dymax BlueWave 75 User manual

Dymax BlueWave®75 Rev. 2.0 User Guide
UV Light-Curing Spot Lamp
■Instructions for Safe Use
■Setup and Operation
■Maintenance
■Ordering Spare Parts and Accessories
System Discontinued 1/1/2018

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Dymax BlueWave® 75 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® 75 User Guide
Contents
Introduction................................................................................................................................................ 4
Where to Get Help .......................................................................................................................................................... 4
Safety.......................................................................................................................................................... 4
UV Light-Curing System Safety Considerations ............................................................................................................... 6
Product Overview........................................................................................................................................ 8
Description of the BlueWave 75...................................................................................................................................... 8
Assembly and Setup .................................................................................................................................... 9
Unpacking and Inspecting Your Shipment....................................................................................................................... 9
Parts Included with the BlueWave 75 ............................................................................................................................. 9
Installation and System Interconnect..........................................................................................................10
Settings and Adjustments...........................................................................................................................12
Intensity Adjustment..................................................................................................................................................... 12
Intensity Validation ....................................................................................................................................................... 12
Intensity Control............................................................................................................................................................ 12
Setting the Cycle Duration............................................................................................................................................. 13
Lamp Dual-Hour Meter.................................................................................................................................................. 14
System Operation.......................................................................................................................................15
Maintenance..............................................................................................................................................16
Lightguide Maintenance................................................................................................................................................ 16
Fuse Replacement ......................................................................................................................................................... 16
Fan Filter Maintenance.................................................................................................................................................. 16
Bulb Replacement ......................................................................................................................................................... 17
Troubleshooting.........................................................................................................................................19
Frequently Asked Questions.......................................................................................................................20
Spare Parts and Accessories........................................................................................................................22
Spare/Replacement Parts.............................................................................................................................................. 22
Options/Accessories...................................................................................................................................................... 23
Specifications.............................................................................................................................................24
Specifications................................................................................................................................................................. 24
Definition of Terms ....................................................................................................................................25
Warranty....................................................................................................................................................26
Replacement Bulb Warranty ......................................................................................................................................... 26
Index..........................................................................................................................................................27

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Dymax BlueWave® 75 User Guide
Introduction
The enclosed BlueWave 75 UV Light-Curing Spot Lamp System was developed and manufactured by the
Dymax team, driven by a desire to best serve your needs. Before shipping, your BlueWave 75 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 would like to pass on your suggestions or
recommendations, please contact our Application Engineering or Customer Service Departments. Trained
Dymax professionals are standing by to serve you.
Par conséquent, nous vous encouragez a 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.
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
CAUTION! Always wear proper eye protection when working with this unit, which emits high-
intensity ultraviolet and visible energy! Note: The rear of the unit also emits stray UV & Visible
energy.
WARNING! Always observe safety requirements!
CAUTION! Risk of electrical shock if cover is removed!

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Dymax BlueWave® 75 User Guide
CAUTION! Cover is warm to the touch when unit is in operation!
To use this system safely, it must be set up and operated in accordance with the instructions given by Dymax.
The system’s design was developed to maximize operator safety and minimize exposure to UV. 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.
Safety Recommendations
◼Use the provided safety eyewear 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: The BlueWave 75 emits UVA and visible light. Never look directly into the lightguide entrance fitting or
end of lightguide 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 expositon 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 lumière. Ne jamais regardez directement à la
source de lumière pendant que l’élément est en opération.
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!

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Dymax BlueWave® 75 User Guide
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 75 und sichtbares Licht aus.
Schauen Sie deshalb niemals direkt in die Lichtquelle, wenn das Gerät angeschaltet ist.
UV Light-Curing System Safety Considerations
Dymax light-curing technology has been used successfully for over 30 years. The fast cure, one-component
nature of our 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 light-curing systems:
UV exposure, high-temperature surfaces, ozone, and bright, visible light.
UV Exposure
Standard Dymax UV light-curing systems 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 OSHA does not
currently regulate ultraviolet-light exposure in the workplace, the American Conference of Governmental
Industrial Hygienists (ACGIH) does recommend Threshold Limit Values (TLV‘s) 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 which includes the more dangerous UVB light, primarily responsible for sun tans, sun burns, and
skin cancer.
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.
Light-curing technology 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.

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Dymax BlueWave® 75 User Guide
Figure 1. Spectrum of Light
Shield the Operator
UV-Blocking Eye Protection –UV-blocking eye protection is recommended when operating UV-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 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 rise in 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 light-curing systems, like those used to cure UV inks, emit primarily “shortwave” (UVB and
UVC) energy. Upon exposure to UVC energy (specifically <240 nm), oxygen molecules (O2) split into oxygen

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Dymax BlueWave® 75 User Guide
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 light-curing systems.
Product Overview
Description of the BlueWave 75
The BlueWave 75 is a high-intensity, UV light-curing spot lamp used for the curing of adhesives, coatings, and
potting materials. It emits UV light from a lightguide which can be hand-held for complete mobility, fixtured
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, a thermostatically-controlled cooling fan, a lightguide mount,
bulb and unit status indicator lights, a combination resettable and non-resettable hour-meter, and a shutter
system. A thermal shutdown sensor is provided for internal temperature control of the unit. A cover-closed
switch and lightguide-sensing switch add to the safety of the unit. Fan filters should be changed or cleaned
frequently to prevent blockage and reduced ventilation airflow. Electric shutters are supplied with timed and
manual shutter operating modes. The lightguide is separate and plugs into the lightguide entrance fitting on
the front panel (the forward facing lightguide mount).
An intensity control feature allows operators to adjust output intensity during process validation and
production. Users can now manually adjust intensity to compensate for bulb degradation and to maintain an
optimized output or allow it to emit direct line of sight energy to unprotected personnel.
CAUTION: Once the lightguide is engaged there exists the possibility of light emitting if the unit is
triggered. Never look directly into the lightguide.
A cooling fan is provided to keep the bulb housing and internal components of the power supply at the
optimum operating temperature. The fan or exhaust opening must not have any restriction in their airflow
path. The UV source is a 75-Watt short-arc bulb mounted in a reflector and pre-focused to provide optimum
light output. The unit is rated for continuous operation.
The blue indicator light (located above the lightguide mount) lights when the bulb is operating. The power
supply operates on line voltages between 100 and 240 VAC and frequency between 50 and 60 Hz.
If the bulb extinguishes due to a momentary power failure the unit must be turned off and allowed to cool 20
minutes before attempting to re-ignite the bulb. Arc-type bulbs are designed to (and prefer) to be run
continuous. Repeated on/off cycling decreases bulb life and accelerates intensity degradation. It is good

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Dymax BlueWave® 75 User Guide
practice to leave the unit running for a full 8-10 hour shift and only turn the unit off if it will be off for more
than a few hours or overnight.
Figure 2. BlueWave 75 Front Face Plate
Assembly and Setup
Unpacking and Inspecting Your Shipment
Depending upon your order, your BlueWave 75 will arrive in one or two boxes. 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.
Parts Included with the BlueWave 75
■BlueWave 75 Spot Curing Lamp (1)
■BlueWave 75 Spot-Curing System User Guide (2)
■UV Protection Goggles (3)
■Power Cord; Style Dependent on Model Ordered (4)
40078 –115V Standard North American Power Cord
40077 –Type G Power Cord
40183 –No Power Cord (Note: For European customers, the appropriate power cord will be added)
■Tools - Hex Wrench (5) & Screw Driver (6)
■Footswitch (7)
Lightguide
Entrance Fitting
Intensity Adjustment
Indicator LEDs
Bulb Hour Meter
Power Switch
Shutter
Cycle Timer
Operation Mode

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Dymax BlueWave® 75 User Guide
Figure 3. BlueWave 75 Unpacking Diagram
NOTE: Units are shipped with the Bulb/Reflector installed
Installation and System Interconnect
1. Connect the Power Cord to the back of unit and plug the other end into a grounded wall outlet.
2. Connect the Footswitch to the connection in the back of the unit. A Ground Stud is provided on the back
of the unit if additional grounding is desired.
Figure 4. Rear Cable Connections
3. Remove the protective end caps from the Lightguide (purchased separately). Visually inspect the two ends
to verify that no foreign material is present. If required, the ends of the Liquid-Filled Lightguide can be
cleaned with isopropyl alcohol to remove oils and debris. Attach the Lightguide by removing the shipping
Power Cord
Ground Stud
Footswitch