dymax BlueWave MX-Series User manual

BlueWave® MX-Series 1-Channel
Curing System User Guide
BlueWave®MX-150 LED Spot-Curing System
BlueWave®MX-250 LED Flood-Curing System
Instructions for Safe Use
Setup and Operation
Maintenance
Ordering Spare Parts and Accessories
BlueWave® MX-150
BlueWave® MX-250

BlueWave® MX-Series 1 Channel Curing Systems User Guide
2
About Dymax
UV/Visible light-curable adhesives. Systems for light curing, fluid dispensing, and fluid packaging.
Dymax manufactures industrial adhesives, light-curable adhesives, epoxy resins, cyanoacrylates, and activator-
cured adhesives. We also manufacture a complete line of manual fluid dispensing systems, automatic fluid
dispensing systems, and light-curing systems. Light-curing systems include UV broad-spectrum and LED curing
sources configured in, 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.

BlueWave® MX-Series 1 Channel Curing Systems User Guide
3
Contents
Introduction ...............................................................................................................5
Introduction to the User Guide .............................................................................. 5
Where to Get Help ................................................................................................. 5
Safety.........................................................................................................................6
General Safety Considerations............................................................................... 6
Safety Symbol Index............................................................................................... 6
Specific Safety Considerations ............................................................................... 7
Dymax UV Light-Curing System Safety Considerations .......................................... 9
Product Overview.....................................................................................................11
Description of BlueWave MX-Series 1CH Systems ............................................... 11
Features & Benefits.............................................................................................. 14
Controller Front Panel.......................................................................................... 15
Controller Back Panel........................................................................................... 16
Unpacking ................................................................................................................17
Parts Included ...................................................................................................... 17
System Setup ........................................................................................................... 17
System Connections............................................................................................. 17
Modes of Operation ................................................................................................. 19
Manual Mode....................................................................................................... 19
Timer Mode.......................................................................................................... 19
PLC (Programmable Logic Controller) Operation ................................................. 20
Examples of PLC Wiring ............................................................................................ 23
Operation.................................................................................................................24
Control Screen...................................................................................................... 25
Irradiation ............................................................................................................ 27
Saving Programs................................................................................................... 28
System Settings ........................................................................................................28
Language Settings ................................................................................................ 29
Volume Settings ................................................................................................... 29
Brightness Settings............................................................................................... 30
User Settings/Boot Modes ................................................................................... 30

BlueWave® MX-Series 1 Channel Curing Systems User Guide
4
System Information.................................................................................................. 31
Troubleshooting & Maintenance ..............................................................................32
Measuring/Checking Intensity ............................................................................. 32
Product Cleaning .................................................................................................. 32
Alarms .................................................................................................................. 32
BlueWave®MX-250 Glass Window Replacement Instructions............................. 33
Accessories............................................................................................................... 36
Spare Parts............................................................................................................... 37
Specifications ...........................................................................................................38
Validation.................................................................................................................42
Set Exposure Time, Determine Intensity.............................................................. 42
Set Intensity, Determine Exposure Time.............................................................. 42
Control ................................................................................................................. 42
Warranty..................................................................................................................43
Index........................................................................................................................44

BlueWave® MX-Series 1 Channel Curing Systems User Guide
5
Introduction
Introduction to the User Guide
This guide describes how to set up, use, and maintain BlueWave® MX-Series 1 Channel
(CH) curing systems 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 www.dymax.com
Dymax adhesive product data sheets on our website
Safety data sheets (SDS) provided with shipments of Dymax materials

BlueWave® MX-Series 1 Channel Curing Systems User Guide
6
Safety
WARNINGS! If you use this LED light source without first reading and
understanding the information in this user guide, injury can result from
exposure to high-intensity light. To reduce the risk of injury, please read and
ensure you understand the information in this user guide before assembling
and operating the Dymax LED light source.
To use a BlueWave MX-Series 1CH system safely, it must be set up and operated in
accordance with the instructions given by Dymax. Using the system in any other manner
will impair the protection of the system. Dymax assumes no liability for any changes that
may impair the protection of the BlueWave MX-Series 1CH system.
General Safety Considerations
All users of Dymax LED light sources should read and understand this user guide before
assembling and using the system.
To learn about the safe handling and use of light-curable formulations, obtain and read
the MSDS for each product. Dymax includes an MSDS with each adhesive sold. In
addition, fluid product MSDS can be requested through our website.
Safety Symbol Index
The following symbols are displayed on BlueWave MX-Series 1CH systems. Please see
below for their meanings.
Refer to Equipment
Manual Before Operating
Equipment
Warning! Use Caution When
Operating Equipment
Eye Protection Required
Product Contains an
Electrostatic Sensitive Device
(EST) Internally
Complies with All Listed
European Directives
Warning! UV Light Hazard (Do
not look directly at light)
WEEE Directive (Waste
electrical and electronic
Warning! Hot Surface

BlueWave® MX-Series 1 Channel Curing Systems User Guide
7
equipment must be
disposed of or recycled at
the nearest collection
facility)
Specific Safety Considerations
The BlueWave MX-Series curing systems are designed to maximize operator safety and
minimize exposure to light-curing energy. To use the unit safely, it must be set up and
operated in accordance with the instructions in this user guide. Please also read and
understand the safety considerations unique to LED-curing systems as described below.
NOTE: Risk Group 3. Product tested against IEC62471.
WARNING! Looking directly at the high-intensity light emitted by the
BlueWave MX-150 or MX-250 can result in eye injury. To prevent eye injury,
never look directly at the energy-emitting end of the high-intensity emitter and
always wear protective goggles.
WARNING! UV emitted from this product. Avoid eye and skin exposure to
unshielded product.
CAUTION! Possibly hazardous optical radiation emitted from this product.
Do not stare at the bright light energy emitting from the unit. May be harmful
to the eye. To avoid accidental exposure, always point the emitter and/or
lightguide away and at the curing substrate.
WARNING! Possibly hazardous optical radiation emitted from this
product. Do not look directly at the light energy emitting from the unit. Eye
injury may result. To avoid accidental exposure, always point the emitter
and/or lightguide away and at the curing substrate.
WARNING! The controller is cooled by natural convection. If you block the
air flow from the controller, equipment damage and malfunction can result. To
prevent damage and malfunction, ensure adequate space around controller
vents to allow the free flow of air. Typically, 1.5 in (38 mm) of space around all
sides of the controller is sufficient.
WARNING! Surface of light emission optics is very hot after continuous use
of MX-150 or MX-250 emitter. Do not touch the distal, light-emitting end of
the MX-150 lightguide-simulator optic or the MX-250 glass window. Touching

BlueWave® MX-Series 1 Channel Curing Systems User Guide
8
these surfaces can result in burns. Please allow either optic to cool for 10
minutes before attempting to replace the optic.

BlueWave® MX-Series 1 Channel Curing Systems User Guide
9
Dymax UV Light-Curing System Safety
Considerations
Operators must understand these three concepts to use the LED light source safely: UV
exposure, high-temperature surfaces, and bright, visible light.
UV Exposure
Figure 1. UV Spectrum
Standard Dymax UV light-curing systems have been designed primarily to emit UVA and
Visible energy (Figure 1). Depending on the model of LED head used, the energy emitted
from a BlueWave MX-Series 1CH curing system can either be in the upper end of the
UVA portion of the spectrum (PrimeCure® and RediCure®) or in the lower portion of the
visible spectrum (VisiCure®). UVA energy is generally considered the safest of the three
UV ranges: UVA, UVB, and UVC. Although OSHA does not currently regulate UV-light
exposure in the workplace, the American Conference of Governmental Industrial
Hygienists (ACGIH) does recommend Threshold Limit Values (TLVs) for ultraviolet light.
The strictest interpretation of the TLV (over the UVA range) for workers’ eyes and skin
allows continuous exposure up to 1 mW/cm2(intensity). Unless you are placing bare
hands into the curing area, it is unusual to exceed these limits. To put 1 mW/cm2limit
into perspective, a cloudless summer day will typically exceed 3 mW/cm2of UVA light,
and also include the more dangerous UVB light (primarily responsible for sun tans, sun
burns, and skin cancer).
Checking the Workstation
The human eye cannot detect "pure" UV light, only visible light. A radiometer should be
used to measure stray UV light to confirm the safety of a UV light-curing process. A

BlueWave® MX-Series 1 Channel Curing Systems User Guide
10
workstation that exposes an operator to more than 1 mW/cm2of UVA continuously
should be redesigned.
Protecting Operators
Light-curing technology can be a regulatory compliant, "worker-friendly" manufacturing
process when the proper safety equipment and operator training is utilized. There are
two ways to protect operators from UV exposure: shield the operator and/or shield the
source.
Shield the Operator
UV-Blocking Eye Protection —UV-blocking eye protection is recommended when
operating UV light-curing systems. Both clear and tinted UV-blocking eye protection is
available from Dymax.
UV-Blocking Skin Protection —Opaque, UV-blocking clothing, gloves, and full-face
shields are recommended when skin may potentially be exposed to UV light.
Shield the Source of UV
Any substrate that blocks UV light can be used as a shield to protect workers. The
following materials can be used to create simple shielding structures:
Rigid Plastic Film —Transparent or translucent/UV-blocking plastics (typically
polycarbonate or acrylic) are commonly used to create shielding where some level of
transparency is also desired.
Flexible Film —Translucent UV-blocking, flexible urethane films can be used to
quickly create workstation shielding. This UV-blocking, flexible urethane film is available
from Dymax, call for assistance.
High-Temperature Surfaces
Surfaces exposed to high-intensity curing energy may rise in temperature. The intensity,
distance, exposure time, cooling fans, and composition of the surface can all affect the
rise in surface temperature. In some cases, exposed surfaces can reach temperatures
capable of producing a burn or causing damage to a substrate. In these cases, operators
should try to maintain a cooler surface temperature or they should have the appropriate
protection/training to avoid injury from the heat. No infrared radiation is produced by
these LED systems, so surface temperatures will be lower than with conventional lamp
systems. Empirical testing should be used to verify the exact temperature rise in each
application.

BlueWave® MX-Series 1 Channel Curing Systems User Guide
11
Bright Visible Light
The bright visible energy emitted by curing systems can cause eyestrain if proper eye
protection or shielding is not used. The use of tinted eye protection and/or opaque/
tinted shielding can be utilized to reduce eyestrain and address this concern.
Product Overview
Description of BlueWave MX-Series 1CH Systems
BlueWave MX-Series curing systems feature all the benefits of LED-curing technology in
smaller, more versatile units. These systems are uniquely designed to offer higher, more
consistent curing intensity than traditional spot or flood curing systems. The systems are
comprised of a power supply, a controller with an easy-to-use control interface, and an
emitter. Emitters are available in two models, the MX-150 for spot curing and MX-250
for flood curing, as well as in three different curing wavelengths, 365, 385, and 405 nm.
The BlueWave MX-150 functions as a high-intensity spot-curing system. The system
has the ability to be set up in many configurations and can be used with a
lightguide if needed.
The BlueWave MX-250 functions as a flood-curing system with a 50 mm x 50 mm (2
in x 2 in) active curing area. It provides manufacturers with additional curing
flexibility and expansion capabilities BlueWave MX-Series emitters can be used as
hand-held units or integrated into an automated manufacturing system allowing
for maximum application flexibility. Their output intensity levels can also be
adjusted from 10% to 100% to meet process and adhesive requirements. BlueWave
MX-Series 1CH systems are rated for continuous operation. However, if the internal
temperature of the system exceeds the maximum safe operating temperature
limits, each emitter contains a thermal sensor that will shut the unit down to
protect the components of the emitter.

BlueWave® MX-Series 1 Channel Curing Systems User Guide
12
Figure 2. Main Components of a BlueWave MX-150 System
Stand
Power
Switch
Controller
Emitter
Cable
Lightguide
Simulator
LED
Emitter
Touch
Screen
Display

BlueWave® MX-Series 1 Channel Curing Systems User Guide
13
Figure 3. Main Components of a BlueWave MX-250
Stand
Power
Switch
Controller
Emitter
Cable
LED
Emitter
Touch
Screen
Display

BlueWave® MX-Series 1 Channel Curing Systems User Guide
14
Features & Benefits
The BlueWave MX-Series 1CH system is engineered for precise performance and long
service life. Key features include:
Features
Benefits
Flexible mounting options
Adaptable to a variety of process and fixture scenarios
Available with spot or flood-
curing emitters
Supports a variety of curing processes
PLC interface
Easily incorporated into automated systems
100% duty cycle capability
Highest throughput (exposure cycles “at the speed of light”)
No mechanical shutter
Instant on/off/no warm up period
Intensity output adjustment
(10% to 100%)
Superior accuracy over “closed-loop feedback" or auto-
adjusting units
Optimum process control
LED emitters available in 365,
385, or 405 nm wavelengths
Compatible with a variety of UV and visible light-curable
materials, including Dymax materials for fewer re-
qualifications
Wavelength flexibility allows co-optimization of adhesive and
curing system for optimal cure
Units can be custom configured to your curing requirements
Stable LED temperature
Comfortable hand-held operating temperature
Maximized continuous operation without overheating
Optimizes cure time efficiency
Temperature monitoring assures maximum LED life

BlueWave® MX-Series 1 Channel Curing Systems User Guide
15
Controller Front Panel
The front panel features the power button and a touchscreen display through which the
unit can be operated.
Power Button —Press the power button to power up the controller. Press the button
a second time to turn the unit off.
Figure 3. Front Control Panel
Touch
Screen
Display
Power
Button

BlueWave® MX-Series 1 Channel Curing Systems User Guide
16
Controller Back Panel
Power Cord Receptacle —Connection point for the power cord.
Foot Pedal Jack —Connection point for the foot pedal.
PLC Connector Terminals —Connection points for an interface with a user-
supplied PLC (for remote operation).
Emitter Connector —Connection point for the system’s emitter.
Figure 4. Back Panel Controls & Connections
Emitter
Connector
PLC Input &
Output
Connection
Terminals
Foot Pedal
Jack
Power Cord
Receptacle

BlueWave® MX-Series 1 Channel Curing Systems User Guide
17
Unpacking
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.
Parts Included
Controller
LED Emitter
Controller
Power Supply
Emitter Cable
Power Cord
Foot Pedal
Safety Glasses
BlueWave MX-Series 1CH User Guide
LED Emitter Assembly
5-mm Lightguide Adapter (MX-150
Emitter Only)
System Setup
System Connections
NOTE: Although this product is designed with protection against ESD (Electrostatic
Discharge) it is recommended to take precautions against static when handling the
BlueWave MX-Series controller or LED emitter independently. Once these devices are
attached together through the interconnect cable, then the threat of ESD damage is
eliminated.
1. Attach the Power Cord to the Power Cord Receptacle located on the unit’s back
panel (Figure 4).
2. At the top of the Controller’s Rear Panel, there is a connector labeled “Emitter”
(Figure 4). Connect one end of the Emitter Cable to this connector and the other end
to the Emitter.

BlueWave® MX-Series 1 Channel Curing Systems User Guide
18
WARNING! Under no circumstance should the interconnect cable from the
BlueWave MX-Series 1CH controller to the LED emitter be connected or disconnected
while power to the unit is on. This procedure is usually called “hot-swapping” and
should not be performed as it could cause damage to the controller or the LED
emitter. Always power down the equipment before disconnecting any of these
devices.
3. Plug the opposite end of the Power Cord into an appropriate AC outlet. The unit is
now powered and ready to be turned on with the On/Off Switch located on the front
of the unit (Figure 3).
WARNING! If the BlueWave MX-Series 1CH controller is powered on with no LED
emitter connected, the controller screen will not show the banner containing the
information of the emitter type or wavelength. An error will appear on the display
and an audible alarm will sound. Power down the controller, connect the LED
emitter, then power on again and the banner will appear.
4. If using the optional foot pedal, plug it into the foot pedal jack on the rear panel of
the controller.
If you are using a PLC - There are input and output PLC Connection Terminals that
can be used to integrate the unit to an automated assembly line. The input
connections consist of PLC Enable, Emitter Interlock, Light Shield Sensor,
Program/Analog, and LED On. The unit normally has high logic levels (24V) and looks
for a low signal (0V) input. The 24VDC is supplied internally allowing use of a simple
contact closure such as a switch or relay to actuate the inputs.
The output PLC connection terminals consist of System Status, LED status and
Reserved. These output signals are 24VDC inactive and 0 Volts active.
The Analog intensity input is a 0 –10 Volt input that controls the LED intensity. This
function is active when the Prog/Analog and PLC Enable inputs are activated.
Refer to Table 1 for more complete description of PLC input and outputs.
5. Your unit is now ready for operation.

BlueWave® MX-Series 1 Channel Curing Systems User Guide
19
Modes of Operation
The system has three basic modes of operation: manual, timer, and PLC.
Manual Mode
In manual mode, the LED is energized when the foot pedal is pressed, passing curing
energy through the delivery optics, and de-energized when the foot pedal is released.
The LED may also be energized by momentarily pressing the run/stop button located in
the center of the touchscreen user interface. The LED will be energized to the power
level set through the touchscreen user interface. Pressing the run/stop button again
during the curing cycle will de-energize the LED.
When manual mode is selected, the time indicator will be initialized to zero. The time
display will count up during an exposure and display the total elapsed time at the end of
the exposure to allow the user to save the time and power values if desired. Starting a
new manual exposure will reset the time value to zero immediately and proceed to
count up.
Timer Mode
In timer mode, the LED is energized for a specific time period each time the foot pedal
or run button is pressed. The specific time is set by adjusting the timer’s value through
the touchscreen user interface. Momentarily pressing the foot pedal or run button
starts the timer and energizes the LED. When the timer counts down to zero, the LED is
de-energized, and no curing energy is emitted. The timer is reset to the pre-set value,
and the system is immediately ready to run another exposure cycle. The LED can be de-
energized at any time during the curing cycle by simply pressing the run/stop button.

BlueWave® MX-Series 1 Channel Curing Systems User Guide
20
PLC (Programmable Logic Controller) Operation
When in PLC mode, an external PLC can control
the unit. The PLC provides input signals to the
BlueWave MX-Series 1CH system to control the
on/off signals and intensity of the LED. The PLC
monitors the status of the system by reading
output signals provided by the unit.
The PLC is typically programmed to start other
machinery when the BlueWave MX- Series 1CH
system becomes ready, or something starts the
unit when other machinery is ready. The input
and output signals are present on connector (J5)
located on the back of the unit.
NOTE: A ferrite will be required on the PLC
(0-10V) analog input cable to reduce noise.
Ferrite bead (PN 0443164251) installed on the
analog PLC cable (looped once) at the EUT end.
Figure 5. PLC Mode Screen
Figure 6. PLC Inputs & Outputs