dymax PC-3D User manual

TM-022 PN 35934
Rev 05/12/98 1
OPERATIONS MANUAL
PC-3D UV CURING
LIGHT SOURCE
Discontinued System

TM-022 PN 35934
Rev 05/12/98 2
TABLE OF
CONTENTS
Description Page
Safety .................................................................................... 1
Description............................................................................. 4
Specifications......................................................................... 5
Unpacking and Inspection...................................................... 6
Installation ............................................................................. 8
Lamp Replacement/Installation.............................................. 9
Maintenance..........................................................................10
Troubleshooting Guide...........................................................11
Spare Parts............................................................................14
Options..................................................................................15
Warranty................................................................................16
Diagrams...............................................................................17

TM-022 PN 35934
Rev 05/12/98 3
SAFETY
Explanation of WARNINGS, CAUTIONS, AND NOTES:
A WARNING indicates when failing to follow the instructions could result in injury to
personnel.
CAUTION
A CAUTION indicates when failing 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-022 PN 35934
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: UVC, UVB, and UVA. UVC is for the wavelengths below 280 nm, UVB is
for the wavelengths between 280-315 nm, and UVA is for the wavelengths between
315-380 nm.
Exposure Hazards
Exposure to UV light, even for short periods of time, can be hazardous. The danger
depends upon the exposure time, the intensity of the light, the wavelength, and the
individual’s sensitivity to UV. UV-B and UV-C can be considered the most hazardous to
the skin, causing such effects as sunburn. Ultraviolet light is considered to be
hazardous to the eyes, this is why eye protection is important when working around UV
light.
Ozone is a form of oxygen. Interaction of ultraviolet light below 220 nm with oxygen in
the surrounding air produces ozone, which is a powerful, toxic agent. It has a
characteristic pungent odor to which most people are quite sensitive (people can
typically detect concentrations of several parts per million). At high concentrations, it
can cause discomfort, or at sufficiently high levels, be dangerous. The EC series of
lamps do not produce ozone as they are made out of a special material for the lamp’s
envelope called ozone-free quartz. Ozone is suppressed in this case, even if it is
generated by the arc.
Safety Guidelines
The National Institute for Occupational Safety and Health (NIOSH) recommends that
exposure to UV energy be controlled and limited in the work place. Recommended
maximum exposures are available, but do not apply to photosensitive individuals.
The total intensity from 320 to 400 nm hitting unprotected skin or eyes should not
exceed
1 mW/cm² for periods longer than 1000 seconds. For shorter exposure times, the total
radiant energy shall not exceed 1000 mWsec/cm².

TM-022 PN 35934
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 completely surround and protect your eyes. Many goggles will also fit
over regular glasses. Be sure your goggles fit comfortably.
•Safety spectacles don't fog as easily as goggles and can be worn at all times.
•A face shield protects your entire face, not just your eyes.
It is important to verify that your selection of safety eyewear is approved for UV
protection.
Individuals should wear protective UV glasses as a minimum precaution.
SKIN PROTECTION
Individuals exhibit different levels of photosensitivity. Therefore, even minimal periods
of exposure of unprotected skin to direct UV light must be avoided.
•UV barrier creams 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-022 PN 35934
Rev 05/12/98 6
PC-3D
DESCRIPTION
The Light-Welder®PC-3D is a combined, special purpose UV curing light source with an
adhesive dispenser. UV light is generated by the lamp in the housing and transmitted
through a flexible light guide. The light guide can be hand-held or machine mounted for
automated applications. The adhesive dispenser is designed to dispense adhesive
from a 10 mL or 30 mL syringe. A hand-held manifold is provided that couples the light
guide and syringe together for wire tacking, SMDs and other spot curing applications
The light source consists of a housing containing the power supply, circuit protection,
power-on light, lamp/reflector, cooling fan, light guide mount and an electric shutter.
Electric shutters are supplied with timed opening and manual modes. The light guide is
separate and plugs into the mount on the front of the unit. Light is not emitted from the
unit when the light guide is removed. Lamps are rated at 500 hours of life.
The power supply operates on line voltages for either 100, 115, or 230 Vac, 50 or 60 Hz
(factory set). AC voltage is stepped down and converted to DC through a full wave
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,
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 re-ignite
after it cools down, if the power switch is left on. The unit is rated for continuous
operation.
A cooling fan keeps the lamp, lamp housing, and internal components of the power
supply operating at optimum temperature. A 50 Watt, short arc, mercury vapor lamp is
mounted in a reflector and pre-focused to provide optimum light output.
Adhesive dispensing is done by a time/pressure system. A vacuum suckback feature is
included to prevent dripping of low viscosity adhesives. Operation is controlled by a foot
switch which initiates the dispense cycle. Both timed and manual modes are provided.
Initiating the dispense cycle causes the dispensing timer to energize a solenoid valve
for a predetermined time. In the manual mode, the solenoid valve is energized directly.
The timer operates on momentary or maintained switch closure, however, the switch
has to be reset to initiate another cycle.

TM-022 PN 35934
Rev 05/12/98 7
PC-3D
SPECIFICATIONS
Voltage:....................................................... 100 Vac
.................................................................... 115 Vac
.................................................................... 230 Vac
Current: ...................................................... 3 A @ 100 Vac
.................................................................... 2.5 A @ 120 Vac
.................................................................... 1.5 A @ 220 Vac
Frequency: .................................................. 50/60 Hz
Lamp/Reflector:........................................... 50 Watt DC (pre-focused)
Shutter Timer:.............................................. 1 to 50 sec. delay
Dispenser Timer:......................................... .1 to 3.5 sec. delay
Air Pressure Requirements: ........................ 100 psi max; clean, dry shop air
Footswitch: .................................................. DPDT, Rocker type
Hour-meter: ................................................. 99,999.9 hours, non-resetable
Output Intensities (Typical W/cm2)**
WAVELENGTH FILTERED UNFILTERED
320 - 390 nm 1.5 2.5+
** Measured with an Accu-Cal®20 Radiometer.
CAUTION
With the filter installed, the PC-3D lamp emits only UV-A light and low amounts of UV-B
and UV-C ultraviolet light. Without the filter, UV-A, UV-B, UV-C, and visible light are
emitted. Never look directly at the light source while the unit is in use.

TM-022 PN 35934
Rev 05/12/98 8
PC-3D
UNPACKING & INSPECTION
Upon receipt of the unit, unpack and check for shipping damage. Report damage to
freight carrier and make any claim for damage through them.
Check box for contents:
❑1 - Light-Welder PC-3D Light Source
❑1 - Lamp/Reflector Assembly
❑1 - Power Cord
❑1 - Liquid Light Guide
❑1 - Filter Assembly *
❑1 - Pair UV Goggles
❑1 - Instruction Manual
❑1 - Warranty Card
❑1 - 1/8" Hex Wrench *
❑1 - 1/16" Hex Wrench *
❑1 - 5/64" Hex Wrench *
❑1 - 10 mL Syringe Adapter Assembly
❑1 - Hand-held Manifold *
❑1 - Assortment of Needles (Quantity of 10)*
❑1 - Quick Disconnect 1/8” Female NTB Air Connector *
❑1 - Quick Disconnect 1/8” Male NTB Air Connector *
❑3 - 10 mL Syringe Adapter Seal *
* These parts make up the PC-3D Accessory Kit P/N 35950
NOTE
REPORT ANY SHORTAGE TO DYMAX CORPORATION CUSTOMER SERVICE:
Phone: [phone] or [phone]
Fax: [phone] or [phone]
Light Sources are shipped with the lamp removed to prevent breakage. (Refer to Page 9,
LAMP REPLACEMENT/INSTALLATION)

TM-022 PN 35934
Rev 05/12/98 9
PC-3D
INSTALLATION
1. Install Lamp (follow directions in the LAMP REPLACEMENT/INSTALLATION
SECTION, Page 9).
2. Connect power cord to rear of unit.
3. Connect light guide to bezel mount by pressing down on lock and inserting guide.
Connect syringe adapter to connector on front panel.
4. Locate foot switch where desired.
5. Connect air supply to fitting on rear of unit.
6. Attach manifold bracket to right side of unit with screws provided.
7. Mounting unit on a short pedestal (5” - 6” high” takes strain off light guide when used
for hand assembly and reduces operator fatigue.
8. Plug into a grounded wall outlet.
9. Press power switch. Switch will illuminate when power is on.
10.Allow lamp to warm up for 4-5 minutes to obtain maximum light output.
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 RE-IGNITE.
NOTE
The lamp must cool before it can be re-ignited. Leave power switch on should the lamp
extinguish. This operates the cooling fan and allows the lamp to ignite when it has cooled
sufficiently. If the lamp fails to ignite, refer to Pages 11-13, TROUBLESHOOTING. Lamp life
is reduced approximately one hour each time the lamp is switched on and off. Avoid repeated
cycles by leaving unit on through breaks.
DURING THE OPERATION OF THE UNIT, THE LAMP WILL REMAIN ON DURING ALL
SHUTTER SEQUENCES. THE SHUTTER IS A MECHANICAL DEVICE WHICH
BLOCKS THE TRANSMISSION OF LIGHT DURING “OFF” SHUTTER DURATION.

TM-022 PN 35934
Rev 05/12/98 10
PC-3D
INSTALLATION
11.Operate shutter by pressing right side of foot switch. With the timer switch in the
manual position, the shutter operates directly from the foot switch. In the timed
position, the shutter opening is determined by the setting of the potentiometer;
clockwise increases the opening time and the foot switch must be released after
each cycle.
12.Set air pressure regulator to 10-15 psi on air gauge.
13.Place a syringe of adhesive with follower plug installed in manifold and install
syringe adapter. Install desired needle. Snug set screw to retain syringe in
manifold.
14.Install light guide in manifold and snug set screw to hold in place. DO NOT
OVERTIGHTEN.
15.Select dispenser timer switch to desired position.
16.Depress foot switch to left to dispense adhesive. Adjust air pressure and time to
dispense correct amount. Increase air pressure and time to dispense more adhesive
and decrease to dispense less adhesive. Experimentation is the best way to
determine correct settings and needle size to dispense correct amount of adhesive.
Excessive dripping or oozing of adhesive from the needle indicates air is entrained in
the adhesive or more vacuum suckback is needed.
17.Adjust vacuum suckback to prevent drips should they occur. Turning knob
counterclockwise increases air flow to transducer which increases vacuum. A
minimum vacuum setting is usually all that is required. Care should be taken not to
use too high a vacuum, since this will suck adhesive up the air line into the solenoid
valve.