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.