Excelitas Technologies OmniCure AC4 Series User manual

035-00538R_r5
OmniCure® AC4 Series User Guide
Applicable for the following UV LED Head models:
Model
Array Curing Width
Part Numbers
365nm Wavelength
395nm Wavelength
AC450
50 mm 019-00194R 019-00191R
AC475
75 mm 019-00193R 019-00192R
AC450P
50 mm 019-00230R 019-00228R
AC475P
75mm 019-00231R 019-00229R
Excelitas Canada Inc.
2260 Argentia Road
Mississauga (ON)
L5N 6H7 Canada
+1 905.821.2600
www.excelitas.com

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Installation/Reference Guide
035-00538R
Excelitas Canada Inc. 2022
All rights reserved
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system or
translated into any language in and form by any means without the prior written consent of Excelitas Canada
Inc. Every effort has been made to ensure information in this manual is accurate; however, information in this
manual is subject to change without notice and does not represent a commitment on the part of the authors.
Trademarks: OmniCure® is a trademark of Excelitas Canada Inc. All rights reserved. All other product names
are trademarks of their respective owners. All product or software photos shown are for reference only and
are subjected to change without notice.
Made in Canada.
Doc. No. 035-00538R

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Table of Contents
1Introduction.........................................................................................................................................................1
2Safety Precautions/ User Warnings ...............................................................................................................2
2.1 Glossary of Symbols:...................................................................................................................................2
2.2 Safety Precautions: ....................................................................................................................................2
3Optical Safety Data ............................................................................................................................................4
4Getting Started ...................................................................................................................................................5
4.1 Packaging Contents....................................................................................................................................5
4.2 System Requirements ................................................................................................................................5
4.3 Connecting the Power Supply and PLC Controller .......................................................................................5
4.4 Powering Up and Powering Down............................................................................................................... 7
5Mounting the UV Head .....................................................................................................................................8
5.1 UV LED Head ..............................................................................................................................................8
5.2 Mounting the UV LED Head........................................................................................................................9
5.3 UV LED Head Dimensions...........................................................................................................................9
6Connecting the UV LED Head .......................................................................................................................11
6.1 Interfacing with the System Controller (PLC)......................................................................................... 11
6.2 Integrating Monitoring with External Circuitry....................................................................................... 12
6.3 Interfacing with the Power Cable........................................................................................................... 12
7Using the LED Head .........................................................................................................................................13
7.1 Understanding the LED Indicators......................................................................................................... 13
7.2 Fault Status........................................................................................................................................... 13
8Troubleshooting...............................................................................................................................................15
8.1 Symptoms and Possible Causes ................................................................................................................ 15
9Care and Maintenance....................................................................................................................................16
9.1 Cautions and Handling.............................................................................................................................. 16
9.2 Cleaning Materials.................................................................................................................................... 16
9.3 Cleaning the LED Head ............................................................................................................................. 17
9.4 Cleaning the LED Head Air Intake ............................................................................................................. 17
10. Technical Specifications....................................................................................................................................18
10.1 Environmental Conditions....................................................................................................................... 18
10.2 UV LED Head Specifications.................................................................................................................... 18
10.3 Regulatory Compliance ........................................................................................................................... 19
12 Warranty .............................................................................................................................................................21
12.1 Checking Your Lamp Hours ..................................................................................................................... 21
12.2 Replacement UV LED Module Warranty.................................................................................................. 21
12.3 Returning your AC4- System to Excelitas Technologies for Service..........................................................22
13 Contact Information ........................................................................................................................................23

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Figures
Figure 1 UV LED Head Connection Ports...................................................................................................................6
Figure 2 PLC Console (PLC2000 Remote Control Console shown).............................................................................. 7
Figure 3 UV LED Head ..............................................................................................................................................8
Figure 4 UV LED Head Dimensions............................................................................................................................9
Figure 5 Underside of AC450 ................................................................................................................................... 10
Figure 6 Underside of AC475 ................................................................................................................................... 10
Figure 7 PLC Connector (looking at UV Head).......................................................................................................... 11
Figure 8 PLC Digital Output Equivalent Circuit......................................................................................................... 12
Figure 9 Power Connector (looking at UV Head)...................................................................................................... 12
Tables
Table 1 PLC Connector Pin Out ............................................................................................................................... 12
Table 2 Power Connector Pin Out............................................................................................................................ 12
Table 3 LED Indicator Status (UV LED Head) ........................................................................................................... 13
Table 4 Environmental Conditions........................................................................................................................... 18
Table 5 UV LED Head Specifications........................................................................................................................ 18
Table 6 UV LED Warranty Status............................................................................................................................. 21

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1Introduction
The OmniCure® AC4-series represents a new standard in UV LED curing systems. The series provides
unsurpassed levels of power, irradiance performance, control and monitoring in a compact form factor. The
OmniCure® AC4-series systems are offered alongside a variety of power supply, controller and cabling
options, providing configuration flexibility to suit any application for end users and integrators alike.
Optical output is controlled via a PLC interface enabling a high degree of automation. At the heart of the
OmniCure® AC4-series are the arrays of LEDs housed within the UV LED Head and located under the optical
lens providing excellent spectral and power stability. The UV LED Head has a typical lifetime in excess of
20,000 hours of accumulated 'on’ time, made possible by the integration of state-of-the-art electronics,
effective thermal management and high performance optics. Acoustic noise is minimised through an
innovative load-adaptive fan that keeps the LEDs operating efficiently and reliably while minimising the
resultant noise levels.
In the Excelitas Technologies family of UV LED light systems, all systems offer the same high level of
innovation, quality and reliability that our customers have come to expect. Since 1984, OmniCure® has
combined next generation optical engineering, state-of-the art electronics and fibre-optics to produce
sophisticated technologies that employ light. Today, OmniCure® is a leading developer of light-based systems
for sectors ranging from manufacturing to bio-medicine, and is unmatched in commitment to quality and
service.
This manual covers the following models:
365nm Wavelength 395nm Wavelength
AC450 019-00194R 019-00191R
AC475 019-00193R 019-00192R
AC450P 019-00230R 019-00228R
AC475P 019-00231R 019-00229R
Excelitas Technologies recommends reading this guide to discover all features of the OmniCure® AC4-series
Systems, and how to use them.

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2Safety Precautions/ User Warnings
2.1 Glossary of Symbols:
Caution risk of danger – consult accompanying documents.
Risk Group 3 (IEC62471)
WARNING: UV emitted from this product. Avoid eye and skin exposure to unshielded product.
CAUTION: Possibly hazardous optical radiation emitted from this product. Do not stare into operating lamp.
Input/ Output Signals
Input Signal
Caution, Hot Surface
Protective Conductor Terminal
Earth (Ground) Terminal
CAUTION, Risk of Electrical Shock
2.2 Safety Precautions:
This series of cautions and warnings relate to the installation, operation and maintenance of the OmniCure®
AC4- System. They are also presented throughout this Installation/Reference Guide as applicable.
WARNING
Do not stare directly at the light emitted from the LED array. This may be harmful, resulting in eye injury.
Always use UV protective eyewear as indicated below. Additionally, protect any exposed skin with appropriate
clothing or shielding as required.
Warning UV protective eyewear must meet the following recommended optical specifications:
•Spectral range; 350-440nm
•Optical Density ≥ 6
Warning Should the OmniCure® AC4- System be used in a manner not specified by Excelitas Technologies,
the protection provided by the equipment may be impaired.

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The UV LED Head operation can be affected if handled incorrectly. Never touch the protective lens cover
assembly of the UV LED Head. The presence of skin oils may result in a decrease in system performance.
Always ensure the power supply unit is turned off prior to disconnecting or re-connecting the UV LED Head.
Warning:
Monitoring the system during automated operation:
The level of UV energy supplied by the OmniCure® AC4- is sufficient to ignite flammable substances.
Therefore, when the unit is operated unattended in an automated environment, an alarm function must be
provided by the user to indicate a malfunction in the associated equipment used. During installation the
appropriate measures must be included to prevent any such occurrence.

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3Optical Safety Data
IEC 62471: Photobiological Safety of Lamps and Lamp Systems
Resulting Classification and Labelling
Hazard
AC450-365 / P
AC475-365 / P
AC450-395 / P
AC475-395 / P
Actinic UV Risk Group 3 Risk Group 3
Near UV Risk Group 3 Risk Group 3
Blue Light Risk Group 1 Risk Group 1
Retinal Thermal Exempt Group Risk Group 2

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4Getting Started
4.1 Packaging Contents
The package contains one of the following UV LED Heads, quick start guide and a safety booklet.
Model
Array Curing Width
Part Numbers
365nm Wavelength
395nm Wavelength
AC450
50 mm 019-00194R 019-00191R
AC475
75 mm 019-00193R 019-00192R
AC450P
50 mm 019-00230R 019-00228R
AC475P
75mm 019-00231R 019-00229R
The package contains an alternative 100ppi filter for applications with more airborne particulates.
Replacement air filters (qty: 10) can be ordered from Excelitas Technologies under the part number 019-
00209R.
Carefully unpack the unit and store the packing material for future use.
4.2 System Requirements
In addition to the UV LED Head, the following components are required:
•Power supply
•Power cable
Note: You will also require a PLC controller unless you are using an existing controller. The PLC controller is
used to discover the extensive functionality of the UV LED Head, but integrators can access the full
feature set through integrating with the PLC interface directly. Refer to Section 6.1.
These components may be sourced separately or may be purchased from Excelitas Technologies. Check with
Excelitas Technologies to determine the appropriate components for your requirements. The following table
provides the part numbers of recommended component parts, as well as a part number to order all
components as a package:
AC450-365nm
AC450-395nm
AC475-365nm
AC475-395nm
UV Head – Standard 019-00194R 019-00191R 019-00193R 019-00192R
UV Head – Print Version 019-00230R 019-00228R 019-00231R 019-00229R
System Controller 019-00195R 019-00195R 019-00195R 019-00195R
DC Power Cable 018-00559R 018-00559R 018-00559R 018-00559R
PLC controller 019-00214R 019-00214R 019-00214R 019-00214R
Package (all
components)
010-00330R 010-00331R 010-00332R 010-00333R
4.3 Connecting the Power Supply and PLC Controller
Note: All connectors are via screw style fastener -- do not over tighten the connector screws.
Note: The following is a generic procedure, illustrated with the common components described above;
please refer to specific documentation related to your power supply and controller.
Tip: After securing the power cable to the power supply, it is recommended to “tie-off” the female
connector cable on to the mounting brackets or process rigging as a form of strain relief.

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1. Make sure the power supply unit is turned off.
2. Connect the AC power cord to the power supply.
3. Attach the male end of the power cable to the power supply unit, and connect the female end of the power cable
to the UV LED Head per Figure 1
4. Attach the female end of the PLC cable to the PLC I/O connector on the PLC2000 (see Figure 2) and the male
end of the PLC cable to the UV LED Head (see Figure 1).
Figure 1UV LED Head Connection Ports
5. Connect the PLC loop-back connector to the PLC pass-through port. Refer to Figure 2.
6. Power up the UV LED Head per Section 4.4, then push the LED Enable button on the controller to turn power on
to the LED Head.
7. Adjust intensity using the up or down buttons to the right of the display (see Figure 2), to increase and decrease
the intensity respectively. Refer to Section 6, “Using the LED Head”.
8. UV LED & Temperature faults will be indicated by an illuminated LED on the control console. To clear, press the
Clear Fault button (see Figure 2).
Power Cable
Connector
PLC
Connector

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Figure 2 PLC Console (PLC2000 Remote Control Console shown)
4.4 Powering Up and Powering Down
1. Ensure that the AC4- system has been properly installed and the UV LED Head is securely mounted with the
optical lens in the desired orientation. Refer to Section 5, “Mounting the UV Head”.
2. Verify that the power supply unit’s AC supply cord is connected to a properly grounded AC outlet.
3. If the power supply has a circuit breaker, switch it to the “ON” position.
4. Turn the main power switch of the power supply to the “ON” position and check the fan for airflow.
5. The LED indicator on the UV LED Head will flash green during “boot-up” and change to a steady green indicating
UV LED Head is ready for use. It is recommended to wait for 15 seconds from initial power-up before attempting
to control the UV head. For more information about the indicators, see Section 7.1, “Understanding the LED
Indicators”.
After turning on UV power, the system will reach a fully stable operating temperature in 2-3 minutes. Caution
– the UV LED Head can become very hot, avoid handling until the UV LED Head has cooled down (approx. 5
min) or use protective gloves.
Before disconnecting any cables, power down the UV LED Head using the PLC
controller and turn off the power supply. (Note: the cooling fan may take up to
10 seconds to stop).
Mode
Up/Down
HD15 Connector
(connect to PLC,
computer or use door
lock jumper for local
operation
Alarm Indicators
Local operation switch
(off for remote operation)
UV Enable
(local mode only)
Clear (alarm)
HD15 Connector
to UV LED Head
End terminal switch
RS485 in/out connectors (for
remote daisy chain operation)
Status indicators (Local mode, UV On)
RS232/RS485
Mode indicators

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5Mounting the UV Head
5.1 UV LED Head
Figure 3 UV LED Head
M
M
Fan Exhaust
All Models Front
AC450
Underside
Mounting
Holes
Power Cable Connector
PLC Connector
Status Indicator
Air Intake Filter
Mounting Holes
All Models Back
AC475
Underside
Optical lens

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5.2 Mounting the UV LED Head
**WARNING**
Do not block the air intake or the exhaust fans for the UV LED module's cooling
system. Ensure that both intake and exhaust vents located on the LED heads
have at least 2 inches (5cm) of clearance to allow sufficient air flow.
The UV LED Head includes twelve threaded mounting holes (four on the front, four on the back, and two on
each side panel) M4 X 7mm deep. Mounting holes are identical in all AC4- models (019-00194R, 019-00191R,
019-00193R, 019-00192R. Refer to Figure 3above.
**CAUTION**
The threaded mounting holes in the AC4- incorporate a blind configuration;
ensure that the appropriate length of mounting hardware is used. Attempting
to install over-length mounting screws could damage the threaded mounting
holes and internal components.
5.3 UV LED Head Dimensions
The UV LED Head (all models) weighs ~1.1kg (2.4lbs).
The dimensions are the same for all models of the AC4- series, except for the underside as shown in Figure 5
and Figure 6below.
Figure 4 UV LED Head Dimensions

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Figure 5 Underside of AC450
Figure 6 Underside of AC475

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6Connecting the UV LED Head
6.1 Interfacing with the System Controller (PLC)
PLC Input Signal Requirements
Digital
Analog
Input
• Voltage: 0 – 24V
•Current: 1 – 40mA
• Voltage: 0 – 5V
•Current: 500uA
Output
•Voltage: 0 – 5V
• Current: 4mA (max.)
•Voltage: 0 – 5V
• Current: 100uA
PLC Connector Pin-Out
Figure 7 PLC Connector (looking at UV Head)
PIN Name Description
1Intensity Input
Input voltage is converted to required current to achieve desired intensity;
intensity will vary linearly between 20% and 100% for voltages between 1V
and 5V respectively.
A minimum voltage of 0.4V is required for proper light source operation. If
the user inputs a voltage below the minimum required, the light source will
not turn on.
2Enable High 0.0V to +0.6V = Turns LEDs off (Open input will default to OFF).
+2.4V to +24.0V = ON.
3Enable Low 0.0V to +0.6V = Turns LEDs on.
+2.4V to +24.0V = Turns LEDs off (Open input will default to OFF).
4Thermal Fault 0.0V to +0.4V (ground) = Fault
+2.4V to +5.0V (open) = No Fault
5 IsoDGND Ground Reference for digital IOs
6 IsoVCC +5.0V Output.
7 Reserved Do not connect
8Door Lock * 0.0V to +0.6V = UV Emission Allowed.
+2.4V to +24V = UV Emission Stopped.
9 IsoGND Ground Reference for analog IOs.
10 LED ON 0.0V to +0.4V (ground) = LED off
+2.4V to +5.0V (open) = LED on.
11 Reserved Do not connect
12 UV LED Fault 0.0V to +0.4V (ground) = Fault
+2.4V to +5.0V (open) = No Fault

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PIN Name Description
13 Reserved Do not connect
14 Clear Fault/
LED Hours
High-to-low transition clears faults; low-to-high transition initiates visual
indicator sequence of accumulated LED hours
15 Temperature
Monitor
Output is a voltage proportional to the maximum UV LED heat sink
temperature.
Conversion Factor: 0.05V/°C.
Table 1 PLC Connector Pin Out
6.2 Integrating Monitoring with External Circuitry
All inputs and outputs from the PLC interface are opto-isolated. The digital outputs are implemented using
NPN logic. The equivalent circuit is shown in Figure 8below
Figure 8 PLC Digital Output Equivalent Circuit
6.3 Interfacing with the Power Cable
Figure 9 Power Connector (looking at UV Head)
PIN
Name
Description
A1,A2 +ve 48V DC power feed. A1 and A2 shorted together internally
A3,A4 -ve 48V DC power return. A3 and A4 shorted together internally
A5 Chassis Chassis ground connection
Table 2 Power Connector Pin Out
48V Input Requirements:
•Voltage: 46-50V DC
•Current: AC450=8A; AC475=12A
Note: For safety, the AC4- series is internally fused at 15A. This fuse is not replaceable. If it is suspected that
the internal fuse has blown, please contact Excelitas Technologies Service Centre for further assistance
and refer to Sections 12 and 13 of this manual.

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7Using the LED Head
The peak wavelength of the UV LED Head is 365nm or 395nm +/- 5nm, depending on model.
For all models, adjusting the UV LED Head intensity can be actuated by an external controller via the PLC
interface. Refer to Section 6 for Pin-Outs.
Input voltage vs. desired intensity; 5V = 100% and 1V = 20%. A minimum voltage of 1V is required for light
source operation.
Note: The light source will maintain a 20% intensity when the input voltage is in the range of 0.5V. If the
input voltage is below this, the light source will turn off.
Ensure the UV LED Head indicator is illuminated to a steady green before applying UV power to the head. The
UV LED Head indicator will illuminate to a steady amber indicating UV is on. When UV is off, the indicator will
revert back to a steady green indicating UV is off.
The UV LED Head is capable of responding to PLC control signals in less than 0.2 seconds.
7.1 Understanding the LED Indicators
LED Indicator
Condition
Steady green System Ready; no critical faults
Steady amber UV LED turned ON
Steady red
Critical fault
•Temperature Fault
•LED Fault
•System Error
Slow flashing green
(~1x/second)
POST and Initialization
Input voltage is less than 46V or greater than 50V. Unit is still
functional.
Slow flashing red Major and critical fault
Slow flashing amber UV LED ON with 48V input voltage out of requirement
Fast flashing green
(~3x/second) Warranty status - operating hours is < 9,000
Fast flashing amber Warranty status - operating hours = between 9,000 and 10,0000
Fast flashing red Warranty status - operating hours is >10,000
Table 3 LED Indicator Status (UV LED Head)
A transition from high-to-low is required to clear the alarm signals. Use the PLC function:
Pin #
Description
I/O
Behaviour
14 Clear fault/
LED hours In
0V to 0.6V (Open) Logic Low
2.4V to 24V Logic High
High-to-low transition = clear faults
Low-to-high transition = LED hours
Caution: Routine maintenance should only be completed by a user qualified personnel to avoid risk of injury
to the end user.No user serviceable components are located within the power supply or UV
LED Head enclosures.
7.2 Fault Status
PLC Output
•LED Fault: At least one module fails to turn on.

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•Thermal Fault that includes:
•At least one module’s temperature is over the maximum limit.
•At least one module’s temperature is lower than the minimum limit or open circuit.
Internal Fault.

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8Troubleshooting
8.1 Symptoms and Possible Causes
Service to be completed by qualified Excelitas Technologies personnel only!
Always wear optical safety glasses while troubleshooting. Never put hands or
fingers in front of the lens. Serious personal injury may result.
Do not place any potentially combustible materials (e.g. paper, card, etc.) in front
of the LED Head. Risk of fire and damage to the UV LED Head may result.
If the system fails to power up:
•Make sure the AC power cord is securely plugged into a functional AC outlet and into the AC inlet on
the power supply unit.
•Make sure that the circuit breaker on the power supply unit is not tripped. If so, reset breaker.
•Make sure all cable connections (power supply to UV LED Head) are secure.
•Ensure that the power supply is switched on and the green LED indicator on the front panel is lit.
•Make sure the door lock electrical loopback on the PLC is installed properly.
If the system powers up but experiences a thermal fault during operation:
•Ensure UV Head is installed with adequate clearance around intake and exhaust ports.
•Ensure intake air filter is not clogged or obstructed.
•If filter is clogged, either clean with compressed air or replace with a new filter insert.
If the system powers up but does not emit UV:
•Check that the door lock loop is intact.
•Ensure that the voltage levels on pins 2 and 3 of the PLC interface match the logic required to enable
the LEDs.
•Check the visual indicator for signs of a fault.
If a fault condition has been detected:
•Attempt to clear the fault by toggling the voltage high on pin 14 of the PLC interface or by pressing the
“Clear Fault” button on the PLC controller.
If the system exhibits a fault condition with a slow-flashing red:
•Power-cycle the UV Head to clear.
If the light intensity is too low:
•Make sure the input voltage is at least 46V (input voltage to the Head for the purposes of powering the
head is typically 48V (46-50V DC)).
•Out-of-range input voltage will be indicated on the visible indicator on the UV LED Head with a slow
flashing green.
•Clean the optical window of the UV LED Head as described in Section 9.3, “Cleaning the LED Head”.
•Verify that the intensity level of the UV LED Head is set to the correct level, using the PLC Controller.
If problems persist beyond these troubleshooting points, please contact Excelitas Technologies Service
Department (refer to Section 13, “Contact Information”).

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9Care and Maintenance
Note: Excelitas Technologies recommends incorporating the cleaning of the optical lens into the
user/operator cleaning and maintenance schedule.
9.1 Cautions and Handling
Caution: Routine maintenance should only be completed by qualified personnel to avoid risk of
injury/electrical shock to the end user.No user serviceable components are located within the
UV LED Head enclosure.
Warning: Use UV radiation eye and skin protection during servicing if access to the UV LED modules is
required during operation.
Risk Group 3 (IEC62471)
WARNING: UV emitted from this product. Avoid eye and skin exposure to unshielded product.
CAUTION: Possibly hazardous optical radiation emitted from this product. Do not stare into operating lamp.
CAUTION UV: Hazardous visible radiation is emitted from this product. Eye or skin irritation may result from
exposure. Use appropriate shielding.
Ensure main power supply is disconnected prior to making any changes to cabling configurations.
Ensure that both intake and exhaust vents located on the LED heads have at least 2 inches (5cm) of clearance
to allow sufficient air flow.
Avoid physical shocks or jarring of the LED Head, especially while the unit is operating.
When necessary, clean the optical lens of the UV LED Head using an optical cleaning solution. Refer to Section
9.3, “Cleaning the LED Head”.
The UV LED Head includes an optical lens assembly. Improper handling and cleaning practices can damage
polished surfaces or coatings which are utilized in this optical lens. Note that damage to the surface of the
glass or coating can degrade the unit’s performance. Proper handling and cleaning technique is very
important. Below are the recommended procedures for cleaning of the OmniCure® UV LED Head optical lens.
Always handle the UV LED Head by the metal enclosure; never touch the optical lens with your fingertips. The
moisture or oils on your fingertips can damage the coating of the lens. Fingerprints left on an optical surface
for an extended period of time, can become a permanent stain. Even if you are wearing gloves, avoid touching
the optical surface.
Never touch the optical lens with metal implements or tweezers.
Do not place the UV LED Heads lens assembly down onto a hard tabletop surface; this can cause scratches in
the lens surface.
To store UV LED Heads, wrap them individually in a clean, lint free bag and store in a safe place, preferably
using the original packaging.
Never store unwrapped LED Heads together in a box or bag, as they may become damaged if they come in
contact with each other.
9.2 Cleaning Materials
•Lint-free lens tissue, lint-free cotton swabs, lint or powder-free gloves or finger cots.
•An organic solvent, such as reagent-grade isopropyl alcohol, reagent-grade acetone, or lens cleaning
solution.