dymax ECE ZIP Shutter User manual
ECE ZIP™ Shutter
For Use with Dymax ECE Flood Lamp Systems
Instructions for Safe Use
Setup and Operation
Maintenance
Ordering Spare Parts and Accessories
2
Dymax ECE ZIP™ Shutter User Guide
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. Data sheets are available for valve controllers or pressure pots upon
request.
3
Dymax ECE ZIP™ Shutter User Guide
Contents
Introduction.................................................................................................................................................... 4
Introduction to the User Guide ....................................................................................................................................... 4
Where to Get Help .......................................................................................................................................................... 4
Safety.............................................................................................................................................................. 4
General Safety Considerations ........................................................................................................................................ 4
Specific Safety Considerations......................................................................................................................................... 5
Product Overview ........................................................................................................................................... 5
Description of the ECE ZIP Shutter................................................................................................................................... 5
System Components........................................................................................................................................................ 6
Assembly and Setup........................................................................................................................................ 7
Unpacking and Inspecting Your Shipment....................................................................................................................... 7
Parts Included in the ECE ZIP Shutter (PN 40885)............................................................................................................ 7
Installation and System Interconnect.............................................................................................................................. 8
Operation ..................................................................................................................................................... 11
Maintenance................................................................................................................................................. 12
Check and Adjust Curtain Drive-Belt Tension................................................................................................................ 12
Shutter Curtain Assembly Replacement........................................................................................................................ 13
Troubleshooting............................................................................................................................................ 14
Spare Parts and Accessories.......................................................................................................................... 15
Specifications................................................................................................................................................ 16
Systems Specifications (Clear Aperture)........................................................................................................................ 16
Definition of Terms ....................................................................................................................................... 17
Warranty ...................................................................................................................................................... 18
Index............................................................................................................................................................. 19
4
Dymax ECE ZIP™ Shutter User Guide
Introduction
Introduction to the User Guide
This guide describes how to assemble, use, and maintain the ECE ZIP™ Shutter safely and efficiently.
Intended Audience
Dymax prepared this user guide for experienced process engineers, technicians, and manufacturing personnel.
If you are new to UV light curing and do not understand the instructions, contact Dymax Application
Engineering to answer your questions before using the equipment.
Where to Get Help
Dymax Customer Support and Application Engineering teams are available 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 (MSDS) provided with shipments of Dymax adhesives
Safety
WARNING! If you use a Dymax shutter 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 a Dymax shutter in a UV flood lamp system.
General Safety Considerations
All users of Dymax equipment should read and understand this user guide before assembling and using the
equipment.
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.
5
Dymax ECE ZIP™ Shutter User Guide
Specific Safety Considerations
Dymax shutters are designed to maximize operator safety and minimize exposure to UV light. To use the
shutter safely, it must be set up and operated in accordance with the instructions in this user guide. Please
also read and understand the following safety considerations.
WARNINGS! To prevent eye injury, always wear protective goggles when working near a UV
light-curing system.
Long-sleeved shirts or a lab coat are recommended to protect the arms and use of UV opaque
gloves will protect the hands from UV exposure.
Product Overview
Description of the ECE ZIP Shutter
Dymax shutters were developed as auxiliary devices to improve operator safety and to control the dose of
curing energy directed onto adhesives in a flood-lamp curing systems. The ECE ZIP Shutter is compatible with
Dymax ECE 2000 and ECE 5000 flood lamps. The shutter can be used as an integral part of the Dymax ECE light
shield.
Dymax flood lamps use a medium-pressure arc bulb as a source of curing energy. The bulb requires a few
minutes to warm up after ignition before it reaches a steady state and needs a few minutes to cool before
being able to re-ignite after being turned off. Repeatedly turning the power to the bulb off and on negatively
affects its lifetime. With a Dymax shutter installed, the flood lamp may stay on continuously. Objects needing
curing may be loaded and unloaded from underneath the shutter when it is closed without exposing parts or
operators to UV light. In addition, control of curing times can be achieved by timed shutter operation.
Dymax flood lamp systems are used for a wide variety of applications where a relatively large area of
illumination is needed. These applications may be cured using one of two types of systems: the first is with
continuous illumination in conveyorized curing systems where the dose is defined by the conveyor belt speed.
The second type uses a free-standing flood lamp where accurate timing is required. In the second type, the
shutter can ensure the proper dose.
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Dymax ECE ZIP™ Shutter User Guide
System Components
Figure 1. ECE ZIP Shutter Component Diagram
Digital Potentiometer (Timer) (1) - The operator sets the shutter’s “open time”using the digital
potentiometer (timer) on the control panel. The shutter’s “open time” can be set from 1 to 99
seconds.
Actuate Button (2) - Depressing the actuate button activates the gear motor inside the shutter. The
unit can also be actuated by foot switch. The foot switch can be connected to the foot switch
connection (5) on top of the rear panel.
Mode Selector Rocker Switch (3) - There are two operation modes available: manual and timed.
The mode selector rocker switch is used to select the mode of operation.
Mounting Plates/Adapter Plates - The ZIP Shutter includes two mounting plates for various reflector
housings. The first has a clear aperture of 5" x 5" and should be used with the ECE 5000. The second
has a clear aperture of 8" x 8" for use with an ECE 2000. The ZIP Shutter has a clear aperture,
therefore there is no distraction of the light flow when the shutter is open.
Reflector Cable Connection (4) - The power (24V) to the ZIP Shutter comes directly from the flood
lamp’s power supply, which is connected through this receptacle on top of the shutter’s rear panel.
Belt Tension Adjustment Screw (6) - Used to tighten the curtain drive belt.
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Dymax ECE ZIP™ Shutter User Guide
Assembly and Setup
Unpacking and Inspecting Your Shipment
When your ECE Zip Shutter arrives, inspect any boxes for damage and notify the shipper immediately of box
damage.
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 in the ECE ZIP Shutter (PN 40885)
ECE ZIP Shutter (1)
Dymax Shutters for ECE Systems User Guide (2)
Interconnect Cable (3) - Connects the Shutter to the Flood Lamp
Foot Switch (4)
Brackets (5) - Connect the ECE Shutter to the ECE Light Shield
Tools & Hardware - M4 x 25 mm Screws (6), M4 x 8 mm Screws (7), & Hex Wrench (8)
Mounting Plates - for the ECE 2000 (9) & ECE 5000 (10)
Plenum Assembly for the ECE 5000 (11)
Figure 2. ECE Zip Shutter Components
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Dymax ECE ZIP™ Shutter User Guide
Installation and System Interconnect
NOTE: Setup of the ECE flood lamps is covered in the ECE-series user guides. Refer to MAN045 –ECE-Series
Flood Lamp User Guide.
ECE 5000 Flood Lamp
1. Remove the Mounting Plate from the ZIP Shutter by removing the four M4 x 8 mm flat head screws (Figure 3).
Figure 3. ECE ZIP Shutter with Mounting Plate Installed
NOTE: If the ZIP Shutter and the Lamp Assembly are NOT installed into a Light Shield, the Glass
Containment Shield must be installed.
2. Install the Glass Shield (if applicable). Follow the instructions below:
Remove the Filler Plate from the Reflector Housing and install the glass on the Reflector Housing
edges.
Replace the Filler Plate and screws securely.
Figure 4. Reflector Housing with Filler Plate
Figure 5. Reflector Housing, Filler Plate
Removed
3. Place the Mounting Plate onto the Reflector Housing (Figure 6) and then place the Air Plenum on top of
the Mounting Plate (Figure 7). Attach all three components together with four new M4 x 25 mm screws.
M4 x 8 mm Flat Head Screws
Mounting Plate
9
Dymax ECE ZIP™ Shutter User Guide
Figure 6. Attach Mounting Plate to
Reflector Housing
Figure 7. Attach Air Plenum to Filler
Plate/Reflector Assembly
4. Install the Lamp Housing Assembly into the ZIP Shutter and attach it with four M4 x 8 screws (Figure 9).
NOTE: One side of the Filler Plate has a third screw hole (Figure 8). When in the correct position, this screw
hole will be at the rear of the Shutter.
Figure 8. Lamp Housing Assembly
Figure 9. ECE 5000 Lamp Housing
Assembly Installed with M4 x 8 Screws
Four M4 x 8 screws (two located on opposite side)
Third Screw Hole
10
Dymax ECE ZIP™ Shutter User Guide
ECE 2000 Flood Lamps
NOTE: If the ZIP Shutter and Lamp Assembly are NOT installed into a Light Shield, the Glass Containment Shield
must be installed.
1. Install the Glass Shield (if applicable) (Figure 10).
2. Install the ECE 2000 Mounting Plate on the base of the ECE 2000 Lamp Housing (Figure 11) by installing
the M4 x 8 mm screws.
3. Install the Glass Shield (if applicable).
Figure 10. Reflector Housing with Glass
Shield Installed
Figure 11. Lamp Housing with
Mounting Plates Installed
4. Install the Lamp Housing Assembly into the ZIP™ Shutter and attach it with four M4 x 8 mm screws
(Figure 13).
NOTE: One side of the Mounting Plate has a third screw hole (Figure 12). When in the correct position, this
screw hole will be at the rear of the Shutter.
Figure 12. Lamp Housing Assembly
Figure 13. ECE 2000 Lamp Housing
Assembly Installed with M4 x 8 Screws
Four M4 x 8 screws (two located on opposite side)
Third Screw Hole
11
Dymax ECE ZIP™ Shutter User Guide
ECE ZIP Shutter Electrical Interconnect
Figure 14. ECE ZIP Shutter Electrical Interconnect Diagram
1. Connect Shielded Cable (4) from J2 on rear of Power Supply (2) to J3 on rear of Reflector Housing (3).
2. Connect Cable (5) from J4 on rear of Reflector (3) to 8-Pin Connector on rear of Shutter (1).
3. Connect Plug (6) into J5 on rear of Reflector (3).
NOTE: Shutter will not operate unless the Adapter Plug is installed.
4. Install Foot Pedal to 4-Pin Connector on rear of Shutter (7).
5. Connect Power Cord to J1 on rear of Power Supply (2).
Operation
1. Check that the ECE ZIP Shutter is in the closed position and load parts to be cured on the Light Shield work
surface (preferably in line with the center of the shutter).
NOTE: The ECE ZIP Shutter incorporates a safety circuit that if the Light Shield door is opened during an
exposure cycle, it will automatically close the shutter curtain and shut the lamp off.
2. Adjust the distance from the bottom plane of the ECE ZIP Shutter to the surface to be cured.
3. Close the Light Shield Door once the parts to be cured are loaded.
4. With the Light Shield Door closed, set the exposure (ECE ZIP Shutter “Open Time”) by adjusting +/- the
Timer located next to the Actuate Button on the Front Panel.
5. Open the ECE ZIP Shutter using the most convenient method for you by using Actuate Button or Foot
Switch.
NOTE: The ECE ZIP Shutter will close automatically in timed mode or will stay open until you release the
Foot Switch or Actuator Button in manual mode
12
Dymax ECE ZIP™ Shutter User Guide
6. Close the ECE ZIP Shutter to end the cycle.
Maintenance
Check and Adjust Curtain Drive-Belt Tension
Figure 15. Belt Tension Adjustment
Dymax recommends that the Curtain Drive-Belt's tension be checked at least once every three months. Follow
the instructions below to check the tension.
1. Turn off and disconnect the Lamp Reflector Housing from the external AC source.
2. Remove the ZIP Shutter from the Flood Lamp Reflector Housing and place it on the bench, bottom-side
up.
3. Remove the screws that attach the ZIP Shutter's bottom panel.
4. Very lightly press in the center of the Curtain Drive Belt with a finger; the Belt should deflect no more
than ¼" to ⅜".
5. If deflection exceeds this value, tighten the Curtain Drive Belt by adjusting the Tension Screw in the back
of the ZIP Shutter.
NOTE: Make sure that both belts are tightened equally.
6. Replace the bottom cover and secure it with its screws.
7. Place the ZIP Shutter back on the Flood Lamp Reflector Housing and re-position it.
8. Reconnect the cables and plug the AC cord into wall socket.
13
Dymax ECE ZIP™ Shutter User Guide
Shutter Curtain Assembly Replacement
Dymax recommends that you check the ZIP Shutter curtain for wear each time you change the lamp. If it
shows any signs of wear, replace it. Additional curtain assembly replacements can be purchased through
Dymax Customer Service.
CAUTION! SHARP EDGES! The edge of the stainless steel curtain is extremely sharp.
To prevent injuries, always wear gloves that are resistant to cuts when handling or installing
equipment. We recommend, at a minimum, CE Cut Level 5 gloves (included with kit).
Figure 16. ZIP™Curtain Assembly Diagram
1. Remove the Flood Lamp Reflector Assembly from the ECE ZIP Shutter and flip the Shutter onto its top.
2. Remove the bottom cover of the ECE ZIP Shutter to expose the inside Roller (7) and Belt Drive Motor.
3. Manually unroll the Curtain (1) until the Curtain (1) reaches Large Limit Switch (8).
4. Loosen the Belt (6) tension by unscrewing the rear screws.
5. Remove the old Curtain (1) by removing the five screws (3) on the Roller (7) and loosening the two Side
Screws (4) on the Clamp Bar (5) and slide curtain off Belts (6).
6. Attach the new Curtain (1) to the Roller (7) and Roller Bar (2) with the 6-32 screw (3) previously removed
from the Roller.
7. Stretch the new Curtain (1) toward front of ZIP Shutter.
8. Slide the Clamp Bar (5) onto the Belt (6) where the Curtain is fully outstretched. The Curtain should be
stretched short of front Limit Switch (8).
9. Tighten the end screws 4-40 (4).
10. Manually roll up the Curtain until the Curtain reaches rear Limit Switch (8). If the Clamp Bar (5) bows,
loosen the screws (4) and allow the Clamp Bar to find its natural straightness and retighten.
11. Replace the ZIP Shutter's bottom cover.
12. Set-up the ZIP Shutter according to the ZIP Shutter directions. Tighten the Belt Tension (10) as needed to
improve Belt performance.
#
Description
1
Curtain
2
Roller Bar
3
Screws (5)
4
Side Screws (2)
5
Clamp Bar
6
Belts
7
Roller and Pulley
8
Limit Switch
9
Limit Switch Standoff
10
Belt Tension
11
Belt Drive Motor
11
14
Dymax ECE ZIP™ Shutter User Guide
Troubleshooting
CAUTION: Only qualified maintenance personnel should attempt the following procedures.
Problem
Possible Cause
Testing
Corrective Action
The shutter curtain
does not open or
close smoothly
One of the tension
screws is not tight
enough
All functions of the ZIP Shutter
operate properly
Adjust the curtain tension
The shutter’s motor
continuously runs
One of the Limit
Switches is not
engaging properly
All functions of the ZIP Shutter
operate properly
Adjust the micro-switch activating
blade
The shutter will not
operate
No power at shutter
Verify the supply voltage being
delivered to the shutter. Test
the voltage at pins 1 & 2 of the
8-pin connector (24 VDC)
Check and replace the wiring if the
light source is operational but the
ZIP Shutter is not. If a problem
occurs within the light source,
consult the user guide
The plug (38317 or
38318) is not installed
in J5 of the reflector
housing
All functions of the ZIP Shutter
operate properly
Install the plug as described in the
installation instructions
15
Dymax ECE ZIP™ Shutter User Guide
Spare Parts and Accessories
Item
Part Number
Hardware
M4x8 Pan Head Screws, Qty. 8
38611
M4x25 Pan Head Screws , Qty. 4
39586
M3x10 Flat Head Screws , Qty. 4
40013
Replacement Parts
Clutch
39396
Motor
39395
Timer Board, 0-99 Seconds
40315
Stainless Steel Curtain Upgrade Kit (Cloth to SS)
41097
Stainless Steel Curtain Replacement Kit (SS to SS)
41146
Cables, Foot Switches, & Plugs
Cable, Reflector Housing to Shutter, ECE Series
40879
Standard Foot Switch
36051
Foot Switch with Extended Cable
38992
Plug, Standard Adapter
41068
16
Dymax ECE ZIP™ Shutter User Guide
Specifications
Systems Specifications (Clear Aperture)
Property
Specification
40885
ZIP™Shutter for ECE-Series Flood Lamps
Operating Voltage
24 VDC (Supplied by the Dymax ECE Power Supply)
Exposure Time
Digital Setting - From 1 to 99 Seconds
Aperture
6" x 8" [15.24 cm x 20.32 cm]
Operation Modes
Timed/Manual
Dimensions
12.5" x 12.9" x 3.8" [31.8 cm x 32.8 cm x 9.7 cm]
Weight
5.45 lbs. [2.47 kg]
Figure 17. ECE ZIP™ Shutter Dimensions
17
Dymax ECE ZIP™ Shutter User Guide
Definition of Terms
UV Curing Light Source - a reflector housing and a power supply furnished with an appropriate bulb (burner)
for generating light energy of required spectra and intensity.
Flood Lamp System - a set of components arranged to generate, collect, condition, and direct UV radiant
energy to perform curing of engineering adhesives, coatings, and inks in a safe and controlled process. It
includes a lamp housing and power supply and may also include a shutter, workstation, UV enclosure, Dymax
light shield, and accessories.
Lamp - light source (bulb or burner) generating ultraviolet, visible, or infrared radiant energy from burning
matter stimulated by electrical power. A bulb or burner is usually placed into a reflector to increase light
source efficiency by collecting and directing radiant energy of selected spectra for a specific curing process.
Intensity - a measure of light energy over the unit of surface area (usually at a specified working distance
from the bottom of a reflector housing) in W/cm2or mW/cm2. For the UV portion of light, this measure is
often called in literature “irradiance”, i.e. radiant energy arriving at a point on a surface per unit area.
Brightness, also known as Luminance - description of energy in the visible region of the spectrum
(approximately from 400 to 700 nm) and recorded in photometric units. “Intensity” (see below) of visible light
energy is called luminance.
Luminance - luminous flux (energy of visible light) incident per unit area, and measured in Lx (lux) or
Lumen/cm2.
Ultraviolet (UV) - the invisible region of the spectrum just beyond the violet end of the visible region. UV is
divided into three spectral parts:
1. Ultraviolet A (UV-A) - UV of long wavelength from within approximately 400 to 320 nm of the spectral
band (4000 to 3200) - predominately produced by Dymax Flood Lamps.
2. Ultraviolet B (UV-B) - UV of medium wavelength from within approximately 320 to 280 nm - Dymax Flood
Lamps produce some amount of their energy within this bandwidth.
3. Ultraviolet C (UV-C) - UV of short wavelength below 280 nm (we say from 280 to 200 nm) –a large
amount of this energy is present in the sunlight.
Dose - is irradiance integrated over time, or Irradiance (W/cm2 ) x Time (s) = Dose (Joules/cm2). Note: Watt is
the power that gives rise to the production of energy at the rate of 1-joule (J) per second (s).
As irradiance can be a far more significant factor in the efficiency of curing adhesives and other UV-curable
materials, the dose and spectral response can also be substantial contributors to the quality cure
performance.
OSHA 1910.145: “Regulation of Accident prevention Signs and Tags” defines the following headers as:
WARNING –is used when there is a hazardous situation that has some probability of severe injury.
CAUTION - is used to indicate a hazardous situation that may result in minor or moderate injury.
NOTICE - is used to convey a message related directly or indirectly to the safety of personnel, or
protection of property.
18
Dymax ECE ZIP™ Shutter User Guide
Warranty
From date of purchase, Dymax Corporation offers a one-year warranty against defects in material and
workmanship on all system components with proof of purchase and purchase date. Unauthorized repair,
modification, or improper use of equipment may void your warranty benefits. The use of aftermarket
replacement parts not supplied or approved by Dymax Corporation, will void any effective warranties and may
result in damage to the equipment.
IMPORTANT NOTE:
DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES,
EXPRESSED OR IMPLIED, DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON DYMAX EQUIPMENT
WITHOUT WRITTEN AUTHORIZATION FROM DYMAX. THOSE CORRECTIVE ACTIONS LISTED ABOVE ARE LIMITED
TO THIS AUTHORIZATION.
19
Dymax ECE ZIP™ Shutter User Guide
Index
Adjust Curtain Drive Belt Tension, 12
Assembly and Setup, 7
Contact Information, 4
Definition of Terms, 17
Glossary, 17
Help, 4
Installtion, 8
Maintenance, 12
Operation, 11
Optional Equipment, 15
Parts Included, 7
Product Overview, 5
Safety, 4
Spare Parts and Accessories, 15
Specifications, 16
Support, 4
System Components, 6
System Interconnect, 8
Troubleshooting, 14
Unpacking, 7
Warranty, 18
Zip Shutter Curtain Replacement, 13
© 2013-2016 Dymax Corporation. All rights reserved. All trademarks in this guide, except where noted, are the property of, or used under license by Dymax Corporation, U.S.A.
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 Dymax’s standard Conditions of Sale. Dymax recommends that any intended application be evaluated and tested by the user to insure 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.
PN40812 MAN051 8/2/2016
Dymax Oligomers & Coatings
Dymax Asia (H.K.) Limited
Dymax UV Adhesives & Equipment (Shanghai) Co. Ltd.
Dymax Asia Pacific Pte. Ltd.
Dymax Engineering Adhesives Ireland Ltd.
Dymax UV Adhesives & Equipment (Shenzhen) Co. Ltd.
Dymax Korea LLC
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