dymax PC-3 User manual

TM-021 PN 35933
Rev 05/06/97 1
OPERATIONS MANUAL
PC-3 UV CURING
LIGHT SOURCE
Discontinued System

TM-021 PN 35933
Rev 05/06/97 2
PC-3 TABLE OF CONTENTS
Description Page
Safety.................................................... 1
General ................................................. 4
Specifications........................................ 5
Unpacking and Inspection..................... 6
Installation............................................. 7
Lamp Replacement/Installation............. 8
Maintenance ......................................... 9
Troubleshooting Guide..........................10
Spare Parts...........................................14
Options..................................................15
Warranty ...............................................16
Diagrams...............................................17

TM-021 PN 35933
Rev 05/06/97 3
SAFETY
The meanings of WARNINGS, CAUTIONS, AND NOTES are:
A WARNING indicates when failure to follow the instructions could result in injury to personnel.
CAUTION
A CAUTION indicates when failure to follow the instructions could result in damage to
equipment.
NOTE
A NOTE is used to highlight an important procedure, practice or condition.
READ, UNDERSTAND AND FOLLOW ALL the safety and operating instructions found in this
manual.
WARNING
WARNING

TM-021 PN 35933
Rev 05/06/97 4
SAFETY
Safety Precautions Must Be Observed By All Personnel
Working Near Or Around Ultraviolet (UV) Light
UV Terminology
The portion of the Electromagnetic spectrum which falls between x-rays and visible light
is called Ultraviolet or UV. Ultraviolet (UV) radiation can be classified into three
categories: UV-C, UV-B, and UV-A. UV-C is for the wavelengths below 280 nm, UV-B
is for the wavelengths between 280-315 nm, and UVA is for the wavelengths between
315-380 nm.
Exposure Hazards
Exposure to UV light, even for short periods of time, can be hazardous. The danger depends
upon the exposure time, the intensity of the light, the wavelength, and the individual’s sensitivity
to UV. UV-B and UV-C can be considered the most hazardous to the skin, causing such effects
as sunburn. UV-A, UV-B, and UV-C is considered to be hazardous to the eyes, and is why eye
protection is important when working around UV light.
Ozone is a form of oxygen. Interaction of ultraviolet light below 220 nm with oxygen in the
surrounding air produces ozone, which is a powerful, toxic agent. It has a characteristic
pungent odor to which most people are quite sensitive (people can typically detect
concentrations of several parts per million). At high concentrations, it can cause discomfort, or
at sufficiently high levels, be dangerous. The PC-3 series of lamps produce minimal amounts of
ozone during start-up and no ozone during operation. The radiation beneath the wavelength of
about 240 nm, given off by the arc, is absorbed by the outer, colder gas layers and therefore,
produce no ozone during operation.
Safety Guidelines
The National Institute for Occupational Safety and Health (NIOSH) recommends that exposure
to UV energy be controlled and limited in the work place. Recommended maximum exposures
are available, but do not apply to photosensitive individuals.
The total intensity from 320 to 400 nm hitting unprotected skin or eyes should not exceed
1 mW/cm² for periods longer than 1000 seconds. For shorter exposure times, the total radiant
energy shall not exceed 1000 mWsec/cm².

TM-021 PN 35933
Rev 05/06/97 5
SAFETY
EYE PROTECTION
Always wear eye protection when working with or near UV equipment. Use goggles, safety
spectacles (glasses) or a face shield to protect your eyes.
•Goggles should completely surround and protect your eyes. Many goggles will also fit
over regular glasses. Be sure your goggles fit comfortably.
•Safety spectacles don't fog as easily as goggles and can be worn at all times.
•A face shield protects your entire face, not just your eyes.
It is important to verify that your selection of safety eyewear is approved for UV protection.
Individuals should wear protective UV glasses as a minimum precaution.
SKIN PROTECTION
Individuals exhibit different levels of photosensitivity. Therefore, even minimal periods of
exposure of unprotected skin to direct UV light, which can cause sunburn, must be avoided.
•UV barrier creams should be used to protect all exposed skin including the face, neck
and arms. UV blocking creams also provide protection to hands with minimal loss of
tactile sensitivity or feel. It is, however, necessary to repeat application regularly
because the cream wears off.
•Gloves which are opaque to UV light can be worn to protect the hands. Proper glove
selection should also include protection from UV curing resins. Consult the resin
manufacturer or product data sheets.
•Long sleeved shirts, or a lab coat, will protect the arms.
WARNING

TM-021 PN 35933
Rev 05/06/97 6
GENERAL
DESCRIPTION
The Light-Welder®PC-3 is a special purpose UV curing lamp used for pinpoint curing of UV
adhesives, coatings, and potting materials. It emits a 5 mm diameter spot of UV light from a
liquid light guide. This guide can be hand-held for complete mobility or clamped into position on
assembly equipment or work stations for repetitive operations.
The unit consists of a housing containing a 50 watt power supply, circuit protection,
lamp/reflector assembly, cooling fan, light guide mount, non resetable hour-meter, and shutter
system. Electric shutters are supplied with timed and manual shutter operating modes. The
light guide is separate and plugs into the mount. Light is not emitted from the unit when the light
guide is removed. A separate filter mounts on the output end of the light guide to reduce visible
light output where desired. Lamps are rated at 500 hours of life, however, a useful life of 1000
hours can be expected for most applications.
The power supply operates on line voltages of either 100, 120, or 220 Vac, and 50 or 60 Hz
(factory set). AC voltage is stepped down and rectified to DC through a transformer and
fullwave bridge rectifier. A separate high voltage winding on the transformer provides ignition
voltage for the lamps. A blocking diode is located between the power regulator and the high
voltage winding to prevent damage to the regulator circuit. When the lamp ignites, the high
voltage is dissipated across the lamp, although the high voltage winding is always energized. If
the lamp extinguishes due to a momentary power failure, it will reignite after it cools down if the
power switch is left on.
A cooling fan is provided to keep the lamp housing and internal components of the power supply
at the optimum operating temperature. The UV source is a 50 Watt short arc mercury vapor
lamp mounted in a reflector and pre-focused to provide optimum light output. The unit is rated
for continuous operation.

TM-021 PN 35933
Rev 05/06/97 7
SPECIFICATIONS
PC-3
SPECIFICATIONS
Voltage* 120 Vac, 60 Hz
Current 2.5 Amp Max.
Fuse 3 Amp 5 x 20 mm
Lamp/Reflector 50 Watt (pre-focused)
Shutter Timer 1 to 50 sec. delay
Foot Switch Rocker type
Hour-Meter 99,999.9 hours, non-resetable
* 100, 220 Vac and 50, 60 Hz Power Supplies are available.
Output Intensities (Typical)**
WAVELENGTH FILTERED UNFILTERED
320-390 nm 1.5+ 2.5+
** Measured with an EIT Spotcure Radiometer. Values in W/cm2.
CAUTION
With the filter installed, the PC-3 lamp emits only UV-A and UV-B light and a low amount of UV-
C light. Without the filter, UV-A, UV-B, and UV-C, and visible light are emitted. Never look
directly at the light source while the unit is in use.

TM-021 PN 35933
Rev 05/06/97 8
UNPACKING & INSPECTION
Upon receipt of lamp, unpack unit and check for shipping damage. Report damage to freight
carrier and make any claim for damage through them.
Check box for contents:
❑1 - Light-Welder®PC-3 Light Source
❑1 - Lamp/Reflector Assembly
❑1 - Power Cord
❑1 - Liquid Light Guide
❑1 - Filter Assembly
❑1 - Pair UV Goggles
❑1 - Warranty Card
❑1 - Operation Manual
❑1 - 1/8" Hex Wrench
NOTE
REPORT ANY SHORTAGE TO DYMAX CORPORATION CUSTOMER SERVICE
Phone: [phone]
Fax: [phone]
LAMPS ARE SHIPPED WITH THE LAMP REMOVED TO PREVENT BREAKAGE (REFER TO
PAGE 9, LAMP REPLACEMENT/INSTALLATION).

TM-021 PN 35933
Rev 05/06/97 9
INSTALLATION
1. Install lamp per LAMP REPLACEMENT/INSTALLATION (Page 9).
2. Connect power cord to rear of unit and plug into a grounded wall outlet.
3. Connect light guide to bezel mount by pressing down on lock and inserting guide.
4. Press power switch. Button will illuminate when power is on.
5. Allow lamp to warm up for 4-5 minutes to obtain maximum light output.
6. Locate foot switch where desired. (Electric shutter)
7. Operate shutter by pressing foot switch. With the timer selector switch in the manual
position, the shutter operates directly from the foot switch. In the timed position, the shutter
opening is determined by the setting of the potentiometer; clockwise increases the opening
time and the foot switch must be released after each cycle.
CAUTION
THIS IS AN ARC, NOT A FILAMENT LAMP. ONCE IGNITED, IT MUST BE LEFT ON FOR A
MINIMUM OF 5 MINUTES TO FULLY VAPORIZE ELEMENTS IN THE LAMP. IF NOT, THE
LAMP MAY BE DIFFICULT TO REIGNITE.
NOTE
The lamp must cool before it can be reignited. Leave power switch on should the lamp
extinguish. This operates the cooling fan and allows the lamp to relight when it has cooled
sufficiently. If the lamp fails to ignite, refer to pages 11-14, TROUBLESHOOTING.
Lamp life is reduced approximately one hour each time the lamp is switched on and off. Avoid
repeated cycles by leaving unit on through breaks.

TM-021 PN 35933
Rev 05/06/97 10
LAMP REPLACEMENT / INSTALLATION
WARNING
BEFORE REPLACING THE LAMP, THE UNIT MUST BE “OFF” FOR A MINIMUM OF 5
MINUTES. THIS WILL ALLOW DANGEROUS CHARGES, WHICH ARE PRESENT FOR
PROPER LAMP OPERATION, TO BLEED OFF.
LAMP REPLACEMENT PROCEDURE
1. Allow the unit to cool before removing the lamp/reflector assembly.
2. Unplug the power cord.
3. Remove the cover screws and cover.
4. Disconnect the lamp electrode wire from the positive electrode clip. Do not disconnect the
wire from lamp.
5. Loosen the retaining nut (see Figure 1.1) and rotate the electrode to one side such that the
lamp/reflector assembly can be removed from mount. Remove the lamp/reflector assembly.
6. Install the new lamp/reflector assembly into the mount and move the negative electrode (see
Figure 1.1) into position. Tighten the screw. Do not bend the electrode to install the new
lamp/reflector assembly.
7. Attach the electrode wire to the positive electrode clip (see Figure 1.1).
8. Replace the housing cover on the unit. If access to the unit is limited, use Allen head
screws instead of thumbscrews.
9. Record the serial number of the unit and hour-meter reading on the Bulb History Record.
Figure 1.1

TM-021 PN 35933
Rev 05/06/97 11
MAINTENANCE
LIGHT GUIDE
Operating temperature should not exceed 55°C. Ends of the guide should be kept clean to
transmit as much light as possible. Cured adhesive can be removed with razor blade. Avoid
sharp bends with the light guide since this reduces light output and damages guide.

TM-021 PN 35933
Rev 05/06/97 12
TROUBLESHOOTING
CAUTION
ONLY QUALIFIED MAINTENANCE PERSONNEL SHOULD ATTEMPT THE
FOLLOWING PROCEDURES:
Problem: Lamp Will Not Ignite
Possible Cause
Testing
Corrective Action
Improperly Fastened
Connections
Visually inspect all input/output
connections (i.e. power cord,
lamp).
Secure all connections.
Lamp Beyond Useful Life
Replace with a known good
lamp/reflector assembly and re-
test unit.
Replace lamp/reflector
assembly if defective
(typical life = 1000 hours).
Corroded Negative
Electrode (Brass Bracket)
Visually inspect the negative
electrode for ANY signs of
corrosion.
Replace, if corroded.
Main Line Fuse Blown
(Nothing in Unit Operates)
Remove fuse from power
receptacle and check with an
ohmmeter.
Replace fuse, if defective.
No High Voltage Off
Transformer Output
Verify ignition voltage off
transformer (refer to Figure 2).
Replace transformer, if
defective.
Insufficient Ignition Voltage
Verify ignition voltage being
supplied to the lamp (refer to
Figure 2 for location and Figure
3 for waveform).
Replace defective component
(typically blocking diode).
No Operating Voltage
(Lamp Flickers)
Verify the operating voltage
(refer to Figure 2).
Replace defective
component.
Problem: Shutter Fails To Open
Other Symptoms: Shutter Remains Open
Possible Cause
Testing
Corrective Action
Shutter Mechanism Binding
Remove power from unit and
manually move the shutter and
solenoid up and down (should
move freely).
Replace component causing
problem.
Solenoid Malfunctioned
Measure the voltage being
delivered to the solenoid during
operation (refer to Figure 2 -
Auxiliary voltage). If good check
solenoid resistance (120
ohms).
Replace solenoid, if defective.
Timer Malfunctioned
If shutter operates in manual
mode but not in timed mode,
timer is defective.
Replace defective timer.

TM-021 PN 35933
Rev 05/06/97 13
TROUBLESHOOTING
Problem: Low Output Intensity
Other Symptoms: Fails To Cure Adhesive In Allotted Time
Possible Cause
Testing
Corrective Action
Lamp Beyond Useful Life
Use a radiometer (model Dymax
Accu-Cal 20) to measure actual
output intensity. Consult manual
for proper output.
Replace lamp/reflector
assembly if beyond useful
life (typical = 1000 hours).
Transmission loss In Light
Guide Too Great
Compare light guide output against
new light guide (or use the Dymax
Light Guide Simulator - P/N
36987) to determine transmission
loss.
Replace light guide.
Transmission loss In Filter
(Blue Filter At End Of Light
Guide) Too Great
Compare filter output against new
filter to determine transmission
loss.
Replace filter.
Contaminants On Light
Guide Or Light Guide Filter
Visually examine ends of light
guide and filter for contaminants.
Clean with isopropyl alcohol
(or equivalent) or replace
light guide filter if it can not
be cleaned.
Lamp/Reflector Assembly
Not Installed Properly
Visually check to make sure the
lamp/reflector assembly is seated
flush in the lamp mount assembly
(any error in installation could
cause a low output).
Properly install
lamp/reflector assembly.

TM-021 PN 35933
Rev 05/06/97 14
TROUBLESHOOTING (Figure 2)
Input
Voltage
(Vac)
Transformer
Clamping Circuit
Power control
circuit.
Rectifier
Bulb output
(50W bulb ass'y)
Filtering
Rectifier / Filtering
Auxiliary
Components
TP5A-B
TP4
TP2A-B
TP6
TP1A-B
TP7
TP8
(open circuit)
TP3
TP8
Auxiliary
Voltage
Operating
Voltage
Ignition
Voltage
Input
Voltage
TP = Test Points
(refer to
schematic
diagrams)

TM-021 PN 35933
Rev 05/06/97 15
TROUBLESHOOTING (Figure 3)
Open Circuit Voltage From Lamp Output
Test Configuration: Remove Power
Remove Lamp/Reflector Assembly From Unit
Measurement Taken Across Lamp Output From Unit
Oscilloscope Setting: DC Coupling
20 ms / Div
500V / Div
Probe Connected Across Lamp Output (*Use a High Voltage
Probe*)
Open Circuit Voltage: 1900V peak

TM-021 PN 35933
Rev 05/06/97 16
SPARE PARTS
PC-3
SPARE PARTS
Item Part Number
Lamp/Reflector Assembly..................................................................................35003
Fuse: 3A 250 Vac............................................................................................35254
2A 250 Vac............................................................................................35636
5A 250 Vac............................................................................................35574
Filter (Light Guide).............................................................................................35301
Liquid Light Guide, 1 Meter................................................................................35102
Solenoid Assembly............................................................................................35928
Blocking Diode ..................................................................................................35660

TM-021 PN 35933
Rev 05/06/97 17
OPTIONS
PC-3
ACCESSORIES
Item Part Number
Liquid Light Guide, 1/2 meter*.....................................................................35101
Liquid Light Guide, 3 mm x 1 meter.............................................................36619
UV Goggles: Yellow ...................................................................................35284
Amber..................................................................................35285
Smoke..................................................................................35286
Face Shield................................................................................................. 35186
Accu-Cal 10 Radiometer.............................................................................35191
Light Guide Simulator..................................................................................36987
•Longer Light Guides Also Available

TM-021 PN 35933
Rev 05/06/97 18
WARRANTY
CAUTION
WARRANTY POLICY
DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES,
EXPRESSED OR IMPLIED, DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON
EC-SERIES LIGHT SOURCES WITHOUT WRITTEN AUTHORIZATION FROM DYMAX.
THOSE CORRECTIVE ACTIONS LISTED BELOW ARE LIMITED TO THIS AUTHORIZATION.
Light Sources:
Warranty is granted for one year from the date of the equipment shipment from
Dymax to the distributor or customer. The warranty start date can be extended
to the date of shipment from the distributor stock to the end-user.
Lamps and Lamp Assemblies:
Warranty will be honored only if the defective lamp/reflector assembly is returned
with a filled out Bulb History Record. The form will be provided with each
lamp/reflector assembly.
The 50 Watt lamp/reflector assemblies are warranted for 500 hours of useful life.
Lamps are not warranted against breakage from handling and shipping.
Notice: The data contained in this bulletin which represents typical results, is furnished for information only, and is believed to be reliable. We cannot assume responsibility for
results obtained by others over whose methods we have no control. It is the user’s responsibility to determine suitability for the user’s purpose of any product or method
mentioned herein and to adopt such precautions as may be advisable for the protection of property and persons against any hazards that may be involved in the handling and
use thereof. Nothing in this bulletin is to be interpreted as a representation of freedom from domination of patents owned by others, or a license under a Dymax Corporation
patent. We recommend that each prospective user test the proposed application before repetitive use, using the data as a guide.

TM-021 PN 35933
Rev 05/06/97 19

TM-021 PN 35933
Rev 05/06/97 20