
PLC UV Control ...........................................................................14
Status Output........................................................................................15
Operation ....................................................................................17
System Initialization..............................................................................17
Rotary Pushbutton................................................................................17
System Initializing.................................................................................18
Information ............................................................................................18
System Settings....................................................................................19
Program Load/Save .............................................................................23
Irradiation Setup ...................................................................................24
Irradiation in Production or Admin Mode ..........................................26
Irradiation in PLC mode.......................................................................27
Maintenance................................................................................29
Product Cleaning..................................................................................29
Emitter Replacement............................................................................29
Replace Fuse ........................................................................................30
Troubleshooting .........................................................................31
Error Screen..........................................................................................31
Spare Parts & Accessories.........................................................33
Accessories...........................................................................................33
Components & Spare Parts ................................................................33
Specifications .............................................................................34
Validation ....................................................................................36
Set Exposure Time, Determine Intensity...........................................36
Set Intensity, Determine Exposure Time ...........................................36
Control ...................................................................................................36
Warranty...................................................................................... 37

4 U S E R G UI D E |B L U E W A V E ®AX-550
Introduction
This guide describes how to set up, use, and maintain BlueWave®
AX-550 LED flood-curing system safely and efficiently.
Intended Audience
This user guide is meant for experienced process engineers,
technicians, and manufacturing personnel. If you are new to high-
intensity LED light sources and do not understand the instructions,
contact Dymax Application Engineering for answers to your
questions before using the equipment.
Where to Get Help
Dymax Customer Support and Application Engineering teams are
available by phone in the United States, Monday through Friday,
from 8:00 a.m. to 5:30 p.m. Eastern Standard Time. You can also
email Dymax at [email protected]. Contact information for additional
Dymax locations can be found on the back cover of this user guide.
Additional resources are available to ensure a trouble-free
experience with our products:
•Detailed product information on our website www.dymax.com
•Dymax adhesive product data sheets on our website
•Safety data sheets (SDS) provided with shipments of Dymax
materials
Safety
WARNING! If you use this UV light source without first
reading and understanding the information in the UV Light
Safety Guide, SAF001, injury can result from exposure to high-
intensity light. To reduce the risk of injury, please read and ensure
you understand the information in that guide before assembling and
operating the Dymax UV LED light source.
This device falls under IEC 62471 Risk Group 3 for UVA and Blue
Light emissions:
WARNING! UV emitted from this product. Avoid eye and skin
exposure to unshielded products.
WARNING! Possibly hazardous optical radiation emitted from
this product. Do not look at operating lamp. Eye injury may result.

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Product Overview
The BlueWave AX-550 is a high-intensity LED flood system
used for curing light-curable materials. The unit is designed to
be integrated into a larger system, such as an automated
manufacturing system, or used with a light shielding enclosure
to create a bench-top curing station.
The BlueWave AX-550 is an all-in-one system that incorporates
an LED flood emitter and control system for manual and
automated process applications. Dymax offers three different
wavelength LED flood emitters: VisiCure®(405 nm),
PrimeCure®(385 nm), and RediCure®(365 nm).
The controller portion includes the controller and power
supply, which is designed to identify the type of emitter that is
connected so the control portion of the system can be used
with any of the three LED emitter configurations.
The BlueWave AX-550 functions as a flood-curing system with
a 125 mm x 125 mm (5 in x 5 in) irradiated curing area.
The unit can be operated in admin mode (unrestricted control)
or production mode (restricted control) which allows for
process management via access restrictions.
The unit can be controlled as well by Programmable Logic
Controller (PLC) for automation applications.
LED technology within the BlueWave AX-550 LED Flood
System allows for instant on/off activation without the need for
a warm-up period and is also rated for continuous operation.
Figure 1.
AX-550 LED Flood Curing System

6 U S E R G UI D E |B L U E W A V E ®AX-550
Unpacking
Unpacking and Inspecting Your Shipment
Upon arrival, inspect all 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.
The parts below are included in every package/order. If parts are missing from your order, contact your local Dymax
representative or Dymax Customer Support to resolve the problem.
Inspect the glass for any damage or residue on the surface. Carefully clean the glass with the alcohol swab. Take care not to
touch the glass with bare hands, as any residue left on the window can adversely affect performance on the unit.
NOTE: The BlueWave AX-550 power cord requires a snap-on EMI Filtering Ferrite Core located near the plug end of the cord.
The ferrite core may be factory installed (with optional wire tie –not required). Reference Quick Start QS101 “BlueWave AX-
550 V2.0 Power Cord Ferrite Core Installation Instructions” for specific wire routing and installation procedure.
Parts Included
•BlueWave AX-550 Controller
•BlueWave AX-550 Emitter (RediCure, PrimeCure, or VisiCure,
model as selected at time of purchase)
•Power Cord
•EMI Filtering Ferrite Core (Assembly Required)
•BlueWave AX-550 LED Flood System User Guide
(document not shown)
•Terminal Block (Plugged on the BlueWave AX-550 Controller)
•Footswitch
•Safety Eyewear
Figure 2.
System Packaging
Figure 3.
Components of the BlueWave AX-550 Curing System
Controller Packaging
Emitter Packaging
Footswitch (CE Compliant)

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Figure 4.
Align Controller and Emitter
Figure 5.
Install 4 Screws
Figure 6.
Minimum Clearance
System Installation
System Assembly
The system includes two major parts, the Controller and the
Emitter. The two parts are shipped separately. To assemble the
two parts together, please follow the instruction below:
1. Locate the 4 Screws to be used to assemble the Emitter to
the Controller.
2. Carefully place the Emitter on a clean and flat surface. Align
the Controller and the Emitter as shown in Figure 4. Plug
the Controller into the Emitter.
NOTE: Be careful to keep the glass at the bottom of the
Emitter clean. To avoid leaving fingerprints on the glass, do
not touch the glass with bare hands.
3. Install the 4 Screws to secure the Emitter to the Controller.
Tighten snugly with appropriate screwdriver, failure to
install screws will leave the potential for poor electrical
grounding of the system.
NOTE: All four screws MUST be installed to ensure proper
grounding of the system chassis.
WARNING! The BlueWave AX-550 is designed and
certified to operate as instructed within this document.
Alteration of the system or its component installation
may pose a shock hazard.
System Cooling
The system can be used in various scenarios with additional
mounting fixtures or Dymax accessories. For example: on a
desktop with a Dymax stand, on a chamber, conveyer, etc. This
system should only be operated in a location that provides proper
cooling. Location requirements are as follows:
•For proper cooling of the unit, upper intake and lower
exhaust must not be blocked.
•Minimum clearance as shown in Figure 6.
•Note that the lower exhaust may have one side blocked for
installations where two units are side by side. The system
will operate safely but run hotter.
Intake
requires
1" vertical
clearance
Minimum of
one side
open with 1"
clearance

8 U S E R G UI D E |B L U E W A V E ®AX-550
Figure 7.
Controller, Topside
Figure 8.
PLC Connector Pin Reference
Wiring and Connections
All the wire and cable connections are at the top side of the controller.
NOTE: For convenience, the I/O Interface contains two chassis ground
connections that are in common with the earth connection of the power
plug. These are the only two connections that should be used to make
external connections to earth ground.
Power Input: The power cord plugs in here. Only use the power cord
supplied by Dymax. The power cord supplied with the Controller is
specifically designed and certified to work with the Controller. The
Dymax supplied power cord contains a special ferrite at the plug end
which is required for proper operation of the Controller.
WARNING! The BlueWave AX-550 is designed and
certified to operate with the Dymax supplied 10Amp, 18AWG,
3 conductor power cord with ferrite core. Do not use any
other non-standard power cord that does not have the same
current rating and does not have the correct ferrite core installed.
Power Switch: Turns the unit on and off.
I/O Interface: Reference connector pin-out on the back of the
controller (Figure 8). Provides for wiring of remote-control features
including footswitch, inhibit/interlock, PLC and status signals.
Note: I/O connector type Phoenix Contact, Combicon, 1790360
Power
Input
Power Switch
I/O Interface with Terminal Block
installed

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Figure 9.
Insert Hard Wire into Terminal Block
Figure 10.
Insert Soft Wire or Pull Wire Out of Terminal
Block
Figure 11.
Remove Jumper from Terminal Block
Connections
An 18-pin removable terminal block (the green part in Figures 9-11)
comes with the controller. The terminal block allows quick and easy
wiring. The terminal block can fit the wire from AWG 24 to AWG 16.
General Instructions for Terminal Attachment
•To connect a hard wire to the terminal block (such as
the footswitch terminals): Plug the end of the wire into the
terminal (Figure 9).
•To connect a soft wire to the terminal block or pull out
the wire from the terminal block: Use a flat screwdriver
to push the orange tab located beside the terminal. Then
plug the wire in or pull the wire out (Figure 10).
•To remove the jumper from the terminal block: Use two
flat screw drivers to simultaneously push the orange tabs
located beside the terminal. Then pull the jumper out.
(Figure 11)

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I/O Interface Summary
Table 1 below shows the summary of all signals on the PLC Connector.
Table 1.
I/O Interface
Signal Name / Description
PIN #
Signal Level
Asserted
De-Asserted
INPUTS
SPARE(S)
1, 2, 9
Do Not Use
ANALOG INTENSITY
Only used in PLC –EXT mode
Sets Emitter intensity level (0~1V=10% output, 10V=100% output)
Input Impedance: 10KΩ
3
0 –10 VDC
N/A
MASTER INTERLOCK
Input Current: 0 –7mA
5
0 VDC, GND
(Open)
PLC ENABLE
Input Current: 0 –7mA
12
0 VDC, GND
(Open)
LED ON/OFF
Input Current: 0 –7mA
6
0 VDC, GND
(Open)
INTENSITY INT/EXT (Internal/External control)
Input Current: 0 –7mA
7
0 VDC, GND
(Open)
LED INHIBIT
Input Current: 0 –7mA
15
0 VDC, GND
(Open)
OUTPUTS
PLC POWER (1)
(24V, 500mA maximum)
8
Always On
SYSTEM HEALTH
Sink Current: 50mA max.
10
0 VDC, GND
Open
LED STATE
Sink Current: 50mA max.
11
0 VDC, GND
Open
RETURNS (These pins are common and may be used interchangeably)
PLC GND
(Common signal return)
4
PLC mode Ground
COM
(Common signal returns)
A, B, 16
Common Grounds
CHASSIS GROUND (These pins are common and may be used interchangeably)
Chassis Grounds (2)
13,14
Chassis Ground
(1) PLC power channel is a 24V source available for use to drive PLC logic but must be current limited using pull-down resistors to protect the BlueWave AX-550
when directly attached to the I/O channels through the PLC connector.
(2) CHASSIS Ground connections do not share a common connection with signal returns and cannot be interchanged with signal returns.

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Connect Power Cord
1. The Dymax supplied Power Cord requires installation of a Ferrite at the plug end for proper operation of the Controller
(Figure 12). Please refer to “QS101 - BlueWave AX-550 V2.0 Power Cord Ferrite Core Installation Instructions” for
complete installation instructions.
Figure 12.
Power Cord with Ferrite (shown with factory-installed wire tire, which is optional –not required)
2. Once the Ferrite has been attached to the Power Cord, plug the Power Cord into the Power Input located on the unit’s top
panel (Figure 7).
3. Plug the opposite end of the Power Cord into an appropriate AC outlet. The system uses universal 100 ~ 240 VAC power.
WARNING! If the BlueWave AX-550 controller is powered on without an LED emitter connected, the controller screen
will show an alert notification and audible alarm.
Connect the Inhibit/Interlock PLC Controls
There are 2 control inputs to disable the UV output. These 2 signals must be connected to PLC GND or COM to enable proper
operation of the system. The factory supplied I/O connector has jumpers installed for basic operation.
The LED INHIBIT is used to disable the UV output at the emitter head when the jumper or circuit attached is open.
•LED INHIBIT is controlled by connecting Pins 15 and 16 on the PLC terminal block.
The MASTER INTERLOCK is used to disable the UV output at the controller when the jumper or circuit attached is open.
•MASTER INTERLOCK is controlled by connecting Pins 4 and 5.
See Figure 13 for the jumper and Figure 15 for the example connection.

12 U S E R G UI D E |B L U E W A V E ®AX-550
Figure 13.
Factory Jumpers on the PLC Connector, Viewed from
Backside
Figure 14.
PLC Connector Pin Map with Jumper locations highlighted
Figure 15.
Example Connection for LED INHIBIT and MASTER INTERLOCK
Jumper
Locations

U S E R G UI D E |B L U E W A V E ®AX-550 13
Connect Footswitch
To control UV illumination with the footswitch option, connect as shown below.
•Red Wire to LED ON/OFF PIN 6
•Black Wire to a COM PIN (A)
•Green/Yellow Wire to CHASSIS GND PIN 14
Figure 16.
Footswitch
Figure 17.
Footswitch Wiring Pin Locations
Figure 18.
Footswitch Schematic
LED ON/OFF
PLC CONNECTOR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A B
Shield_GND
COM
Foot Petal

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PLC UV Control
PLC switching may be driven by manual switch, relay, or optical coupler. Only analog intensity uses a voltage input to the PLC.
To use the PLC mode inputs, the PLC ENABLE pin 12 must be pulled down to low by grounding to the PLC return, PLC GND
or a COM ground point
The PLC can control the UV on/off using the LED ON/OFF input Pin 6. When this input is pulled down by grounding to COM
ground, the UV LED will turn on.
The PLC can also control the intensity of the UV output.
•When the INTENSITY IN/EXT input Pin 7 is pulled down low by grounding to COM ground, the Intensity will be
controlled by the EXTERNAL ANALOG INTENSITY input voltage.
•The ANALOG INTENSITY input, Pin 3, is an analog voltage input. The voltage range is 0 to 10VDC.
Any setting 1 VDC or below will set the Intensity to 10% and each additional volt increases intensity by 10%. (Example: 5V =
50%, 7.5V = 75%, 10V = 100%) All three PLC inputs, LED ON/OFF, INTENSITY IN/EXT and ANALOG INTENSITY work in PLC
mode only. They are ignored in other working modes. The example connection for the PLC control signal is shown in Figure 19.
Figure 19.
PLC Connection

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Status Output
There are two status outputs. They are driven by an optical coupler. These outputs work in any mode, and can be used as
status inputs for PLC or any status display/monitor purpose.
•System Health - Output low to indicate the unit is normally working.
•LED State - Output low to indicate the UV LEDs are ON.
The example application of these signals is shown below in Figure 20.
Figure 20.
Status Outputs Connection Using On-Board 24V Source
PLC Power channel is a 24V source available for use to drive PLC logic but must be current limited using pull-down resistors
to protect the BlueWave AX-550 when directly attached to the I/O channels through the PLC connector.
Figure 21.
PLC Status Outputs Using Customer-Supplied 24V Source
For sinking current below 7mA it is suggested when using solid state relays to use one of these devices:
Weidmuller 8820710000, Phoenix Contact 2980636.

16 U S E R G UI D E |B L U E W A V E ®AX-550
Figure 22.
Examples of Customer Configurations for Monitoring Outputs
PLC Power channel is a 24V source available for use to drive PLC logic but must be current limited using pull-down resistors
to protect the BlueWave AX-550 when directly attached to the I/O channels through the PLC connector.

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Figure 23.
Front Panel
Figure 24.
Initializing Screen
Figure 25.
Set and Modify a new value.
Operation
To operate the BlueWave AX-550 system:
1. Verify that the Controller and Emitter are assembled
properly, the input power is correctly plugged into the AC
Inlet on the top of the unit, and the Interlock Jumpers (or
external safety sensor) are installed between Pins 4 & 5,
and 15 & 16 of the I/O Connector on the top of the unit.
2. When all connections are properly made, toggle the Power
Switch on the top of the unit. The system is now ready for
use.
System Initialization
Upon startup of the unit, a splash screen displays the controller
and emitter FW versions. After about 6 seconds, the control
screen should appear in the display. The unit loads in
administrator mode the first time it’s started.
The control screen is used to set up and run curing cycles. Admin
screen allows users to switch back and forth between
admin/production mode if the PLC mode is disabled. Curing
parameters are set in the admin screen.
Rotary Pushbutton
The front panel on the controller features a rotary pushbutton which
can be used for function selection and for modifying all adjustable
irradiation parameters when not in PLC mode. Specific irradiation
settings may also be saved and loaded using the Program Load/Save
feature explained in a later section. All settings and status can be
viewed on a color LCD display.
•Turning the rotary pushbutton moves the selection field as
indicated on the LCD display.
•Pressing the center of the rotary pushbutton selects the menu
item or sets the input for the active field.
NOTE: The selected value will appear in blue color, when selected
value requires modification press the rotary pushbutton, then, this
value will turn yellow indicating it is ready to be modified. Turning the
rotary pushbutton changes the value to be selected.
LCD
Display
Rotary
Push
Button
Control

18 U S E R G UI D E |B L U E W A V E ®AX-550
Figure 26.
Padlock location
Figure 27.
Information screen
System Initializing
The system is designed to work in any one of three modes of operation as
indicated in the upper left of the display:
Admin Mode: The administration mode allows full control of
system functions.
Production Mode: This mode doesn’t allow changes to the
irradiation parameters.
PLC Mode: in PLC mode, an external PLC can control the unit.*
*NOTE: PLC Mode icon is located in the upper right of the display.
To enter PLC mode, connect the external PLC system and toggle the PLC
ENABLE (Pin 12) input Low to 0VDC. The PLC icon will be seen on the
screen automatically. Leave the PLC ENABLE open to enter the
Administrator or Production mode.
Selecting the padlock button switches between Administration and
Production modes, a password will be required to enter admin mode.
The default password to enter admin mode is 00000. To change the
password, please see “System Settings” and Figure 32.
NOTE: Switching between PLC and non-PLC mode can happen when the
system is powered ON or OFF, but the LED must be OFF for safety.
Information
Information: Displays system information.
Only available in Admin mode, using the rotary pushbutton select the
information icon in the upper right area of the LCD screen.
Push the rotary pushbutton and the “Information” screen will appear.
The following Controller/Emitter system information will be
displayed.
1. The Controller Serial Number and Firmware Revision.
2. The Emitter Array Type (RediCure, PrimeCure, VisiCure).
3. The Emitter Array Serial Number and Version.
4. The Calibration Date (yymm): target intensity.
5. The maximum (temperature, current draw, voltage level),
experienced by the Emitter Array.
6. LED HRS (Total time the emitter array has been illuminated).
7. LED PRH (Power Rated Hours = Total time the emitter array
has been illuminated* Power Setting / 100).
Push the rotary pushbutton to return to the main screen.

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Figure 28.
Admin Mode Settings Screen
Figure 29.
Production Mode Setting Screen
Figure 30.
Configuration Settings
System Settings
In Admin Mode or Production Mode, select the settings icon
located at the upper right corner.
Settings: Loads the settings screen where the volume,
language, screen brightness, and other user settings
can be adjusted.
In admin mode, the settings screen shows all settings (Figure 28).
In the production mode, the settings screen layout is identical to
the admin screen, except the admin settings option is not available
(Figure 29).
Settings Screen
The settings and operations for both Admin and Production Mode
are shown below:
Language - Future support for multiple languages.
Brightness - Opens the brightness screen where the
adjustment of the LCD backlight can be modified in a
range from 1 to 10.
Volume - Opens the volume screen where the operation
volume can be modified in a range from 0 to 10.
Admin - While in Admin mode opens the user screen
where boot mode can be selected and the Admin
password may be accessed.

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Table 2.
Production and Admin Settings Menu
Setting
Symbol
Operation
Operation Result
Press the rotary pushbutton when it turns blue to
return to the previous menu or to ignore the
changes made and keep the current value
Used to change the language (only English is
available at this time)
Opens the brightness screen where the
adjustment of the LCD backlight can be modified
in a range from 1 to 10, 1 to get the lowest
luminosity and 10 the highest luminosity
Used to change the operation volume in a range
from 0 to 10, 0 to get the mute mode and 10 the
highest volume