dymax PORTA-RAY 400R User manual

PORTA-RAY® 400R
Portable UV Light-Curing
Flood Lamp User Guide

2 U S E R G U I D E |PO R T A - R A Y ®400R
About Dymax
UV/Visible light-curable adhesives. Systems for light curing,
fluid dispensing, and fluid packaging.
Dymax manufactures industrial, light-curable, epoxy, 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.

U S E R G U I D E |P O R T A - R AY ®400R 3
Contents
Introduction.................................................................................4
Where to Get Help........................................................................................... 4
Safety...........................................................................................4
UV Light-Curing System Safety Considerations ......................................... 4
Electrical Safety ............................................................................................... 6
High Temperatures ......................................................................................... 6
Shielding........................................................................................................... 6
Product Overview .......................................................................6
Description of the PORTA-RAY 400R........................................................... 6
System Components....................................................................................... 6
Assembly and Setup...................................................................8
Unpacking and Inspecting Your Shipment................................................... 8
Parts Included .................................................................................................. 8
Mounting........................................................................................................... 8
System Operation .......................................................................9
Start Up............................................................................................................. 9
Shut Down......................................................................................................10
Accessories Storage, Packaging, and Carrying ........................................11
Maintenance..............................................................................11
Maintenance Considerations .......................................................................11
Cleaning of Optics and Bulb Replacement ................................................11
Troubleshooting .......................................................................13
Spare Parts and Accessories...................................................13
Specifications ...........................................................................14
Definition of Terms ...................................................................16
Warranty....................................................................................17
Index ..........................................................................................18

4 U S E R G U I D E |P O R T A - R AY ®400R
Introduction
This guide describes how to assemble, use, and maintain
the Dymax PORTA-RAY®400R flood-lamp system 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 systems 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
To use this 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 the
protection of the system. Dymax assumes no liability for
any changes that may impair the protection of the system.
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
Standard Dymax UV light-curing systems and bulbs have
been designed to primarily emit UVA light (as shown in
Figure 1). UVA light is generally considered the safest of
the three UV ranges: UVA, UVB, and UVC. Although
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/cm2
of UVA light and also include the more dangerous UVB
light (primarily responsible for sun tans, sun burns, and
skin cancer) as well.
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.
UV-adhesive curing 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.

U S E R G U I D E |P O R T A - R AY ®400R 5
Shield the Source of UV Light
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.
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 either 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-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 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 energy emitted by curing systems
can cause eyestrain if proper eye protection or shielding is
not used. 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. Both the lower working
temperature and lack of spurious frequency transmission
that this system produces make it even more user friendly.
Contact your Dymax representative for information
regarding the proper use of Dymax UV light-curing
systems.
Figure 1.
Spectrum of Light

6 U S E R G U I D E |P O R T A - R AY ®400R
Electrical Safety
High voltage and current energize the UV Lamp. A high-
voltage Power Supply and Igniter combination is designed
to provide lamp-starting voltages, to limit current, and
subsequently provide a uniform output of energy.
NOTE: To avoid the risk of electrical shock, do not attempt
to replace the Lamp before turning off the Power Input
Switch, and disconnecting the Input Power Cord.
The electrical system of this unit should be serviced
by qualified service personnel.
High Temperatures
Due to the high output power of this system, high
temperatures may be present on the surfaces of the Lamp,
Reflector, Lamp Head, and Headrest.
NOTE: Extreme care should be taken to prevent touching
any of the surfaces before allowing sufficient time for all
temperatures to drop to safely back to room temperature
after power has been removed.
The Lamp Head Assembly should never be placed on or
near any flammable surface while the Lamp is on, or before
its temperature has cooled back to room temperature.
Never place the Lamp Head or parts to be cured on a heat-
sensitive surface. Always cure parts on a metallic or non-
flammable surface. When the unit is not in use, place the
Lamp Head on the Headrest and switch the standby switch
to the low power position to minimize temperature rise.
WARNING! Placing the Lamp Housing
Assembly on or near flammable surfaces while
the Lamp is on or still hot could result in fire.
Shielding
All installations should incorporate adequate shielding of
radiated UV light in order to prevent eye and skin burn of
the operator or others passing through the work area
(refer to the UV safety warnings in the safety
considerations section of this manual). The supplied
Headrest/Curing Chamber can be used with the
PORTA-RAY 400R to minimize the amount of stray UV
light scattering in the work area. Custom shielding may be
constructed using sheet metal or UV-blocking acrylic or
polycarbonate to prevent operator exposure to UV
radiation.
WARNING! To prevent risk of eye or skin burn,
all personnel must be protected from direct or
indirect exposure to the UV light produced by the PORTA-
RAY 400R light-curing system. Extreme care should be
used when designing custom UV shielding to ensure
personnel will not be exposed to harmful UV radiation.
Additionally, UV protective glasses and protective clothing
should be used at all times while working in the vicinity of
the UV light-curing system.
Product Overview
Description of the PORTA-RAY 400R
The PORTA-RAY 400R light-curing system may be placed
on any bench or shelf that has access to an 115 VAC
50/60-cycle single-phase power source in a clean
operation area.
CAUTION: The PORTA-RAY 400R is available in 115 VAC
and 230 VAC configurations. The unit’s voltage
configuration is clearly identified by a bright orange label,
located adjacent to the unit’s AC power input connector at
the side of the Lamp Head. Operating with voltage outside
the specified range will result in damage to the system.
Since the PORTA-RAY 400R is an air-cooled unit, dust or
airborne particles can clog the internal cooling passages
and cause overheating. Allow a 4-inch clearance on all
sides of the Lamp Head during operation for unrestricted
airflow.
System Components
•Mounting Holes (A) - Two threaded holes that can be
used for fastening the Lamp Head to a fixture, machine,
or conveyor.
•Input Power Switch & Receptacle (B) - Input Power
Switch used to apply or remove main power to the
PORTA-RAY 400R system. Co-located with the Input
Power Switch is the IEC-type Receptacle where the
Input Line Cord is inserted.
•Handle (C) - The PORTA-RAY 400R Handle can be
used to carry the curing system when the Lamp Head

U S E R G U I D E |P O R T A - R AY ®400R 7
is latched to the bottom Accessory Compartment or to
hold the Lamp Head during manual curing operations.
•Lamp Power Select Switch (D) - The Lamp Power
Select Switch selects either the “full” or “standby”
lamp power setting. When curing or warming up the
Lamp, the Lamp Power Select Switch should be set to
full power. Between curing operations, the Lamp
Power Select Switch can be set to the half-power
standby setting, which reduces the amount of heat and
stray UV light radiated by the unit. The Lamp Power
Select Switch should always be set to “standby” when
the Lamp Head is idling on the Headrest. When
switching back to full power, the Lamp will be ready for
curing again after a brief 10-second re-warming period.
•Input/Output Cooling Air Louvers (E & F) - The Input
and Output Air Louvers channel cooling air from the
Fan in and out of the Lamp Head. These must remain
unobstructed.
•Cooling Fan (G) - The Lamp Head Fan cools the
Lamp, Reflector, and Internal Power Supply Circuit-
Board Assembly.
•Arc Bulb (H) - Medium-pressure Arc Bulb which
produces UV and visible light.
•Reflector (I) - Lamp Reflector which collects and
concentrates light from all sides of the Arc Bulb. This
surface should be kept clean to ensure maximum light
output.
•Accessories Storage Compartment (J) - The
Accessories Storage Compartment can be used to
store and transport curing accessories (i.e. headrest,
glasses, power cord, and adhesive).
•Lamp-Head Latches (K) - The Lamp-Head Latches
are used to secure the Lamp Head to the bottom
Accessories Storage Compartment during transport
and storage.
Figure 2.
Lamp-Head Unit, Top View
Figure 3.
Lamp-Head Unit and Storage Compartment
(D) Lamp Power
Select Switch
(A) Mounting Holes
(C) Handle
(F) Input Air Louvers
(G) Cooling
Fan
(H) Arc Bulb
(I) Reflector
(J) Accessories Storage
Compartment
(K) Lamp Head
Latches
(E) Output Air Louvers
(B) Input
Power Switch
& Receptacle

8 U S E R G U I D E |P O R T A - R AY ®400R
Figure 4.
PORTA-RAY 400R (Open & Closed)
(PN 39639, PN 39640, PN 39697, PN 39713)
Figure 5.
PORTA-RAY 400R Lamp Head Mounting-Hole
Dimensions (inches)
Assembly and Setup
Unpacking and Inspecting Your Shipment
When your PORTA-RAY arrives, inspect the boxes for damage
and notify the shipper of any box damage immediately.
Open each box and check for equipment damage. If parts are
damaged, notify the shipper and submit a claim for the
damaged parts. Contact Dymax so that new parts can be
shipped to you immediately.
Check that the parts included in your order match those listed
below. If parts are missing, contact your local Dymax
representative or Dymax Customer Support to resolve the
problem.
Parts Included
•PORTA-RAY 400R lamp head with attached bottom
accessory compartment
•400-Watt UVA-enhanced arc bulb (installed) - other
spectral versions optional
•Lamp headrest/mini curing chamber with drawer
•UV/IR protective glasses
•AC power cord
•PORTA-RAY 400R Use Guide
•Face shield
Mounting
The lamp head should always be placed on the headrest or
held away from any flammable surfaces. Never place the lamp
head directly on the work surface. The PORTA-RAY 400R is
also designed to be machine or conveyor mounted using the
two threaded holes in the top surface of the lamp head.
The lamp head can also be placed on a shelf-type structure, supporting
the unit by its bottom outside edges. For this type of mounting, a
windowed hole must be cut in the shelf to provide adequate clearance
for the unit’s bottom-side light exposure opening, and also for the
cooling air-exhaust holes.

U S E R G U I D E |P O R T A - R AY ®400R 9
Figure 6.
Unlatching the Lamp Head
from the Storage Compartment
Figure 7.
Removing the Lamp Head from the Storage
Compartment
Figure 8.
Lamp Head on Headrest
System Operation
The PORTA-RAY 400R is designed to be an extremely user-friendly
system. This system was designed with minimum controls, making it
easy to operate.
Start Up
Open the Latches on the side of the storage compartment unit, and remove the Lamp Head from the bottom enclosure
by lifting it by the Handle (Figure 6 &
1. Figure 7).
2. Place the Lamp Head on the Headrest with the drawer closed
(Figure 8).
3. Plug the IEC-Type Connector of the AC Power Cord into the
Power Input Receptacle in the side of the Lamp Head. Plug in
the opposite end of the Input Line Cord into a nearby single-
phase power outlet.
4. To start the system, turn on the Power Switch (Figure 2, B) at
the side of the unit. The Lamp Head should turn on.
5. During the warm-up period, the Lamp Power Select Switch
(Figure 2, D) on the top of the Lamp Head should be set to full
power mode. A one- to two-minute warm-up time is required
for the Lamp to reach full intensity.
WARNING! Bluish light is projected from the unit,
becoming brighter as the unit warms up. This
ultraviolet light can be harmful to the eyes and skin. UV
protective glasses and clothing are required to prevent burns
of eyes and skin. Care should also be taken to protect other
personnel in the area from unintentional exposure to the UV
light (see the safety section for additional UV safety
information).
6. To change to the standby power mode, switch the Lamp Power
Selector Switch (Figure 2, D) to the half power position (Rocker
Paddle pressed toward the closest Handle stem). The Lamp
Head intensity will visibly dim when the unit is in this low-power
mode.
NOTE: The PORTA-RAY 400R system is designed for
continuous operation. It is suggested that the Lamp remain on
during work breaks. Frequent stopping and starting of the
Lamp Head will reduce Lamp Head life. In general, leave the
unit in standby power mode for periods of non-use of less than
30 minutes. The unit will require only a brief 10 second re-

10 U S E R G U I D E |P O R T A - R AY ®400R
Figure 9.
Curing in Headrest
Figure 10.
Handheld Curing
warming period before the Lamp Head returns to full intensity.
Once the input power is switched off, the Lamp Head will
require a minimum of five minutes of cooling time before
restarting.
7. The Headrest can be used as a Curing Chamber for small
parts. To cure parts in the Headrest, pull the drawer open
using the black pull knob and load components onto the center
of the tray (Figure 9). Close the drawer and set the Lamp
Power Select Switch to the full power position and wait the
appropriate amount of time for curing to complete.
WARNING: While the drawer is in the fully open position, the
back side of the drawer will block most of the UV light and
prevent it from scattering into the work area. However, UV
glasses and skin protection should still be worn during curing
to ensure safe operation.
8. When curing is complete, set the Lamp Power Select Switch to
the standby position to minimize temperature rise of the Lamp
Head and Headrest. Open the drawer and remove the cured
parts.
9. To perform handheld curing (Figure 15), lift the Lamp Head
from the Headrest using the Handle. Switch the Lamp Head to
full-power mode and hold the Lamp Head 2-6 inches from the
target substrate.
NOTE: The height of the Lamp can be adjusted up or down to
control the intensity of light reaching the substrate being cured.
Refer to the adhesive manufacturer’s data sheet for
appropriate exposure time and intensity levels. The optimum
height and exposure time required to provide proper curing
may need to be adjusted experimentally.
10. When curing is complete, place the Lamp Head back on the
Headrest and set the Power Mode Switch back to the standby
position.
Shut Down
To shut down the light-curing system, place the Lamp Head back on
the Headrest, and shut off the Input Power Switch. Allow the Lamp
Head and surrounding components time to cool before placing the
Lamp Head close to temperature-sensitive materials or before
repackaging the system for transportation.

U S E R G U I D E |P O R T A - R AY ®400R 11
Figure 11.
Packing and Carrying the PORTA-RAY 400R
Figure 12.
Accessories Storage Compartment
Accessories Storage, Packaging, and Carrying
Once the Lamp Head has cooled sufficiently, the system can be re-packaged
and transported. The bottom portion of the PORTA-RAY 400R can be used for
storing related curing accessories (such as the Headrest, Power Cord, UV
glasses, and adhesive). After accessories have been inserted, the Lamp Head
can be latched onto the bottom enclosure for system storage or transportation
to another location
Maintenance
Maintenance Considerations
During the production process, various deposits of foreign matter may
accumulate on the lamp head and reflector surfaces. Product vapors can also
condense on these surfaces over time, causing poor transmittance/reflectance
of UV light and reduced curing efficiency. To ensure maximum light output of
the curing system, these surfaces should be inspected and cleaned at regular
intervals as required.
The bulb will also need to be replaced when its intensity output drops below
levels to meet curing process requirements. A radiometer should be used to
monitor system UV-light output.
Cleaning of Optics and Bulb Replacement
The following procedure should be followed carefully for optics cleaning and
bulb replacement:
WARNING! To avoid coming in contact with dangerous high voltages
or high temperatures, the following power-down and cooling procedure
must be completed before attempting any maintenance operations on the
PORTA-RAY 400R UV Lamp: Turn off the Input Power Switch at the side of the
Lamp Head and unplug the Power Cord from the Input Power Receptacle. Wait
15 minutes or until the Lamp and other hot components cool before proceeding
with any maintenance operations.
1. Remove the Lamp Head from its Headrest or fixture and place it upside-
down on a soft clean surface.
CAUTION: It is extremely important to avoid touching (with your hand) the
aluminum Reflector, and the glass portion of the Bulb. Contaminants from
your skin will damage these components. Clean cotton gloves or a clean, soft
cloth should be used when handling or cleaning the Bulb and Reflector.
2. Using cotton gloves or a clean, soft cloth, remove the Bulb by holding it
near one end and pushing into the adjacent Spring-Loaded Socket. Once
the other end of the Bulb has cleared the walls of its Socket, tilt the cleared
end of the Bulb up slightly, and remove the Bulb from the other Socket that
is still engaged.

12 U S E R G U I D E |P O R T A - R AY ®400R
3. Using a clean, soft cloth dampened with isopropyl alcohol, clean the
surfaces of the aluminum Reflector.
CAUTION: Do not use abrasive cleaning compounds or steel wool
for cleaning the Reflector. These harsh products will remove the
finish and reduce the Reflector efficiency.
4. Wipe the Bulb lightly with a clean isopropyl-dampened cloth. If the
Bulb shows signs of bulging or shape distortion, replace it.
Otherwise, dry and polish the Bulb with a clean, dry cloth.
5. Re-insert the cleaned or new Bulb between the Bulb Sockets, with
the Filler Nipple facing the Reflector. Be sure to center each Bulb
Electrode in its Socket to ensure proper electrical connection and
to avoid arcing (which will damage the Bulb and Socket). The Bulb
is non-polarized so it does not matter which Electrode is placed in
which Socket.
6. Mount the Lamp Head back on its Headrest or fixture and
reconnect the Input Power Cord.
7. Re-test the unit to ensure satisfactory light intensity and cure time is
achieved.

U S E R G U I D E |P O R T A - R AY ®400R 13
Troubleshooting
NOTE: When contacting Dymax, an authorized Dymax distributor, or a Dymax representative, be sure to know and provide the
following:
•Model number of light source in question.
•Serial number of light source in question.
•Product number of adhesive in question (if applicable).
•Lot number of adhesive in question (if applicable).
All returns to Dymax must be accompanied by a Return Merchandize Number (RMA). This number must be obtained from a
Dymax Customer Service Representative.
NOTE: Only qualified maintenance personnel should attempt the following procedures.
Problem
Possible Cause
Corrective Action
The lamp
operates but
has low output
or slow curing
The lamp’s power switch is in
the half-power position
Place the switch in the full-power position during curing.
The lamp too far from the
substrate being cured
Adjust the lamp height to within 2” to 4”of surface being cured.
The adhesive is not
compatible with the lamp type
Compare the adhesive’s light spectral requirements with the
lamp’s spectral chart under Specifications. Contact Dymax for
optional lamp types if required.
The reflector or bulb requires
cleaning
Clean the reflector and the bulb. Instructions can be found under
Maintenance.
The bulb is past its usable life
Replace the bulb (see Bulb Replacement Procedure under
Maintenance).
The lamp does
not light, but
the fan is
running
The bulb is not properly
installed
Disconnect the power and verify that both the bulb electrodes are
properly centered in the sockets.
The over-temperature
protection has activated
Allow the unit to cool. Operate the unit in a cooler environment
(see Specifications for the operating temperature range).
The bulb is past its usable life
See the Bulb Replacement Procedure under Maintenance.
The lamp does
not start, the fan
is not running
Power Cord not properly
connected or defective
Verify that both ends of the power cord are fully inserted into their
sockets or replace the power cord.
There is no power at the outlet
Test for power at the wall outlet.
Spare Parts and Accessories
Item
Part Number
Lamps
Metal Halide 400 Watt UV (Standard) Lamp*
38560
Mercury Vapor 400 Watt UV (Optional) Lamp
36970
Safety Equipment
Face Shield
35186
Safety Glasses
35285
* Recommended spare parts

14 U S E R G U I D E |P O R T A - R AY ®400R
Specifications
Property
Specifications
Part Numbers
39639 120 VAC, Metal Halide Bulb
39640 240 VAC Metal Halide Bulb
39697 120 VAC, Mercury Bulb
39713 240 VAC Mercury Bulb
Typical Output Intensity
400 @ UV-A* (365 nm)
Dimensions (L x W x H)
8" x 5" x 16.5" [20.3 cm x 12.7 cm x 41.9 cm]
Weight
With bottom box: 6 lbs. / With lamp head only: 3.5 lbs.
Max Chamber Part Size
(for curing in Headrest)
4.25" x 4.25" x 2" [10.8 cm x 10.8 cm x 5.1 cm]
Power Supply
Input Voltage
100-120 VAC + -10%
200-240 VAC + -10%
Input Current (max)
7 Amperes
3.5 Amperes
Source Input Frequency
47 Hz to 63 Hz
Lamp Power Regulation
± 1%
Protection
Inrush current limit, hot re-strike, line
voltage surge, short circuit, open circuit,
over temperature, ignition retry timeout
5 minutes
Lamp
Lamp Type
400 Watt metal halide
Quartz, ozone free
Lamp Voltage
135 ± 15V
Arc Length
32 mm
Burning Position
Horizontal
Radiation Flux
72 Watts, 315-440 nm
Warm-Up Time (min)
1-2
Cooling Time Before
Restart
5 minutes (typical)
Lamp protection prevents the restart of a
hot lamp
Lamp Peak Irradiance
500 mW/cm2UVA
2" from base of lamp head
Curing Area (minimum)
5" x 3" [12.7 cm x 7.62 cm]
Affected by lamp height
Lamp Life
1,000 hours typical
Affected by # of on/off cycles
Environmental
Operating Temperature
+10 °C to +40 °C (+50 °F to +104 °F)
Storage Temperature
0 °C to +60 °C (+32 °F to +140 °F)
Relative Humidity
30 to 75% operating, 10 to 100% storage, non-condensing
Cooling
Forced air
Over-Temp Shutdown
67°C (internal)
* Intensity with the beam focused and measured with an ACCU-CAL™ 50 UV Radiometer calibrated and traceable to NIST.

U S E R G U I D E |P O R T A - R AY ®400R 15
Figure 13.
PORTA-RAY 400R Lamp Head, Overall Dimensions (inches)
Figure 14.
Spectral Output of Standard Metal-Halide Bulb
Figure 15.
Spectral Output of Mercury Bulb

16 U S E R G U I D E |P O R T A - R AY ®400R
Definition of Terms
Flood Lamp System - Set of components arranged to generate, collect, condition and direct UV radiant energy to perform
curing of engineering adhesives, coatings, and inks within 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, or other accessories.
Lamp - Light source (bulb or burner) generating ultraviolet, visible, and infrared radiant energy from burning matter stimulated
by electrical power conditioned by a proper power supply which is an integral part of a Lamp. A light source is usually placed
into a reflector (of various geometry) to increase light-source efficiency by collecting and directing radiant energy of selected
spectra (for a given curing process).
Intensity - a measure of light energy over the unit of surface area (usually surface at the 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 Illuminance.
Illuminance - 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. Wavelength ranges in
general from 1.0 to 400 nm. Dymax bulbs (burners) do not radiate energy in deep ultraviolet; there are very minute amounts
below 220 nm and practically nothing can be sensed below 200 nm. This is due to the use of an ozone-blocking quartz-bulb
envelope (See Ozone).
Ultraviolet is used beneficially in various fields of industry and medicine. In order to standardize light sources used in medicine,
in Copenhagen in 1932, The International Congress on Light recommended dividing the ultraviolet spectrum 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).
Ozone - oxidizing agent (O3) produced by the action of ultraviolet radiant energy (below 185 nm) or electrical corona
discharge of oxygen on air.
OSHA 1910.145: “Regulation of Accident prevention Signs and Tags” defines the following headers as:
WARNING: Calls out a hazardous situation that has some probability of severe injury.
CAUTION: Indicates 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.

U S E R G U I D E |P O R T A - R AY ®400R 17
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.

18 U S E R G U I D E |P O R T A - R AY ®400R
Index
Accessories Storage....................................................................... 11
Assembly and Setup..........................................................................8
Bulb Replacement........................................................................... 12
Carrying............................................................................................ 11
Cleaning Optics............................................................................... 12
Definition of Terms.......................................................................... 16
Glossary............................................................................................ 16
Help......................................................................................................4
Maintenance .................................................................................... 12
Mounting .............................................................................................8
Operation ............................................................................................9
Shut Down................................................................................... 11
Start Up...........................................................................................9
Parts List..............................................................................................8
Product Overview...............................................................................6
Safety...................................................................................................4
Electrical Safety .............................................................................6
High Temperatures .......................................................................6
Shielding.........................................................................................6
Spare Parts and Accessories ........................................................ 13
Specifications .................................................................................. 14
Support................................................................................................4
System Components .........................................................................6
Troubleshooting .............................................................................. 13
Unpacking ...........................................................................................8
UV Light-Curing System Safety Considerations ............................4
Bright, Visible Light .......................................................................5
High-Temperature Surfaces.........................................................5
Ozone..............................................................................................5
Shield the Operator.......................................................................4
Shield the Source of UV Light .....................................................5
UV Exposure ..................................................................................4
Warranty........................................................................................... 17

U S E R G U I D E |P O R T A - R AY ®400R 19

www.dymax.com
Americas
USA | +1.860.482.1010 | [e-mail]
Europe
Germany | +49 611.962.7900 | [email protected]
Ireland | +353 21.237.3016 | [email protected]
Asia
Singapore | +65.67522887 | [email protected]
Shanghai | +86.21.37285759 | [email protected]
Shenzhen | +86.755.83485759 | d[email protected]
Hong Kong | +852.2460.7038 | [e-mail]
Korea | +82.31.608.3434 | [email protected]
© 2006-2013 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 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. PN39957 MAN009 2/25/2013