dymax BluWave QX4 User manual

BlueWave®QX4®User Guide
Multi-Head LED Spot-Curing System
■Instructions for Safe Use
■Setup and Operation
■Maintenance
■Ordering Spare Parts and Accessories

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About Dymax
UV/Visible light-curable adhesives. Systems for light curing, fluid dispensing, and fluid packaging.
Dymax manufactures industrial adhesives, light-curable adhesives, epoxy resins, cyanoacrylates, and activator-
cured adhesives. We also manufacture a complete line of manual fluid dispensing systems, automatic fluid
dispensing systems, and light-curing systems. Light-curing systems include LED light sources, spot, flood, and
conveyor systems designed for compatibility and high performance with Dymax adhesives.
Dymax adhesives and light-curing systems optimize the speed of automated assembly, allow for 100% in-line
inspection, and increase throughput. System designs enable stand-alone configuration or integration into your
existing assembly line.
Please note that most dispensing and curing system applications are unique. Dymax does not warrant the fitness
of the product for the intended application. Any warranty applicable to the product, its application, and use is
strictly limited to that contained in the Dymax standard Conditions of Sale. Dymax recommends that any
intended application be evaluated and tested by the user to ensure that desired performance criteria are
satisfied. Dymax is willing to assist users in their performance testing and evaluation by offering equipment trial
rental and leasing programs to assist in such testing and evaluations.

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Contents
Introduction .............................................................................................................4
Introduction to the User Guide .............................................................................. 4
Where to Get Help ................................................................................................. 4
Safety....................................................................................................................... 4
General Safety Considerations............................................................................... 5
Specific Safety Considerations ............................................................................... 5
Dymax UV Light-Curing System Safety Considerations .......................................... 5
Product Overview..................................................................................................... 8
Description of the BlueWave QX4.......................................................................... 8
Features & Benefits of the BlueWave QX4 System ................................................ 9
Validation ............................................................................................................... 9
Front Control Panel .............................................................................................. 10
Back Panel ............................................................................................................ 12
Unpacking ................................................................................................................13
Parts Included ...................................................................................................... 13
System Setup ........................................................................................................... 13
System Connections............................................................................................. 13
LED Heads & Lenses ............................................................................................. 14
Constant Mode .................................................................................................... 16
Variable Mode...................................................................................................... 18
PLC Operation ...................................................................................................... 22
4-Channel Mode....................................................................................................... 25
Controller Set Up.................................................................................................. 25
I/O Connection..................................................................................................... 25
System Settings ........................................................................................................29
Intensity Control Feature.......................................................................................... 31
Cleaning & Maintenance ..........................................................................................31
LED Head Optic Lens ............................................................................................ 31
Error Codes & Troubleshooting.................................................................................31
Error Codes .......................................................................................................... 31
Spare Parts and Accessories ..................................................................................... 34
Specifications ...........................................................................................................35
Warranty.................................................................................................................. 37
Index........................................................................................................................ 38

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Introduction
Introduction to the User Guide
This guide describes how to set up, use, and maintain the BlueWave® QX4® LED Spot-
Curing System safely and efficiently.
Intended Audience
Dymax prepared this user guide 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 (PDS) on our website
■Material safety data sheets (SDS) provided with shipments of Dymax adhesives
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, read
and ensure you understand the information in this user guide before
assembling and operating the Dymax LED light source.
To use the BlueWave QX4 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

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the protection of the system. Dymax assumes no liability for any changes that may
impair the protection of the BlueWave QX4 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 are available on our website.
Specific Safety Considerations
The BlueWave QX4 is 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.
WARNINGS! Looking directly at the high-intensity light emitted by the
heads of the BlueWave QX4 can result in eye injury. To prevent eye injury,
never look directly at the end of the high-intensity head and always wear
protective goggles. To avoid accidental exposure, always point the LED
head away and at the curing substrate.
Removing the cover from the BlueWave QX4 controller may result in electrical shock. To
prevent the possibility of an electrical shock, never remove the controller’s cover
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 of space around all sides of the controller is sufficient.
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.

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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 type of LED head used, the energy emitted
from the BlueWave QX4 can either be in the upper end of the UVA portion of the
spectrum (PrimeCure® & 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
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

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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 lights 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, care must
be taken to ensure either a more moderate surface temperature or appropriate
protection/training for operators. 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.
Bright Visible Light
The bright visible light 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.

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Product Overview
Description of the BlueWave QX4
The BlueWave QX4 high-intensity spot-curing system features all the benefits of LED-
curing technology in a smaller, more versatile unit. This system is comprised of a power
supply, a controller with an easy-to-use control interface, and up to four LED heads. LED
heads are available in 365, 385, and 405 nm and can be outfitted with 3-, 5-, or 8-mm
diameter focusing lenses. LED heads and focusing lenses can be used in any combination
and can be operated in constant or variable mode.
The system’s LED heads 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. The BlueWave QX4 is rated for continuous operation. However, if the
internal temperature of the system exceeds the maximum safe operating temperature
limits, each LED head contains a thermal sensor that will shut the unit down to protect
the components of the head.
Figure 2. Main Components of a BlueWave QX4
LED Heads
Focusing
Lenses
Controller
Front Panel
Display

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Features & Benefits of the BlueWave QX4 System
The Dymax BlueWave QX4 is engineered for precise performance and long service life.
Key features include:
Features
Benefits
One controller controls up to four
LED heads
Provides maximum application flexibility
LED heads available in 365, 385,
or
405 nm wavelengths
Compatible with a variety of UV and visible light-curable
materials
Wavelength flexibility allows co-optimization of adhesive
and curing system for optimal cure
Units can be custom configured to your curing
requirements
Variable mode allows each LED
head to be programmed
independently
Individual exposure times and intensity settings available
in 1% increments for each LED head allows for maximum
curing flexibility
Interchangeable/Replaceable
focusing lenses in 3-, 5-, and 8-
mm diameters
Allows tailoring of the unit to your curing requirements
Instant on-off
No warm-up period
More energy efficient
Efficient LED-head temperature
management
Maximized continuous operation without overheating
Comfortable hand-held operating temperature
Temperature monitoring assures maximum LED life
PLC interface with 4-channel
mode
Easily incorporated into automated systems
Allows the four LED heads to be operated and activated
independently in PLC mode
Validation
Tests should be conducted prior to production to determine the time and light intensity
required to fully cure your resin. The following approaches may be used to validate the
curing process.
Set Exposure Time, Determine Intensity
Users can specify a cure time and, through empirical testing, determine the intensity
required to achieve a full cure. As with any manufacturing process, it is advisable to
incorporate a safety factor.

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Set Intensity, Determine Exposure Time
Users can specify light intensity and, through empirical testing, determine the exposure
time required to achieve a full cure. As with any manufacturing process, it is advisable to
incorporate a safety factor.
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
adjust the output to a specific intensity level. To ensure consistent and repeatable
process results, intensity levels should be monitored with a radiometer. This enables
users to identify light intensity changes and take corrective action (either adjusting the
light intensity or performing maintenance).
Front Control Panel
■Front Control Panel Display —Displays the currently selected menu.
■Up Button ()—Navigates the selector up one position. It is also used to
increase the selection value.
■Down Button ()—Navigates the selector down one position. It is also used to
decrease the selection value.
■Right Button () —Selects the highlighted option and advances the screen to
the next menu.
■Left Button ()—Navigates to the previous menu. Holding this button down
for more than one second will return you back to the main menu. It can also be
used to cancel a selected option and return to the previous menu.
■Run Button ( ) —Activates the irradiation when the run option is selected. This
button is also used as an enter button.
■LED Head Indicators —Colored lights indicate the status of each connected
head. A green light indicates that a head is active. An orange light indicates an over-
temperature warning. A red light indicates that the critical temperature has been
exceeded.

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Figure 3. Front Control Panel
Front Control
Panel Display
LED Head
Indicators
Run Button

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Back Panel
■Power Cord Receptacle —Connection point for the power cord.
■On/Off (I/O) Switch —Moving the switch to the on position (I) powers up the
controller. Moving the switch to the off position (O) cuts power to the controller.
■Footswitch Jack —Connection point for the footswitch. Pressing the
footswitch starts a curing cycle. In timed operation, pressing and releasing the
footswitch initiates the curing cycle. A second press will terminate a timed cure
cycle immediately.
■PLC Connector Terminals —Connection points for an interface with a user-
supplied PLC (for remote operation).
■RS232 —The RS232 port is a Dymax applicable troubleshooting port. No user
functionality is available at this time.
■LED Head Connectors —Connection points for up to four LED heads. Each
connector corresponds to an available channel and indicator on the front panel.
Figure 4. Back Panel Controls & Connections
LED Head
Connectors
PLC Input
Connection
Terminal
On/Off
Switch
RS232 Port
PLC Output
Connection
Terminal
Footswitch Jack
Power Cord Receptacle

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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.
Check that the parts included in your order match those listed below. If parts are
missing, contact your local Dymax representative or Dymax Customer Support to resolve
the problem.
Parts Included
Controller
■Controller Base
■Power Adapter
■Power Cord
■Foot Switch
■Safety Glasses
■BlueWave QX4 User Guide
LED Heads
■LED Head Assembly
■Accessory Focusing Lenses
■Extra connection cable extensions
can be ordered as accessories
System Setup
System Connections
Power Cable Connection —Attach the Power Cord to the Power Cord Receptacle
located on the unit’s back panel (Figure 4). Press the Power Cord firmly into the
receptacle until it clicks and locks into place. The unit is now powered and ready to be
turned on with the On/Off Switch.
To remove the Power Cord, pull the retaining body of the Connector to unlock it from
the receptacle.
LED Head Connection Jacks —Along the top of the Controller’s Rear Panel, there
are four LED Head Connection Jacks labeled CH 1 - 4. Press the LED Head Connector into
any available jack until it clicks and locks in place.

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To remove the LED Head, slide the retaining body of the Connector away from the
Controller to unlock it from the Jack.
Footswitch Connection —Located on the rear panel of the controller. It can be
used as an optional irradiation trigger.
PLC Connection Terminals —There are input and output PLC Connection
Terminals that can be used to integrate the unit to an automated assembly line. The
input connections are separated into two main groups: the exposure connections and
the program selection connections. The unit normally has high logic levels (+5 V) and
looks for a low signal (0 V) input. The exposure connections can be used to activate
specific wands or all wands simultaneously. The program selection bits determine which
program mode the unit will operate in. See the PLC operation Section for more details.
When the PLC sense connection has a low signal, the Front Screen will display the PLC
connection and will lock out the buttons on the Front Control Display. A low signal on
the interlock connection will lock out the unit.
LED Heads & Lenses
The BlueWave QX4 led heads are available in three different wavelength: 365 nm
(RediCure), 385 nm (PrimeCure), and 405 nm (VisiCure). Each LED head is made up of
three main components: the handle, a collimating lens, and a spot lens. LED head
assemblies are 1.5 M in length. Extensions can be purchased for extra length.
Figure 5. LED Head Components
The handle indicates the wavelength with a type label. The collimating and focusing
lenses in each head are interchangeable, but the handle is unique to a specific
wavelength.
Handle
Collimating Lens
Spot Lens
Cooling Fins

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Figure 6. Color-Coded LED Heads
RediCure, 365 nm
PrimeCure, 385 nm
VisiCure, 405 nm
Figure 7. Focus Lenses
The focusing lens and collimating lens can be removed by unscrewing from the handle;
however, removing the collimating lens is not recommended. (Error! Reference source
not found.)
Fixturing
If fixturing the LED head, do not cover the cooling fins or overheating can result. We
suggest clamping on the flat portion of the handle.
Figure 8. Fixturing Recommendations
Do Not Cover
Cooling Fins
Attach Fixture to the
Flat Section of the Handle

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Operation
WARNING! Looking directly at the high-intensity light emitted
by the heads of the BlueWave QX4 can result in eye injury. To
prevent eye injury, never look directly at the high-intensity light
and always wear protective goggles (provided).
Verify that all connectors are firmly plugged
into the rear panel of the unit. See System
Connections, pg. 13 for more details.
On the rear panel of the controller, move the
Power Switch to the on position (I). The
system is now ready for use.
Upon startup of the unit, the main menu
screen should appear in the display. The main
menu displays the two working modes of the
unit as well as the system settings. Hold down
the left button for longer than one second to
bring the display back to the main menu page.
Figure 9. Main Menu Screen
Constant Mode
Constant mode allows the user to configure
each head at a predefined (constant) power
output for a given amount of time. Each head
can be adjusted independently of each other.
To enter constant mode, use the up and
down buttons to highlight constant
mode on the main menu screen. Press
the right button to enter.
Figure 10. Select Constant Mode

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Set Up
In the constant mode menu, the user can
see the current power and time
configuration for each one of the LED
Heads. To update any LED Head, navigate
to the LED Head using the up and down
buttons. The selected option will be
highlighted in green. Press the right
button to edit. Any LED Head that is not
connected will appear grayed out. The
user can still select and program any
grayed-out rows, but the unit will not run
the program for the disconnected LED
Head.
Another screen will show the power and
time (Figure 12). To change the power,
press the run button (Figure 13). The
number will start blinking. Use the up
and down buttons to modify the value.
Press the run button again to set. The
power can be set from a value of 10-
100%, at 1% increments. To edit the time,
navigate to it using the Down button.
Press the run button (Figure 13) to edit.
Use the up and down buttons to change
the value, then press the run button
again to set. The maximum time setting is
999 seconds. To turn off an LED Head,
set the power or time setting to 0.
Pressing and holding the up or down
buttons will increase/decrease the value
at a faster pace.
When editing is finished, press the left
button to go back to the constant model
menu.
Figure 11. Constant Mode Menu
Figure 12. Power & Time Editing
Screen
Figure 13. Run Button

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Irradiation
Once all of the LED heads have been configured, navigate to the RUN option. Press the
run button to start irradiation.
Figure 14. Select Run Row
Figure 15. Screen During Irradiation
During irradiation, the time will count down to indicate the time remaining on the
current curing session. Press the run button during an irradiation cycle to stop the
irradiation and reset the cycle. The Footswitch can also be used instead of pressing the
run button.
An indicator light will show on the bottom of the front display to show which heads are
active during the irradiation cycle. A green light shows that the head is active with no
faults. An orange indicator light shows that the corresponding head has reached the
user-set temperature-warning threshold. The head will continue to function as normal
until it reaches a critical temperature condition.
Variable Mode
Variable mode allows the user to set
different power profiles in a given time
frame for each head. Up to seven
different programs can be stored into
the unit.
To enter variable mode, navigate using
the up/down buttons, then press right
button to enter.
Figure 16. Select Variable Mode

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Set Up
On the variable mode menu (Figure 17), the user will see seven programs. Each program
is a collection of steps and cycles. The programs are stored in local memory and can be
used via the GUI interface or the PLC interface. Each LED Head can be programmed
independently of the other LED Heads.
To run or edit a program, navigate using the up and down buttons. Once highlighted,
press the Right button to enter.
Figure 17. Variable Mode Menu
Figure 18. Program Menu
The program menu (Figure 18 ) allows the user to see the number of steps and cycles
active for each one of the LED Heads in the given program. To edit the configuration of
an LED Head, navigate using the up and down buttons, then press the right button to
edit. Any LED Head that is not connected will be grayed out on the display. The user can
still select and program any grayed out rows, but the unit will not run the program for
the disconnected LED Head.
On the edit menu (Figure 19), the user will see the number of steps and cycles currently
configured for a head. A step consists of a power configuration for a given amount of
time. The collection of steps will repeat for the number of cycles. The user can adjust
the number of cycles from 0-99. Setting the number of cycles to 0 will disable the
highlighted head.
To edit the steps, navigate using the up and down buttons, then press Right button to
edit.

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Figure 19. Edit Menu
Figure 20. Steps Menu
On the steps menu (Figure 20), the user can see the power and time settings for each
step. To edit the step, navigate using the up and down buttons, then Right button to
edit.
In a similar fashion to the constant mode, the power can be adjusted by first pressing
the right button. Use the up and down buttons to adjust the power, then the run button
to set. Use the up and down buttons to set the time, then press the run button to set.
The user can set an “off” step by entering 0% into the power field and setting a time
period. Adding an “off” step to the last step in a cycle allows the user to set a “cool
down” time or an “off” period for a precise amount of time in between cycles.
Press the left button to go back to the previous menu.
Once the steps are set, the cycles can be adjusted by pressing the right button while
highlighting the cycles row (Figure 22). Use the up and down buttons to set the cycles.
Figure 21. Power Menu
Figure 22. Adjust Cycles