Excelitas Technologies OmniCure AC7 Series User manual

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OmniCure® AC7 Series User Guide
Applicable for the following UV LED Head models:
Model Optical Length Part Numbers
365nm Wavelength 395nm Wavelength
AC7150 150 mm 019-00197R 019-00198R
AC7300 300 mm 019-00187R 019-00196R
Excelitas Canada Inc.
2260 Argentia Road
Mississauga (ON)
L5N 6H7 Canada
+1 905.821.2600
www.excelitas.com
Installation/Reference Guide
035-00540R
Excelitas Canada Inc. 2020
All rights reserved

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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.
Excelitas Technologies
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. 035-00540R

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Table of Contents
1 Introduction ......................................................................................................................... 1
2 Safety Precautions/ User Warnings ........................................................................................ 2
2.1 Glossary of Symbols: ............................................................................................................................... 2
2.2 Safety Precautions: ................................................................................................................................. 3
3 Optical Safety Data ............................................................................................................... 4
4 Getting 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
5 Mounting the UV Head .......................................................................................................... 8
5.1 UV LED Head (same for all models) ......................................................................................................... 8
5.2 Mounting the UV LED Head .................................................................................................................... 9
5.3 Adjusting the Side Reflectors .................................................................................................................. 9
5.4 UV LED Head Dimensions ..................................................................................................................... 10
6 Connecting the UV LED Head .............................................................................................. 13
6.1 Interfacing with the PLC ........................................................................................................................ 13
6.2 Integrating Monitoring with External Circuitry ....................................................................................... 14
6.3 Interfacing with the Power Cable ........................................................................................................... 14
7 Using the LED Head ............................................................................................................ 15
7.1 Understanding the LED Indicators ......................................................................................................... 15
7.2 Fault Status ........................................................................................................................................... 15
8 Troubleshooting ................................................................................................................. 17
8.1 Symptoms and Possible Causes ............................................................................................................. 17
9 Care and Maintenance ......................................................................................................... 18
9.1 Cautions and Handling .......................................................................................................................... 18
9.2 Cleaning Materials................................................................................................................................. 18
9.3 Cleaning the LED Head .......................................................................................................................... 19
9.4 Cleaning the LED Head Air Intake .......................................................................................................... 19
10 Technical Specifications ...................................................................................................... 20
10.1 Environmental Conditions ..................................................................................................................... 20
10.2 UV LED Head Specifications .................................................................................................................. 20
10.3 Regulatory Compliance ......................................................................................................................... 21
11 Warranty ............................................................................................................................ 23
11.1 Checking Your Lamp Hours ................................................................................................................... 23
11.2 Replacement UV LED Module Warranty ................................................................................................ 23
11.3 Returning your AC7- System to Excelitas Technologies for Service ........................................................ 24
12 Contact Information ........................................................................................................... 25

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Figures
Figure 1 UV LED Head Connection Ports (additional features annotated)................................................................... 6
Figure 2 PLC Console (PLC2000 Remote Control Console shown) .............................................................................. 7
Figure 3 UV LED Head Mounting Details ................................................................................................................... 8
Figure 4 UV LED Head Side Dimensions (both models) ............................................................................................ 10
Figure 5 Top, Front, Underside of AC7150 ................................................................................................................ 11
Figure 6 Top, Front, Underside of AC7300 ............................................................................................................... 12
Figure 7 PLC Connector (looking at UV Head) .......................................................................................................... 13
Figure 8 PLC digital output equivalent circuit........................................................................................................... 14
Figure 9 Power Connector (looking at UV Head) ...................................................................................................... 14
Tables
Table 1 PLC Connector Pin Out ............................................................................................................................... 14
Table 2 Power Connector Pin Out ............................................................................................................................ 14
Table 3 LED Indicator Status (UV LED Head) ........................................................................................................... 15
Table 4 Environmental Conditions ........................................................................................................................... 20
Table 5 UV LED Head Specifications ........................................................................................................................ 20
Table 7 UV LED Warranty Status ............................................................................................................................. 23

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1 Introduction
The OmniCure® AC7-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® AC7-series systems are offered alongside a variety of power supply, controller, accessory 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® AC7-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 innovative
load-adaptive fans that keep the LEDs operating efficiently and reliably while minimising the resultant noise
levels.
In the OmniCure® 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. OmniCure® has combined next generation optical
engineering, state-of-the art electronics and fibre-optics to produce sophisticated technologies that employ
light. Today, Excelitas Technologies is a leading developer of light-based systems for sectors ranging from
manufacturing to bio-medicine, and we are unmatched in our commitment to quality and service.
This manual covers the following models:
365nm 395nm
AC7150 019-00197R 019-00198R
AC7300 019-00187R 019-00196R
We recommend reading this guide to discover all features of the OmniCure® AC7-series Systems, and how to
use them.

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2 Safety 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

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2.2 Safety Precautions:
This series of cautions and warnings relate to the installation, operation and maintenance of the OmniCure®
AC7- 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® AC7- System be used in a manner not specified by Excelitas Technologies, the
protection provided by the equipment may be impaired.
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® AC7- 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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3 Optical Safety Data
IEC 62471: Photobiological Safety of Lamps and Lamp Systems
Resulting Classification and Labelling
Hazard AC7300-365 AC7300-395
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 Exempt Group

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4 Getting Started
4.1 Packaging Contents
Your package contains one of the following UV LED Heads, as well as a documentation CD:
Model Optical Length Part Numbers
365nm Wavelength 395nm Wavelength
AC7150 150 mm 019-00197R 019-00198R
AC7300 300 mm 019-00187R 019-00196R
Carefully unpack the unit and store the packing material for future use.
4.2 System Requirements
In addition to the UV LED Head, you will require the following components:
 Power supply
 Power cable
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. Integrators can access the full feature set through
integrating with the PLC interface directly. Refer to Section 6.1.
These 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.
AC7150-365nm AC7150-395nm AC7300-365nm AC7300-395nm
UV Head 019-00197R 019-00198R 019-00187R 019-00196R
System Controller 019-00195R 019-00195R 019-00199R 019-00199R
DC Power Cable 018-00559R 018-00559R 018-00559R 018-00559R
PLC Controller 019-00214R 019-00214R 019-00214R 019-00214R
Package (all components) 010-00334R 010-00335R 010-00336R 010-00337R
Other units are available for different purposes; check with Excelitas Technologies to determine the
appropriate components for your requirements.
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.
1. Make sure the power supply unit is turned off.
2. Connect the AC power cord to the power supply

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Figure 1 UV LED Head Connection Ports (additional features annotated)
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).
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).
Mount
ing
Power Cable Connector
PLC Connector
Status Indicator
Removable End Reflectors
Mounti
ng
Intake Air
Filter
Mounti
ng
Fan
Exhausts
Power Cable Connector
PLC Connector
Status Indicator
AC7150
AC7
300

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Figure 2 PLC Console (PLC2000 Remote Control Console shown)
4.4 Powering Up and Powering Down
1. Ensure that the AC7- system has been properly installed and the UV LED Head is securely mounted with
the optical window 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 your 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 1 minute from “cold state” to “ready state” before
applying UV power to the 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 (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 connector
s (for
remote daisy chain operation)
Status indicators (Local mode, UV On)
RS232/RS485
switch
Mode indicators

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5 Mounting the UV Head
5.1 UV LED Head (same for all models)
Figure 3 UV LED Head Mounting Details
Mounti
ng
Holes
Mounting Holes
4 holes – M4x6mm
Right-Hand and Left-Hand Mounting Locations
Underside Mounting Locations
Mounting Holes
4 holes – M4x7mm
AC7150
AC7
300
Mounting Holes
8 holes – M4x6mm

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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 5 inches (12cm) of clearance to allow sufficient air flow.
The UV LED Heads incorporate both side mounting and underside mounting features.
Refer to Figure 3 above.
For single-head applications, either the side or underside mounting features can be used. Never mount the
system using only one row of mounting features or from one side as this may damage the unit.
For applications requiring adjoining UV LED heads, the underside mounting features are the only features that
can be employed. To prevent any unnecessary mechanical compression-loading on the unit, mounting rails
can be constructed from two long L-brackets, facing each other and spaced 75mm apart. Remember in
adjoining-head applications to remove the end-reflectors from all head-head abutment regions to
maximise head-head optical uniformity. The end-reflectors on the end-most points of the optical line can
remain in place to further extend uniform operating length and operate as a UV shield for operators.
**CAUTION**
The threaded mounting holes in the AC7- 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 Adjusting the Side Reflectors
To improve the longitudinal uniformity at the ends of the UV light line, the AC7- series products are equipped
with adjustable end reflectors (see Figure 1). These reflectors can be lowered in 10mm increments and can
provide about 15mm of extended useful length when fully extended to 30mm working distance. They may also
be useful in providing additional operator shielding of UV light.
To gain best effect from this mechanical feature, ensure that in the intended installation location the reflectors
will not interfere with conveyed parts or conveyor belt or other mechanical attachments. Failure to do so may
result in damage to ancillary hardware or the UV LED Head itself.
To adjust the reflectors:
1. Ensure that power to the unit is switched off.
2. Remove the two screws holding the end reflector in place.
3. Move the reflector down to the desired position, insert and tighten the two retaining screws.
This operation can be performed on a single head using either the side- or front-mounting scheme.
**CAUTION**
When the end reflectors are detached from the head, the ends of the optical
assembly and LED modules can be physically accessed. Take extreme care not to
allow fingers, tools or other foreign objects or debris to come into contact with
these areas. Doing so may severely damage or impair the function of your AC7-
series UV LED head. The installer should minimise the amount of time or frequency
that these regions of the LED head are left unprotected.

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5.4 UV LED Head Dimensions
The UV LED heads have the following masses:
Model Weight kg (lbs)
AC7150 1.8kg (4.0lbs)
AC7300 3.2kg (7.0lbs)
The height and depth dimensions shown in Figure 4 are the same for both models of the AC7- series.
Differences in length between the two models are shown in Figure 5 and Figure 6 below.
Figure 4 UV LED Head Side Dimensions (both models)

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Figure 5 Top, Front, Underside of AC7150

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Figure 6 Top, Front, Underside of AC7300

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6 Connecting the UV LED Head
6.1 Interfacing with the PLC
PLC Input Signal Requirements
Digital Analog
Input  Voltage: 0 – 24V
 Current: 1 – 30mA
 Voltage: 0 – 5V
 Current: 500uA
Output  Voltage: 0 – 5V
 Current: 2.5mA (max.)
PLC Connector Pin-Out
Figure 7 PLC Connector (looking at UV Head)
PIN Name Description
1 Intensity 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.
2 Enable High 0.0V to +0.6V = Turns LEDs off (Open input will default to OFF).
+2.4V to +24.0V = ON.
3 Enable Low 0.0V to +0.6V = Turns LEDs on.
+2.4V to +24.0V = Turns LEDs off (Open input will default to OFF).
4 Thermal 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
8 Door 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
13 Reserved Do not connect

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PIN Name Description
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 8 below
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: AC7150=7.5A; AC7300=14.5A
Note: For safety, the AC7- 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 11 and 12 of this manual.

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7 Using 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 ~0.5-1V. 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
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 Warranty status - operating hours is < 9000
Fast flashing amber Warranty status - operating hours = between 9,000 and
10,0000
Fast flashing red Warranty status - operating hours is >10000
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.
 Thermal Fault that includes:

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 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.
 Ensure air intake and exhaust are unobstructed and filter is unclogged.
Refer to Section 9.4