dymax PC-3 User manual

TM-023 PN 37099
Rev 05/12/98 1
OPERATIONS MANUAL
PC-3 ULTRA
UV CURING
LIGHT SOURCE
Discontinued System

TM-023 PN 37099
Rev 05/12/98 2
PC-3 ULTRA TABLE OF CONTENTS
Description Page
Safety.................................................... 1
General ................................................. 4
Specifications........................................ 5
Unpacking and Inspection..................... 6
Installation............................................. 7
Lamp Replacement/Installation............. 8
Maintenance ......................................... 9
Troubleshooting ....................................10
Spare Parts...........................................12
Options..................................................13
Warranty ...............................................14
Diagram ................................................15

TM-023 PN 37099
Rev 05/12/98 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-023 PN 37099
Rev 05/12/98 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 UV-A denotes 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 are hazardous to the
eyes, which is why eye protection is important when working around UV light.
The lamps produce minimal amounts of ozone during start-up and no ozone during
operation. At high concentrations, it can cause discomfort, or at sufficiently high levels,
be dangerous.
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.
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.
Do not operate the unit without the light guide installed into the bezel.
With the internal filter installed, the PC-3 Ultra emits UVA and visible light. Never look
directly at the light source while the unit is in use.
WARNING

TM-023 PN 37099
Rev 05/12/98 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.
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-023 PN 37099
Rev 05/12/98 6
GENERAL
DESCRIPTION
The PC-3 Ultra is a special purpose UV curing lamp used for small area curing of
adhesives, coatings, and potting materials. It emits a 5 mm diameter spot of UV light
from a liquid light guide. This guide is hand-held for complete mobility or clamped into
position on assembly equipment or work stations for repetitive operations.
The unit consists of a stainless steel housing containing a 50 watt power transformer,
circuit protection, lamp/reflector assembly, internal light filter for extended lightguide life,
cooling fan, light guide mount, lamp status indicator light, 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 bezel. Light normally is not
emitted from the unit when the light guide is removed. But the light can escape when
the shutter is activated. That is why it is important to have the liquid guide engaged
within the bezel. Light can be emitted from the unit when the light guide is removed
from the bezel. Lamps are rated at 500 hours of life.
The light source contains circuitry which allows the user to monitor whether the lamp is
operating or not. This circuit will operate with a simple, audible alarm, a visual display,
a PLC or a computer system. The software to monitor via a personal computer (IBM
compatible) is available upon request from Dymax Corporation.
The power supply operates on line voltages of either 115 or 230 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 fan must not be covered or
otherwise blocked. 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-023 PN 37099
Rev 05/12/98 7
SPECIFICATIONS
PC-3 Ultra
SPECIFICATIONS
Voltage* 115 Vac, 60 Hz
Current 2.0 Amp Max.
Fuse 2 Amp 5 x 20 mm IEC 127 Fast Acting
Lamp/Reflector 50 Watt (pre-focused)
Shutter Timer 1 to 99 sec. delay
Foot Switch Rocker type
Hour-Meter 99,999.9 hours, non-resetable
* 230 Vac and 50, 60 Hz Power Supplies are available.
Output Intensities (Typical)**
WAVELENGTH
320-390 nm 4.0+ W/cm²
** Measured with an EIT Spotcure Radiometer. Values in W/cm2.

TM-023 PN 37099
Rev 05/12/98 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 - PC-3 Ultra Light Source
❑1 - Lamp/Reflector Assembly
❑1 - Power Cord
❑1 - Liquid Light Guide
❑1 - Pair UV Goggles
❑1 - Warranty Card
❑1 - Operation Manual
❑1 - Foot Switch
NOTE
REPORT ANY SHORTAGE TO DYMAX CORPORATION CUSTOMER SERVICE
Phone: [phone]
Fax: [phone]
LAMPS ARE SHIPPED WITH THE BULB/REFLECTOR REMOVED TO PREVENT
BREAKAGE (REFER TO LAMP REPLACEMENT/INSTALLATION).

TM-023 PN 37099
Rev 05/12/98 9
INSTALLATION
1. Install lamp per LAMP REPLACEMENT/INSTALLATION.
2. Connect power cord to rear of unit and plug into a grounded wall outlet.
3. Connect light guide to bezel mount by inserting and snapping into place.
4. Toggle lamp switch to ON (1).
5. Allow lamp to warm up for 4-5 minutes to obtain maximum light output.
6. Locate foot switch where desired; connect to foot pedal outlet.
7. Operate shutter by pressing foot switch. With the shutter 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 on the digital display on the
left side of the front panel. Simply push the + or - buttons to enter the desired
number of seconds the shutter is to remain open.
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 the TROUBLESHOOTING section
of this manual. 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-023 PN 37099
Rev 05/12/98 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 MUST BE EXECUTED BY THE TRAINED SERVICE
PERSONNEL ONLY!
LAMP REPLACEMENT PROCEDURE
1. Allow the unit to cool before removing the lamp/reflector assembly.
2. You must unplug the power cord.
3. Loosen the top housing by removing the top four thumbscrews and slightly loosening the
bottom four. Tilt the cover back to access bulb.
4. To remove the old bulb: A) remove the positive electrode wire from electrode board (see
Figure 1.1). Do not disconnect the wire from lamp. B) Gently lift the brass negative
electrode while lifting the bulb/reflector out.
5. To install a new bulb, simply reverse the steps followed in #4 above. Gently lift the brass
negative electrode while positioning the bulb/reflector in the reflector mount.
6. Attach the electrode wire to the positive electrode board (see Figure 1.1).
7. Close the top housing and tighten all screws.
8. Record the serial number of the unit and hour-meter reading on the Bulb History Record and
return to Equipment Customer Service.
A)
B)
Figure 1.1
WARNING

TM-023 PN 37099
Rev 05/12/98 11
MAINTENANCE
LIGHT GUIDE
The unit should not be operated when ambient temperature is above 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-023 PN 37099
Rev 05/12/98 12
TROUBLESHOOTING
ONLY QUALIFIED MAINTENANCE PERSONNEL SHOULD ATTEMPT THE
FOLLOWING PROCEDURES:
Problem: Lamp Will Not Ignite
Possible Cause
Testing
Corrective Action
Improper 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 = 500 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 of 1200 Vrms off
transformer.
Replace transformer, if defective.
Insufficient ignition voltage
Verify ignition voltage across open
circuit (should be half rectified
shortwave of 1200 Vrms).
Replace defective component
(typically blocking diode).
No operating voltage (lamp
flickers)
Verify the operating voltage of 20 Vac
across bulb with dummy load.
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. 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.
WARNING

TM-023 PN 37099
Rev 05/12/98 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 output intensity. Should
be more than 50% of initial power.
Replace lamp/reflector assembly if
beyond useful life (typical = 500
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.
Contaminants on light guide
Visually examine ends of light guide
contaminants.
Clean with isopropyl alcohol (or
equivalent) or replace light guide
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-023 PN 37099
Rev 05/12/98 14
SPARE PARTS
PC-3 Ultra
SPARE PARTS
Item Part Number
Lamp/Reflector Assembly.....................................................................................37123
Fuses: for 115 volt unit 2 Amp IEC 127F.............................................................37236
for 230 volt unit 1 Amp IEC 127F..............................................................37235
for 100 volt unit 2.5 Amp IEC 127F...........................................................37237
Liquid Light Guide, 1 Meter...................................................................................35102

TM-023 PN 37099
Rev 05/12/98 15
OPTIONS
PC-3 Ultra
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
Dymax Accu-Cal 20 Radiometer .................................................................36629
Light Guide Simulator..................................................................................36987
* Longer Light Guides Also Available

TM-023 PN 37099
Rev 05/12/98 16
WARRANTY
CAUTION
WARRANTY POLICY
DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES,
EXPRESSED OR IMPLIED, DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON
PC-3 ULTRA 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.