EXFO Novacure 2100 User manual

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Novacure®2100
USER’S GUIDE
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Novacure®2100 User’s Guide
©EXFO Photonic Solutions Inc., 2001
All rights reserved
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system or translated into any language in any form by any means without the prior written
consent of EXFO Photonic Solutions Inc. Information in this manual is subject to change without
notice and does not represent a commitment on the part of the authors.
Trademarks
Novacure, StepCure, Opto Link and Intelli-Lamp are registered trademarks of EXFO Photonic
Solutions Inc.
Windows is a trademark of Microsoft Corporation.
All other product names are trademarks of their respective owners.
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Contents i
Contents
1 Introduction .............................................................................. 1
1.1 What’s New? .............................................................................. 2
2 Safety Precautions................................................................... 3
2.1 Glossary of Symbols .................................................................. 7
3 Setting Up the Novacure ......................................................... 9
3.1 Checking the contents of the box............................................. 10
3.2 Front panel ............................................................................... 11
3.3 Rear Panel ............................................................................... 11
3.4 Installing / Replacing the Lamp Module ................................... 12
3.5 Care and handling of your lamp module .................................. 15
3.6 Bandpass filter replacement..................................................... 16
3.7 Inserting the light guide ............................................................ 17
3.8 Removing the light guide.......................................................... 17
4 Turning Power on to the Novacure ...................................... 19
4.1 Powering up ............................................................................. 20
4.2 Powering down......................................................................... 21
5 Programming the Novacure .................................................. 23
5.1 Viewing/selecting a register ..................................................... 24
5.2 Running a register .................................................................... 25
5.3 Working from the Set Up menu................................................ 26
5.4 Setting the clock/calendar ........................................................ 27
5.5 Setting up registers (application parameters) .......................... 28
5.5.1 Setup #1: Intensity..................................................... 29
5.5.2 Setup #2: Exposure Time.......................................... 32
5.5.3 Setup #3: Dose.......................................................... 34
5.5.4 Setup #4: Dwell Interval ............................................ 37
5.6 Choosing mode of operation .................................................... 38
5.7 Choosing a password............................................................... 39
5.8 Setting up StepCure................................................................. 40
5.9 Selecting the correct light guide diameter................................ 41
5.10 Turning the History data saving On/Off.................................... 42
5.11 Turn Extended Life feature On/Off ........................................... 43
6 Using the Radiometer ............................................................ 45
7 Calibrating the Novacure....................................................... 49
8 Data Downloading .................................................................. 51
8.1 Hardware Requirements .......................................................... 52
8.1.1 Opto Link 2100 min. Computer Configuration.......... 52
8.1.2 Operating System...................................................... 52
8.2 Installing Opto Link 2100.......................................................... 52
8.2.1 Creating a Shortcut to Opto Link 2100...................... 53
8.2.2 Launching Opto Link 2100 ........................................ 53
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ii Contents
8.3 When you should download data ............................................. 54
8.4 Performing a History Download ............................................... 54
8.5 Clearing the History data from the Unit .................................... 55
8.6 Turning on/off saving the history data...................................... 55
8.7 Typical history data download.................................................. 56
9 Interfacing with the Novacure............................................... 57
9.1 Connection options................................................................... 58
9.2 Input and output signals ........................................................... 59
9.3 Signal descriptions ................................................................... 62
9.3.1 D-Sub 9-position socket connector ........................... 62
9.3.2 HD D-Sub 15 pin male connector ............................. 62
9.3.3 4 position circular connector ..................................... 64
10 Error Messages ...................................................................... 65
11 Maintenance and Service ...................................................... 71
11.1 Routine care and maintenance ................................................ 72
11.2 Replacing the external fuses.................................................... 73
11.3 Removing the cover ................................................................. 74
11.4 Re-attaching the cover ............................................................. 74
11.5 Replacing the radiometer ......................................................... 75
11.6 Replacing the lamp housing drawer......................................... 76
12 Troubleshooting..................................................................... 79
12.1 Check these areas first ............................................................ 80
12.2 Unit does not power up (fan, display not functional) ................ 81
12.3 Lamp module does not power up............................................. 81
12.4 Shutter does not open.............................................................. 82
12.5 Light intensity is too low ........................................................... 83
12.6 Maximum intensity available is abnormally high/ low............... 83
12.7 Radiometer check abnormally low /high .................................. 84
12.8 Fan does not work properly...................................................... 84
12.9 Fan speed is too slow after warm up ....................................... 85
12.10 LCD does not work properly .................................................... 85
12.11 Password is entered incorrectly............................................... 85
12.12 Calendar and/or clock readout is incorrect .............................. 85
12.13 Data downloading doesn't work properly................................. 86
12.14 Remote trigger input does not work......................................... 86
12.15 Remote input signals do not work............................................ 87
12.16 Remote output signals do not work ......................................... 87
12.17 The intensity monitor signal reads incorrectly.......................... 87
12.18 Toll free customer service........................................................ 88
13 Technical Specifications ....................................................... 89
13.1 Lamp module............................................................................ 90
13.2 Light guide................................................................................ 91
13.3 Removable radiometer............................................................. 92
13.4 Power supply and battery backup ............................................ 93
13.5 Environmental Conditions ........................................................ 94
13.6 Regulatory Compliance............................................................ 94
13.7 Mechanical Specifications........................................................ 95
13.8 Miscellaneous........................................................................... 95
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Contents iii
14 Replacement Parts................................................................. 97
14.1 Ordering information................................................................. 98
14.2 Standard parts and accessories............................................... 99
14.3 Optional liquid light guides ..................................................... 100
14.4 Specialty optics ...................................................................... 101
15 Warranty................................................................................ 103
15.1 Novacure Warranty ................................................................ 104
15.2 Returning your Novacure to EXFO ........................................ 105
15.3 EXFO Service Centers………………………………..………….106
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iv Contents
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Introduction
1
Introduction
By providing up to 20,000 mW/cm² of curing power, the Novacure®2100 can reduce cure times.
It can also be used in a wider variety of applications than most commercially available spot
curing systems. However, the real benefit lies in its ability to provide the user with a repeatable
process and guaranteed cures. It is designed to allow the user to enter the exact intensity required
by the application and provide that specified intensity time after time.
The Novacure is the only intelligent spot cure system that gives the user complete exposure
control. Menu driven, user friendly software prompts the user to enter application parameters
such as intensity, exposure time and/or dose. Internal system monitoring and logic maintain these
parameters and advise the user in the form of a flashing LCD and alarm beeper when they cannot
be met. In automated environments, the advice appears in the form of a signal from the client
status line and alarm output signal.
The microprocessor receives a continuous signal from the Novacure’s closed loop intensity
monitor and adjusts the proportional shutter to ensure requested intensity levels are maintained. A
daily calibration procedure measures the intensity output at the end of the light guide via the
built-in radiometer, and adjusts the internal feedback loop accordingly. This means that
intensities displayed take light guide transmission variances into consideration. Software
selectable light guide diameter works with the radiometer to measure and display irradiance
accurately. The built-in radiometer is calibrated to NIST and is easily removed for calibration,
ensuring the integrity of the Novacure. The radiometer must be calibrated every 6 months by
EXFO Photonic Solutions Inc., to insure continued accuracy. The radiometer is available as a
replacement part for rotation while the other radiometer is returned to EXFO Photonic Solutions
Inc. for its biannual calibration.
To further ensure repeatability, the Novacure monitors other possible areas of concern, such as
shutter functionality, operating temperature, AC power status and lamp module power status.
Internal sensors monitor the position of the on/off shutter and proportional shutter and continually
verify shutter functionality. To ensure optimum performance in any climate, the lamp temperature
is continually monitored and the fan speed is adjusted accordingly.
The Novacure’s slide out lamp housing facilitates fast and simple lamp module replacement from
the front of the unit. The lamp housing drawer is available as a replacement to minimize down
time during service.
Not only does the Novacure monitor its functionality, it also validates it with system reporting.
The Novacure reports internal calibrations, accumulated hours on the bulb, intensity requested
and the number of exposures, by date and time. Opto Link®2100 side software is provided with
each Novacure for data downloading and communication with any connected PC.
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2Introduction
1.1 What’s New?
The Novacure 2100 has several changes from the previous model. The most apparent change is
the new color and design of the system, along with our new name: EXFO Photonic Solutions Inc.
With the new name we have added features, which serve to increase it’s functionality and
capabilities, thereby ensuring it’s continued position as the leader in spot curing systems.
An extended lamp life feature has been added to the Novacure 2100 to provide even longer
typical lifetimes for the lamps. The extended life feature can be turned on and off by the user
depending upon the application. Running continuously in extended life mode has shown to
provide over 2000 hours of lamp life.
Our improved power supply technology dramatically improves lamp maintenance over the
lifetime of the lamp. This results in a more stable lamp output over an extended period of time,
and leads to a longer useful lamp life.
The Novacure 2100 now has an enhanced Intelli-lamp technology, to accumulate lamp hours
directly on the lamps and automatically updating the unit with the number of lamp hours. When
changing lamps, the lamp hours are automatically reset on the Novacure unit.
The Novacure 2100 includes Opto Link®2100; a new Windows based history download software
to monitor its functionality with system reporting. The Novacure reports internal calibrations,
accumulated lamp hours, intensity requested and number of exposures by date and time. There is
now an added feature of turning off the history data saving feature if it is not required for your
application. This eliminates the need to periodically download the history data from the unit when
the memory is full.
The Novacure incorporates a new proprietary optical measurement system into the radiometer.
The new radiometer has a flat response over the spectral range of 250nm to 600nm. Its new
optical interface has eliminated measurement inaccuracies due to variations in light guide
diameter or positioning. The new radiometer is still removable for easy replacement, as is
required periodically for calibration purposes.
In support of the radiometer change, the intensity monitor provides an output that is related to
power, as opposed to irradiance. The transfer standard remains similar, 250mV per W of optical
output power. The exception is that older models had a transfer standard of 250mV per W/cm2
that was valid only for 5mm liquid light guides.
There are a number of changes to the Novacure 2100 to make it easier to control externally. The
ability to send the unit to a known register, having StepCure methods automatically return to the
starting register when stopped and a shutter interlock input have all been added to the Novacure
2100. Use the optional ACS 1000 Automated Control System to monitor, control and program
the registers the Novacure 2100 from your PC using the WINDOWS based Opto Link UV
software.
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Safety Precautions
3
2 Safety Precautions
2.1 Glossary of Symbols
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4Safety Precautions
Warning
Eye damage may result from directly viewing the light produced by
the lamp used in this product. Always turn the lamp off before
removing cover.
Safety Precautions
This series of cautions, warnings and dangers relate to the operation and maintenance of
the Novacure. They are also presented throughout the User’s Guide where necessary.
Caution
Never look into the light emitting end of the light guide. The light
could severely damage the cornea and retina of the eye if the light is
observed directly. UV protective eye shielding must be used at all
times as well as clothing to protect exposed skin.
A shielded line cord and I/O cord (used for interfacing with the
Novacure) must always be used to ensure trouble-free operation.
Danger
This unit contains HIGH VOLTAGE components. It is recommended
that ONLY QUALIFIED TECHNICAL PERSONNEL perform any
testing or repairs described in this manual. Disconnect the AC power
cord from the unit before opening the cover of this unit. All cover
screws (quantity 7) must be replaced prior to applying power to the
unit, or safety of the unit will be impaired.
Monitoring the unit during Manual mode operation
The level of UV energy supplied by the Novacure is sufficient to
ignite flammable substances. While the unit is in Manual mode, the
unit must be attended at all times by a qualified operator. The unit
must not be left unattended while turned on. If an operator leaves the
work area of the unit, the rear panel switch must be turned off and the
display must read "Lamp cooling down...".
Warning
To reduce the risk of fire or shock, always replace the fuses with the
same t
yp
e and ratin
g
.
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Safety Precautions
5
Monitoring the unit during Automated mode operation
The level of UV energy supplied by the Novacure is sufficient to
ignite flammable substances. Therefore, when the unit is operated
unattended in the Automated mode, an alarm function must be
provided by the user to indicate a malfunction in the associated
equipment used.
Danger
Lamps must always be handled in the clear plastic safety cover
included with lamp carton. The high internal pressure may cause the
lamp to burst either when cold or hot. When unpacking or installing,
always wear protective clothing and a face mask. Operate lamp only
in the Novacure lamp housing. This prevents direct viewing of the arc
and in the case of lamp bursting, contains lamp particles. In the rare
instance in which a lamp bursting occurs, and the mercury content is
released, the following safety precautions are recommended: All
personnel should be immediately evacuated from the area to prevent
inhalation of the mercury vapor. The area should be well ventilated
for a minimum of 30 minutes. After the lamp housing/fragments have
cooled, the mercury residue should be collected with the use of a
special absorbing agent available from laboratory equipment
suppliers.
Warning
Should this Novacure unit be used in a manner not specified by
EXFO Photonic Solutions Inc., the protection provided by the
e
q
ui
p
ment ma
y
be im
p
aired.
Warning
Hg – LAMP CONTAINS MERCURY, Manage in Accord with
Disposal Laws, see: www.lamprecycle.org or 1-800-668-8752.
Lamps may be returned to EXFO Photonic Solutions Inc., providing
it is returned in its original packaging and postage-paid. EXFO
Photonic Solutions Inc. will dispose of them in the appropriate
manner.
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6Safety Precautions
Warning
Disconnecting of mains supply source is only possible by unplugging
the attachment
p
lu
g
.
Caution
The lamp module’s operational life can be significantly shortened if it
is handled incorrectly. Be sure only to handle the ceramic surfaces.
Do not touch the bulb’s glass envelope or the inside surface of the
reflector. Skin oils can cause the lamp module to fail prematurely.
Caution
Prior to opening the unit and handling the lamp module, allow the
lamp module to cool down completely. Do not interrupt the auto-cool
down sequence.
Caution
Any electronic equipment connected to the Novacure must be IEC950
certified.
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Safety Precautions
7
2.1 Glossary of Symbols
Symbols as they appear in this User's Guide and on the Novacure unit
Caution, risk of
danger, consult
accompanying
documents
Shock hazard
ON,
Part of the
equipment
OFF,
Part of the
equipment
WARNING:
Eye damage may result
from directly viewing
the light produced by the
lamp used in this
product. Always turn
off lamp before
removing cover.
Input / Output
signals
Protective earth
DC Voltage
(Intensity
Monitor
Output)
History
Download
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8Safety Precautions
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Setting Up the Novacure 9
Warning: Routine Maintenance and Service is to be
performed only by Qualified Service Personnel.
3 Setting Up the Novacure
3.1 Checking the contents of the box
3.2 Front Panel
3.3 Rear Panel
3.4 Installing the Lamp Module
3.5 Installing the bandpass filter
3.6 Bandpass Filter Replacement
3.7 Inserting the Light guide
3.8 Removing the Light guide
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10 Setting Up the Novacure
3.1 Checking the contents of the box
1. Carefully unpack the unit and accessories.
2. Store the packing material for future use.
Note The lamp module is a pre-focused precision optical device and as such must be handled
with care. It is packed in a protective container within the master carton.
Box Contents
1. The Novacure 2100 curing unit
2. The Novacure lamp module
3. Light guide (if ordered)
4. Protective eyewear
5. Grounded and shielded power cord
6. Hexcap ball driver
7. Foot pedal
8. Instruction manual, including PC side software and radiometer certificate of calibration
9. Radiometer adapters (3mm, 5mm)
If your packaged unit is missing any of the above components, call EXFO Photonic Solutions Inc.
at 1-905-821-2600 or TOLL FREE 1-800-668-8752.
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Setting Up the Novacure 11
3.2 Front panel
ALamp Housing Front Panel
BLCD And Keypad
CRadiometer Port
3.3 Rear Panel
AFan with Filter
BAC Receptacle Module (main inlet)
C Intensity Monitor Output/Shutter Interlock Input
DD-Sub, 9 pin socket Connector (data download)
EHigh density D-Sub, 15 pin male Connector (I/O signal port)
A
CB
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12 Setting Up the Novacure
3.4 Installing / Replacing the Lamp Module
1. Be sure the AC power cord is disconnected from the unit.
2. Remove the two hexcap screws with the supplied tool from the lamp housing front panel and
set them aside.
3. Hold the lamp housing handle and give it a firm, controlled pull to disengage it from the
internal electromechanical connections.
You will probably find it easiest to give the handle a quick and forceful pull of about five inches to
overcome the initial force.
4. Slide the lamp housing out along the guide rails until it reaches the stop position.
From here you should be able to look
straight down on the back end of the
lamp housing.
Note The lamp housing assembly is not
designed to be completely removed from
the Novacure chassis during lamp
module installation or replacement.
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Setting Up the Novacure 13
5. If there is currently a lamp installed, disconnect the temperature sensor termination from its
mate on the heat shield of the lamp drawer housing. Disconnect the positive and negative
terminals from the lamp. Remove the lamp from the spring clips.
*Contact the service department to return all lamps in their original packaging to EXFO
Photonic Solutions Inc. for disposal
A, C : Ceramic components. B: Negative terminal. D: Temperature sensor termination. E:
Positive terminal. F: Glass envelope.
6. Carefully remove the lamp module from its container, holding only the ceramic components.
7. Locate the temperature sensor termination at the rear of the lamp module and connect it to
its mate located on the heat shield of the lamp drawer housing.
Caution
The lamp module’s operational life can be significantly shortened
if it is handled incorrectly. Be sure only to handle the ceramic
surfaces. Do not touch the bulb’s glass envelope or the inside
surface of the reflector. Skin oils can cause the lamp module to
fail
p
rematurel
y
.
C
D
F
A
B E
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