dymax BlueWave 200 User manual

Dymax BlueWave®200 Version 1.1
User Guide
UV Light-Curing Spot Lamp System with Patented Intensity Control
Adjustment
Instructions for Safe Use
Setup and Operation
Maintenance
Ordering Spare Parts and Accessories

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Dymax BlueWave® 200 Rev. 1.1 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 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.

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Contents
Introduction.................................................................................................................................................... 4
Introduction to the User Guide ....................................................................................................................................... 4
Where to Get Help .......................................................................................................................................................... 4
Safety.............................................................................................................................................................. 5
Safety Recommendations................................................................................................................................................ 5
Dymax UV Light-Curing System Safety Considerations ................................................................................................... 6
Product Overview ........................................................................................................................................... 8
Description of the BlueWave 200.................................................................................................................................... 8
Assembly and Setup........................................................................................................................................ 9
Unpacking and Inspecting Your Shipment....................................................................................................................... 9
Parts Included in the BlueWave 200 Spot Lamp System ................................................................................................. 9
Installation & System Interconnect ................................................................................................................................. 9
Settings and Adjustments ............................................................................................................................. 11
Intensity Adjustment..................................................................................................................................................... 11
Intensity Validation ....................................................................................................................................................... 12
Setting the Cycle Duration............................................................................................................................................. 12
Lamp Dual-Hour Meter.................................................................................................................................................. 14
System Operation ......................................................................................................................................... 14
9-Pin Connector I/O Signals .......................................................................................................................... 15
Cleaning and Maintenance ........................................................................................................................... 18
Lightguide...................................................................................................................................................................... 18
Fan Filter........................................................................................................................................................................ 18
Fuse Replacement ......................................................................................................................................................... 18
Bulb Replacement ......................................................................................................................................................... 19
Troubleshooting............................................................................................................................................ 21
Frequently Asked Questions ......................................................................................................................... 21
Spare Parts and Accessories.......................................................................................................................... 23
Options/Accessories...................................................................................................................................................... 23
Spare/Replacement Parts.............................................................................................................................................. 24
Specifications................................................................................................................................................ 25
Definition of Terms ....................................................................................................................................... 26
Warranty ...................................................................................................................................................... 27
Replacement Bulb Warranty ......................................................................................................................................... 27
Index............................................................................................................................................................. 27

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Introduction
Introduction to the User Guide
The enclosed BlueWave 200 Spot-Curing System was developed and manufactured by the Dymax team,
driven by a desire to best serve your needs. Before shipping, your BlueWave 200 was thoroughly checked
and tested for trouble-free performance.
The proper setup and operation of this system will maximize safety and user-friendly performance,
providing optimum yield of your technological process.
Therefore, we encourage you to read, understand, and follow all safety and operating instructions and
recommendations compiled in this and other related manuals prior to setting up and operating this new
spot-lamp system or its individual components.
If you encounter a problem, have any questions, or have a suggestion or recommendation, please contact
our Technical or Customer Service Departments. Trained Dymax professionals are standing by to serve
you.
Par conséquent, nous vous encouragez à lire, comprend, et suivre tout sécurité et instructions
d’opération et conseillations rédiger dans cette et autre manuels établir un lien avant de mettre en place
et de faire marcher cette nouveau système de lampe de tache ou cette composants individuel.
Si vous rencontrez un problème, avait n’importe de questions, ou si vous voudrez de nous aider avec tes
suggestions ou conseillations, s’il vous plait contacte notre départements technique ou service client.
Dymax formé professionnels attendre à vous servir.
Intended Audience
Dymax prepared this user guide for experienced process engineers, technicians, and manufacturing
personnel. If you are new to UV light-curing systems and do not understand the instructions, contact
Dymax Application Engineering to answer your questions before using the equipment.
Where to Get Help
Additional resources are available to ensure a trouble-free experience with our products:
Detailed product information on www.dymax.com
Customer Support and Application Engineering teams are available by phone and email 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]. Please see the back cover for additional Dymax locations.
Dymax adhesive Product Data Sheets (PDS) on our website
Material Safety Data Sheets (MSDS) provided with shipments of Dymax adhesives

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Safety
Before continuing with the installation, please read the following chapters of this manual for safety
recommendations and installation, operation, and troubleshooting instructions.
CAUTION! Always wear protective goggles or a face shield when working near the front of
the unit, which emits high-intensity visible light!
WARNING! Always observe safety requirements!
CAUTION! Risk of electrical shock if cover is removed!
CAUTION! Cover is warm to the touch when the unit is in operation!
Equipment is designed to be used properly set up, with components correctly connected, and operated in
accordance with relevant instructions. The system's design was developed to maximize operator safety
and minimize exposure to UV.
Safety Recommendations
Use the goggles provided or an approved face shield for eye/face protection.
Long-sleeved shirts or a lab coat are recommended to protect arms and the use of UV-opaque gloves will
protect the hands.
NOTE: With the internal filter installed, the BlueWave 200 emits UVA and visible light. Never look directly
at the light source while the unit is on.
Sécurité
PRÉ-CAUTION! Toujours faisez de l’usage des lunettes de protection ou protéger de
visage marche près du devant d’élément!
AVERTISSEMENT! Remmarquez toujours besoin de sécurité!
PRÉ-CAUTION! Risque de décharge électrique quand le couvert est enlever!
PRÉ-CAUTION! Le couvert est chaud a le touche quand l’élément est en opération!
L’équipment ètre concu pour ètre utilisé correctement constituer, avec composants brancher
correctement, et marché en conformément avec instructions important. Le plan étais developer pour
render au maxime opérateur sécurité et minimiser exposition à ultraviolette.
Recommander de Sécurité
Emploi lunettes, ou un protéger de visage pour protection de ultraviolet pour protéger vous oeux.
Chemises à manche long, ou manteau de labo, sont recommander pour protéger les bras, et utilisation de
ultraviolette gants opague vais protéger les mains.
REMARQUER: avec le filtre intérieur installé, l’onde bleu émettre UVA et lumière visible. Ne jamais
regardez directement à la source de lumière pendant que l’élément est en opération.

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Sicherheitshinweise
ACHTUNG! Tragen Sie immer eine Sicherheitsbrille oder einen Gesichtsschutz, wenn Sie nahe
an der UV Lichtquelle arbeiten. Die Rückseite des Gerätes emittiert gestreutes UV Licht!
WARNHINWEIS! Bitte beachten Sie immer die Sicherheitshinweise!
ACHTUNG! Gefahr eines Stromschlages bei geöffnetem Gehäuse!
ACHTUNG! Gehäuse erwärmt sich während des Betriebs: Vorsicht bei Berührung!
Dieses Gerät wurde so entwickelt, dass es nur vollständig, alle Komponenten korrekt miteinander
verbunden, in Übereinstimmung mit relevanten Instruktionen betrieben wird. Bei der Entwicklung wurde
weiterhin großen Wert auf die Benutzersicherheit und minimale UV Belastung gelegt.
Sicherheitshinweise
Tragen Sie immer die mitgelieferten Sicherheitsbrille oder speziellen Gesichtsschutz, der Ihre Augen vor UV
Licht schützt.
Wir empfehlen Langarm - Hemden oder einen Laborkittel zu tragen, um die Arme zu schützen. Für die Hände
empfehlen wir UV-geblockte Handschuhe.
BITTE BEACHTEN SIE: Durch den installierten inneren Filter strahlt die BlueWave 200 UVA und sichtbares
Licht aus. Schauen Sie deshalb niemals direkt in die Lichtquelle, wenn das Gerät angeschaltet ist.
Dymax UV Light-Curing System Safety Considerations
Dymax UV light-curing technology has been used successfully for over 30 years. The fast cure, one-
component nature of our UV light-curing technology has made it the process of choice for many
manufacturers requiring a cure-on-demand assembly process. There are four common
questions/concerns related to UV light-curing systems: UV exposure, high-temperature surfaces, ozone,
and bright, visible light.
UV Exposure
Figure 1. UV Spectrum
Standard Dymax UV light-curing systems and bulbs have been designed to primarily emit UVA light (Figure
1). UVA light is generally considered the safest of the three UV ranges: UVA, UVB, and UVC. Although

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Dymax BlueWave® 200 Rev. 1.1 User Guide
OSHA does not currently regulate ultraviolet 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 is 1 mW/cm2
(intensity), continuous exposure. Unless workers are placing bare hands into the curing area, it is unusual
to exceed these limits. To put 1 mW/cm2limit into perspective, cloudless summer days in Connecticut
regularly exceed 3 mW/cm2of UVA light and also include the more dangerous UVB light (primarily
responsible for suntans, sun burns, and skin cancer) as well.
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-curing process. A workstation that exposes an operator to
more than 1 mW/cm2of UVA continuously should be redesigned.
Protecting Operators
UV light-curing of adhesives can be a regulatory compliant, “worker-friendly” manufacturing process when
the proper safety equipment and operator training is utilized. There are two ways to protect operators
from UV exposure: shield the operator and/or shield the source.
Shield the Operator
UV-Blocking Eye Protection - UV-blocking eye protection is recommended when operating UV light-
curing systems. Both clear and tinted UV-blocking eye protection is available from Dymax.
UV-Blocking Skin Protection -Where the potential exists for UV exposure upon skin, opaque, UV-
blocking clothing, gloves, and full-face shields are recommended.
Shield the Source of UV
Any substrate that blocks UV light can be used as a shield to protect workers from stray UV light. The
following materials can be used to create simple shielding structures:
Sheet Metal -Aluminum, steel, stainless steel, etc. Sheet metal should be coated black or black anodized
to minimize reflection of UV and visible light toward operators.
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 will rise in temperature. The intensity, distance, exposure
time, cooling fans, and the type/color of the surface can all affect the actual 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 a more moderate surface temperature or
appropriate protection/training for operators.
Ozone
Standard Dymax bulbs (UVA type) generate an insignificant amount of UVC and therefore essentially no
ozone. Some UV light-curing systems, like those used to cure UV inks, emit primarily “shortwave” (UVB
and UVC) energy. Upon exposure to UVC light (specifically <240 nm), oxygen molecules (O2) split into

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Dymax BlueWave® 200 Rev. 1.1 User Guide
oxygen atoms (O) and recombine with O2to create ozone O3. The current, long-term ozone concentration
limit recommended by ACGIH, NIOSH, and OSHA is 0.1 ppm (0.2mg/m3).
Bright, Visible Light
The bright, visible light emitted by some UV light-curing systems can be objectionable to some workers
and can cause eyestrain. Tinted eye protection and/or opaque/tinted shielding can be utilized to address
this concern.
Summary
UV light sources can be more “worker friendly” than many commonly accepted industrial processes,
provided the potential concerns are addressed. Contact your Dymax representative for information
regarding the proper use of Dymax UV light-curing systems.
Product Overview
Description of the BlueWave 200
The BlueWave 200 is a high-intensity, UV light-curing spot lamp used for curing adhesives, coatings, and
potting materials. It emits UV light from a lightguide (sold separately). The lightguide can be hand-held for
complete mobility, clamped into position for repetitive operations, or integrated into automated
equipment.
The unit consists of an anodized aluminum housing containing an electronic power supply, circuit
protection, a bulb/reflector assembly, an internal light filter for extended lightguide life, thermostatically
controlled cooling fans, a lightguide mount, a bulb status indicator light, a combination resettable/non-
resettable hour meter, and a shutter system. A thermal shutdown sensor is also provided for internal
temperature control of the unit. Electric shutters are supplied with timed and manual shutter operating
modes. The lightguide is separate and plugs into the lightguide mount, located on the unit’s front panel.
This unit features a patented intensity control which allows operators to manually adjust output intensity
during process validation and production. Users can use this control to manually adjust intensity to
compensate for bulb degradation.
The blue indicator light located above the lightguide mount lights when the bulb is operating. The power
supply operates on line voltages of either 115 or 230 VAC, 50/60 Hz. If the bulb extinguishes due to a
momentary power failure, the unit must be turned off, allowed to cool, and then turned on again to re-
ignite the bulb.
A cooling fan is provided to keep the bulb housing and internal components of the power supply at the
optimum operating temperature. The cooling fan must not be covered or otherwise blocked. Fan filters
should be changed or cleaned frequently to prevent blockage and reduced ventilation airflow. The UV
source is a 200-Watt short-arc mercury-vapor bulb mounted in a reflector and pre-focused to provide
optimum light output. The unit is rated for continuous operation.

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Assembly and Setup
Unpacking and Inspecting Your Shipment
When your BlueWave 200 arrives, inspect the 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.
Figure 2. BlueWave 200 Components
Parts Included in the BlueWave 200 Spot Lamp System
BlueWave 200 System (1)
Footswitch (2)
UV Protection Goggles (3)
BlueWave 200 User Guide (4)
Tools - Flat Blade Screwdriver (5) & Hex Wrench (6)
Power Cord (7)
Model 38905 - Standard 120V Plug
Model 38605 - Type G Plug
Model 38903 –No Power Cord Included (Note: For European customers, the appropriate power cord is
added)
Installation & System Interconnect
1. Connect the Power Cord to the Power Receptacle on the rear of the unit. Plug the Power Cord into a
grounded wall outlet.
2. Connect the Footswitch to the Footswitch Connection (Figure 3) in the rear of the unit. A ground stud
is provided on the back of the unit if additional grounding is desired.

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Figure 3. Cable Connection, BlueWave 200 Rear Panel
3. Remove the protective cover from the Lightguide Mount (Figure 4).
Note: Always have a Lightguide or the protective cap engaged in the Lightguide Mount. UV light can
escape when the Shutter is activated.
Figure 4. Lightguide Mount Protective Cover Installed (left);
Protective Cover Removed (right)
4. Remove the protective end caps from the Lightguide. Visually inspect the two ends of the Lightguide
to verify that no foreign material is present. The ends of a Dymax liquid-filled Lightguide can be
cleaned with isopropyl alcohol as required to remove foreign material and deposition from
outgassing.
5. Insert the large end of the Lightguide into the Lightguide Mount until it snaps into place (Figure 5).
Figure 5. Insert Lightguide into Lightguide Mount
Footswitch Connection
Power Receptacle
Power Cord

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Dymax BlueWave® 200 Rev. 1.1 User Guide
6. If desired, the Lightguide may be fastened into place by lightly tightening the securing Setscrew
installed in the Lightguide Mount. A hex wrench is provided with the BlueWave 200 for this purpose.
The Setscrew should be tightened gently to prevent damaging the Lightguide.
NOTE: Multi-Leg Lightguides should be balanced by rotating the Lightguide to obtain the desired UV
intensity of each leg before tightening the setscrew.
7. Turn the BlueWave 200's Power Switch on.
8. Allow the bulb to warm up 4-5 minutes to obtain the maximum light output.
CAUTION: This is an arc, not a filament bulb. Once ignited, it must be left on for a minimum of 10
minutes to fully vaporize elements in the bulb. If not, the bulb may be difficult to re-ignite. Each re-
ignition increases the rate of bulb degradation.
NOTE: The bulb must cool before it can be re-ignited. Turn the unit off and allow 5 to 10 minutes for it
to cool down. If the bulb fails to ignite, refer to the Troubleshooting Section of this manual. Bulb life is
reduced each time the unit is switched on and off. Avoid repeated cycles that shorten bulb life by
leaving unit on through breaks.
9. Operate the Shutter by pressing the Footswitch. With the Shutter Selector Switch in the manual
position, the Shutter operates directly from the Footswitch. In the timed position, the Shutter
opening is determined by the setting on the Electronic Timer. Simply push the Timer Setting Buttons
to enter the desired number of seconds the Shutter is to remain open.
10. With the Shutter open, adjust the Intensity Adjustment Screw as required to achieve the desired
output intensity (Figure 6).
Figure 6. Adjust the Intensity Adjustment Screw
Settings and Adjustments
Intensity Adjustment
The bulbs used to power all high-intensity UV light-curing spot lamps degrade with use. Intensity,
therefore, decreases as the bulb ages. Using the BlueWave 200’s patented intensity control feature, users
can eliminate this variation by manually increasing output intensity to offset this degradation.
The intensity can be adjusted with a tool (Figure 7) or a removable knob (Figure 8). This feature is useful
for both validation and control.

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Figure 7. Intensity
Adjustment with Tool
Figure 8. Intensity
Adjustment with Knob
Figure 9. Intensity
Adjustment (Interior View)
Intensity Validation
Tests should be conducted prior to production to determine the time and light intensity required to fully
cure your light-curable material in your specific application. 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.
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.
Intensity 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 maintain a constant intensity through
periodic manual adjustments. BlueWave 200 bulbs will typically vary less than 1% over eight hours of
normal use and so daily or weekly adjustments are adequate to maintain a tightly controlled process. A
change bulb indicator light is provided to alert the operator to check bulb operation or to change the Bulb
if required.
Setting the Cycle Duration
The Shutter Timer located on the front panel of the BlueWave 200 is factory set to the most common
operating mode and recommended operation of the Shutter Timer with the BlueWave 200. Some modes
available on this Shutter Timer may not operate correctly with the BlueWave 200 unit and have been
disabled.
The front panel of the Shutter Timer contains a LCD Display and Keypad. The LCD Display has a Power
Indicator, Signal Input Indicator, Reset Indicator, Gate Input Indicator, Key Protect Indicator, Output
Indicator, Present Value, Set Value, and Timing Operation Indicator. Below is a brief description of each
display and location.

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Figure 10. Shutter Timer
PW [Power Indicator] –Upper left corner of Timer Display. Displayed when external power for
operation is present.
SIG [Signal Input Indicator] –Upper left corner of Timer Display, located to right of Power
Indicator. Displayed when activate signal is present.
OUT [Output Indicator] –Displayed when relay is switched on; is not displayed when relay is
switched to off.
K/P [Key Protect] –Will always be lit as the function of the Shutter Timer is programmed at the
factory and locked before shipment.
Timing Operation Indicator –Displays RUN in upper right corner to the left of Output Indicator.
Displayed when Timer is active.
Timing Value –Four digits segmented display in center of Timer. Shows current status of time.
Set Value –Four-digit segmented display in lower right corner of the Shutter Timer. Shows set
length of time.
In addition to the indicators, the Shutter Timer contains six buttons with their functions described as
follows:
Mode –Disabled at the factory and locked before shipment.
RST [Reset Indicator] –Active when the Shutter Timer is reset by pressing the “RST” button on the
lower left face of Shutter Timer.
Digit Increment 1-4 –Pressing these buttons up or down will increment or decrement that digit by
one. The timer digits are formatted MM:SS for a maximum Shutter time of 99 minutes and 0.99
seconds. Consult Dymax for information on changing the format of this Timer.
To set the Shutter’s open duration, press the appropriate up/down button until the corresponding digit
increments in the Set Value. By pressing the key labeled (1), it will increment the left most digit on the Set
Value. By pressing the key labeled (2), it will increment the second digit of the Set Value and similar for
digits 3 and 4. The small grey buttons are “rocker” style so pressing the top half increments the digit up
while pressing the bottom half will increment down. The Timer will increment from 9 back to 0. If the
Timing Value
Set Value
Digital Increment 1-4
Press top half to
increment digit up
Digital Increment 1-4
Press bottom half to
increment digit down
Reset Button
Reset Indicator
Key Protect
Output Indicator
Mode

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Timer is not operating, the Timer should periodically update the Present Value with the Set Value. If the
Timer does not, press the Reset Button. Reset value will become the Present Value. The Timer comes
programmed for a range of 00.01 seconds to 99.99 seconds. Consult factory for other time ranges and
functions.
To operate the Timer, select the Timer Operation Mode on the front panel (large Rocker Switch left of the
Timer). Program the time into the Timer (described above) and depress the Footswitch. Factory settings
will open the Shutter and the Present Value will begin to count backward. When the Timer reaches 00.00,
it will reset the value to the Set Value and close the Shutter. The Timer cannot be stopped once started. If
power is removed from unit, the Timer will reset to the Set Value.
Lamp Dual-Hour Meter
The Lamp Dual-Hour Meter (Figure 11) provides the elapsed
time of unit operation (top display), as well as bulb usage
(bottom display). The top display (Elapsed-Time Meter)
continues to count hours of operation on the unit and cannot
be reset. The lower display reflects the number of hours on the
bulb. Bulb hours should only be reset when a new bulb is
installed.
When the Total Bulb Hours Line of the Lamp Dual-Hour Meter
reaches 2,000 hours, the display will alternate between
“CHANGE BULB” and "2000.0". This indicates that the bulb has
reached the end of its useful life and needs replacement.
Instructions for bulb replacement are found in the Bulb
Replacement Section of this manual as well as being located on
the sticker under the unit cover next to where the bulb is
located.
Figure 11. Lamp Dual-Hour Meter
WARNING! Operating a BlueWave 200 Lamp beyond 2,000 hours will result in a non-passive failure of
the lamp! Do not reset the Lamp Dual-Hour Meter without replacing the bulb.
System Operation
The BlueWave 200 will arrive almost fully assembled.
Please refer to the Installation and Interconnection
Section for instructions on installation of the lightguide,
power cord, and footswitch. The system should be
positioned in a dry location that does not obstruct
airflow from the rear of the unit.
IMPORTANT: To ensure proper operation of the shutter,
be sure to completely insert the lightguide into the
lightguide mount prior to tightening the setscrew. Be
sure to lightly tighten the setscrew to ensure the
lightguide remains in place during use.
Figure 12. BlueWave 200 Front Panel

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Dymax BlueWave® 200 Rev. 1.1 User Guide
WARNING! Always engage the lightguide in the lightguide mount before the system is turned on. Also
remove the lightguide from the lightguide mount ONLY AFTER the light is turned off to avoid the possibility
of exposure to the light. Lightly tighten the setscrew for safety.
AVERTISSEMENT! Engager le guide de lumière dans le biseau avant la lumière est allumer, et
enlève le guide de lumière de le biseau SEULEMENT après la lumière est fermer pour éviter la possiblité
d’exposition à la lumière. Reserrer doucement la vis pour sécurité.
To energize the system turn the Power Switch from the “O” position to the “l” position. The fan, hour
meter, timer, and 200 Watt lamp should begin to function. This can be confirmed by viewing the
illuminated blue lens above the Lightguide Mount. Before operating unit, allow the 200 Watt Lamp to
warm-up for approximately 5 minutes.
CAUTION! Always wear protective goggles or face shield when working near UV light. Never look
directly at the light exiting the Lightguide.
PRE-CAUTION! Toujours porte lunettes de protection ou protéger de visage en travaillant près
lumière ultraviolette. J’amais regarde directement à lumière sortie de le guide de lumière.
Position the Lightguide end no closer than 0.25" from the material being cured. Locating the Lightguide
end too close can cause the Lightguide end to become cloudy from vapors coming off of curing material.
This cloudiness can reduce UV output by as much as 50%.
Bulb life is reduced each time it is started. To avoid premature bulb deterioration, leave the unit on
through breaks, short shutdowns, and lunch hours. These UV light sources are designed for continuous
operation. If the power is momentarily lost, shut the unit “off” and let it cool down for 5 to 10 minutes
then switch back “ON” and wait for warm-up.
As the bulb degrades, some adjustment may be needed to the lamp intensity. To use the patented Lamp
Intensity Adjustment, the Intensity Adjustment Knob must be installed. This knob installs into the Intensity
Adjustment Screw.
9-Pin Connector I/O Signals
The BlueWave 200 is equipped with a 9-Pin D-
Subminiature Connector (Figure 26) that provides
interface between the BlueWave 200 and PLC and
similar factory-control equipment. The following
discussion will describe inputs and outputs, their
properties, and how to use them.
Input Signals
Pin 1 –Shutter Activate
Figure 13. 9-Pin I/O Signals
This signal line may be used to remotely open the BlueWave 200 Shutter. When it is being used, the local
Shutter Enable Jack on the rear of the BlueWave is still capable of opening the Shutter. Similar to the local
Shutter Enable, if the Timer/Manual Switch is in timer mode, the Shutter will stay open for the time set on
the Timer. In the manual mode, the Shutter will stay open for the duration of the remote Shutter Activate

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Dymax BlueWave® 200 Rev. 1.1 User Guide
Signal. The Shutter is opened when Pin 1 of the DSUB9 Connector is connected to Pin 2. When the
connection between DSUB9 Connector Pins 1 & 2 is broken, the Shutter is closed.
Pin 7 –Shutter De-Activate
This signal line may be used to remotely prevent the Shutter from being open under any circumstances. If
the operator wishes to use the Shutter Deactivate Feature, they must first remove both Outer and Inner
Cover Assemblies and remove the Jumper JP-2 from the Communications Board.
200 Watt units are shipped from the factory with the Jumper JP-2 installed on the Communications Board.
This board is located on the rear of the OMRON Timer and can be accessed only by removing the Outer
and Inner Cover Assemblies.
Once the JP-2 is removed, this will allow the operator to remotely enable or disable the Shutter
deployment from any input.
If using a PLC to control this signal, an Isolated Relay Contact (normally open) will provide the proper
sense in the event a disable of Shutter is required. Closing the contact, connecting Pin 7 to Pin 2 of the
DSUB9 Connector will provide normal Shutter operation. Opening the connection between Pins 7 and 2 of
the DSUB9 Connector will disable Shutter operation and leave the Shutter closed. Under this condition,
the Shutter may not be operated locally or remotely.
In summary, both input signals are said to be enabled when there is electrical contact between their pin
and Pin 2 of the 9-Pin D-Subminiature Connector. Closure can be supplied either by dry contacts or by
Opto-Coupler output as shown in Figure 14.
Output Signals
The output signals are all opto-isolated signals. Each signal has an NPN Output Transistor. The emitters of
all Output Transistors are tied together and connected to the PLC common on DSUB9 Pin 4. Each
individual Output Signal Line is connected to the collector of each Transistor. When the Transistor is
turned on, this provides a ground to the PLC system that can be used to enable a relay coil or an enable
signal to an Opto-Coupler. The Conducting Transistor can also function as a set of contacts that can initiate
actions within the PLC. When the Transistor is on, the signal is said to be enabled or asserted. When the
Transistor is off, the signal is said to be disabled or unasserted. The Transistors have a max current rating
of 30 mA, and a max power rating of 150 mW. Only positive voltages with respect to the PLC common
should be used to a maximum of 24 V. D. C. Series Limiting Resistors should be used to insure that the max
conditions are not exceeded.
Pin 3 - Shutter Fault & Pin 6 - Shutter Open
Shutter fault and Shutter open are gated by two Photocells monitoring the position of the Shutter. When
the Shutter is closed, both Photocells will be conducting due to their exposure to Lamp intensity. When
the Shutter begins to deploy to an open position, first Shutter fault, then Shutter open will be blocked
from Lamp intensity by the Shutter Assembly itself. Should the Shutter get stuck, one of these signals will
indicate the wrong sense, and will flag the problem.
When the Shutter is off, Pins 3 and 6 will be shorted to Pin 4. When the Shutter opens, both Pins will be
open with respect to Pin 4. Since a shorted condition would be used to indicate a failure, these signals
should only be polled 45 milliseconds after the Shutter closes. By this time they will be open with respect
to Pin 4 in normal operation. Should either of these lines remain shorted to Pin 4 after the 45 millisecond
delay, the operator should conclude that a Shutter fault condition exists.

17
Dymax BlueWave® 200 Rev. 1.1 User Guide
Pin 8 –Lamp Lit
Pin 8 will be shorted to Pin 4 when the Bulb is lit. Pin 8 will be open with respect to Pin 4, during startup
prior to the Bulb lighting, or if the Bulb has failed.
Pin 9 –Lamp Replace
When the Elapsed Time Meter reaches 2,000 hours, it disables the Lamp from lighting. At this point in
time, Pin 9 becomes shorted to Pin 4. Pin 8 will no longer be shorted to Pin 4 indicating that the Lamp is
no longer lit. Otherwise, Pin 9 will be open with respect to Pin 4.
Pin 5 of the DSUB9 Connector is not used at this time.
Figure 14 shows the suggested relationship for both inputs and outputs between the BlueWave 200 and a
PLC system. The component values shown are appropriate for a 24 VDC PLC Power Supply to limit current
flow to safe levels for the opto-coupler devices within the BlueWave 200.
Figure 14. 9-Pin I/O Signals

18
Dymax BlueWave® 200 Rev. 1.1 User Guide
Cleaning and Maintenance
The BlueWave 200 was designed to operate with a minimal amount of maintenance. Follow the schedule
below to assure top performance from the unit.
Lightguide
Clean the ends of the lightguide monthly or as required. The ends of the lightguide should be kept clean
to transmit as much light as possible. Cured adhesive can be removed with a razor blade. Avoid sharp
bends with the lightguide since this reduces light output and damages guide.
Fan Filter
The external fan filters should be inspected and cleaned periodically to prevent dust buildup from
affecting airflow through the unit. Spare fan filters are provided with each unit and with replacement
bulbs. The fan filters are washable and may be reused. Remove the Fan Filter by removing the snap-on
cover from the rear of each grill.
Fuse Replacement
The unit has two fuses that are installed in the power receptacle. To remove the fuses, unplug the unit
and remove the fuse holder with a small screwdriver. Remove the fuses from the fuse holder and install
new fuses. Replace the fuse holder into the power receptacle. The correct fuses are Dymax PN 37869, 4.0
Amp fast-acting type.
Figure 15. Cooling Fan
Figure 16. Cooling Fan Cover and Filter
Figure 17. Power Receptacle
Figure 18. Fuse Holder
Figure 19. Fuses
Removed from Holder

19
Dymax BlueWave® 200 Rev. 1.1 User Guide
Bulb Replacement
Bulb replacement is easily accomplished by following the steps below. Refer to the labeled diagrams
under the light source cover.
1. Ensure that the Power Cord is unplugged from the rear of the unit.
2. Remove the top cover from the BlueWave 200 by loosening the four cover fasteners.
3. Unplug the Bulb and Lift the Bulb Mounting Bracket from it. Remove the Bulb from the Bulb Mount
(Figure 22).
Figure 20. Bulb Installed
in Bulb Mount
Figure 21. Lift Bulb
Mounting Bracket
Figure 22. Remove Bulb
4. Unpack the new Bulb. Take care not to bend the flat Electrode in the center of the Bulb.
Figure 23. Unpack New Bulb
5. Install the new Bulb into the unit (Figure 23), plug the Bulb in (Figure 25), and tighten the two
Mounting Bracket Thumbscrews (Figure 26).
Figure 24.
Install Bulb
Figure 25.
Plug in Bulb
Figure 26. Tighten Mounting
Bracket Thumbscrews

20
Dymax BlueWave® 200 Rev. 1.1 User Guide
6. Make sure that the center Electrode is positioned as shown in Error! Reference source not found..
Figure 27. Bulb Electrode
7. Press Hour Meter Reset Switch (Figure 28).
8. Re-install the BlueWave 200's cover.
9. This completes Bulb installation. The Bulb will now ignite. If the Bulb does not light, repeat instruction
5. The unit is now reset to operate for 2,000 hours.
Figure 28. Hour Meter Reset Button
This metal Electrode connecting the Bulb to
the wire from the Reflector should be
parallel to the bottom of the unit.
Mounting Bracket Thumbscrews