Fusion F300SQ User manual

F300S/F300SQ
Ultraviolet Lamp System
Installation, Operation, and Maintenance
Manual No. 509252 Rev R 3/04
FUSION UV SYSTEMS, INC.
910 Clopper Road
Gaithersburg, MD 20878-1357 USA
[phone] • FAX [phone]

F300S/F300SQ Ultraviolet
Lamp System
Installation, Operation, and Maintenance
Manual No. 509252 Rev R 3/04
Applies to systems using P300M/P300MQ/P300MT power supplies,
and I300M/I310M series irradiators Serial Numbers 1001 and later.
(C) Copyright 2004 Fusion UV Systems, Inc. All Rights Reserved.
The products covered herein conform to EC standards.
See Appendix A for details.
FUSION UV SYSTEMS, INC.
910 Clopper Road
Gaithersburg, MD 20878-1357 USA
[phone] • FAX [phone]

Installation, Operation, and Maintenance Manual # 509252 Rev R 5
Table Of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Indications of Note, Caution, Warning, and Danger . . . . . . . . . 12
Icon Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reflector and Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
P300M/P300MQ/P300MT . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RF Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shipping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Returned Material Authorization Number . . . . . . . . . . . . . . . . 22
General Packing Instructions . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Magnetrons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
UV Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
RF Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ultraviolet Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Microwave Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Personnel Effects of Microwave Radiation . . . . . . . . . . . . . . . . . . . 27
Radio Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ozone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6F300S/F300SQ Ultraviolet Lamp System
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
UV Curable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 2. Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Mechanical Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 31
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Supply Unit(s) Placement . . . . . . . . . . . . . . . . . . . . . . . . . 32
Irradiator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lamps Mounted in Opposing Configuration . . . . . . . . . . . . . . . . . . 34
UV Light Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RF Detector Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Remote Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Irradiator Exhaust Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Quartz Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 3. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical Installation/Setup Checklist . . . . . . . . . . . . . . . . . . . . . . 39
Accessory Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connection and Program Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installing the External Interlocks Control . . . . . . . . . . . . . . . . 40
User Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Supply Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Settings for Six-Position Switch S1 . . . . . . . . . . . . . . . . . . . . 41
Single Unit Programming and Connections . . . . . . . . . . . . . . . . . . 43
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Irradiator Cable H340 Connections . . . . . . . . . . . . . . . . . . . . 44
Input/Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remote Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Output Ports (J105B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Alternate Function for K5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Multiple-Unit Programming and Connections . . . . . . . . . . . . . . . . . 48
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Installation, Operation, and Maintenance Manual # 509252 Rev R 7
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
System Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Frequency Tapping of HV Capacitors . . . . . . . . . . . . . . . . . . . 51
QRO HV Capacitors (For QRO only) . . . . . . . . . . . . . . . . . . . . 51
High Voltage Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . 51
QRO Transformer Taps (FOR QRO only) . . . . . . . . . . . . . . . . . 52
F300S Relay Coil Resistor Assembly Installation . . . . . . . . . . . . . . 53
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
System Operation Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Lamp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Off/Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Initial Startup Procedure, Single Unit . . . . . . . . . . . . . . . . . . . . . . 56
Initial Startup Procedure, Multiple-Unit Systems . . . . . . . . . . . . . . 57
Master/Slave Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Operating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Resetting the System After a Fault . . . . . . . . . . . . . . . . . . . . 58
Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operation with Remote Controls . . . . . . . . . . . . . . . . . . . . . . 60
Quick Restart Option (QRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical Installation and Setup . . . . . . . . . . . . . . . . . . . . . . 63
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Basic Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Safety Interlock Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Unit Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fault Diagnosis Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Failure Diagnosis Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . 68
Chapter 6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
I300M Irradiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8F300S/F300SQ Ultraviolet Lamp System
Bulb, Screen, and Reflector Maintenance . . . . . . . . . . . . . . . . 79
Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bulb Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Reflector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Screen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
I300M Screen Assembly Removal/Replacement . . . . . . . . . . . 80
Lamp Bulb Removal/Replacement . . . . . . . . . . . . . . . . . . . . 81
Reflector Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 82
I300M Irradiator Housing Removal/Replacement . . . . . . . . . . 86
Direct View Photoresistor Removal/Replacement . . . . . . . . . . . 87
Filament Transformer Removal/Replacement . . . . . . . . . . . . . 88
Magnetron Removal/Replacement . . . . . . . . . . . . . . . . . . . . . 89
Air Pressure Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Air Pressure Switch Replacement . . . . . . . . . . . . . . . . . . 91
I310M/I311M Irradiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Bulb, Screen, and Reflector Maintenance . . . . . . . . . . . . . . . . 91
Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Bulb Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Reflector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Screen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Screen Assembly Removal/Replacement . . . . . . . . . . . . . . . . 93
Lamp Bulb Removal/Replacement . . . . . . . . . . . . . . . . . . . . 93
Reflector Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 94
Replacing the RF Gasket Assembly . . . . . . . . . . . . . . . . . 99
I310M/I311M Irradiator Housing Removal/Replacement . . . . . 100
I310M/I311M Scatter View Photoresistor Removal/Replacement . .
100
Direct View Photoresistor Removal/Replacement . . . . . . . . . . 101
Filament Transformer Removal/Replacement . . . . . . . . . . . . 103
Magnetron Removal/Replacement . . . . . . . . . . . . . . . . . . . . 104
Air Pressure Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Air Pressure Switch Replacement . . . . . . . . . . . . . . . . . 105
P300M/P300MQ Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Test Point Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Installation, Operation, and Maintenance Manual # 509252 Rev R 9
Control Card Removal/Replacement . . . . . . . . . . . . . . . 107
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
High Voltage Transformer Removal/Replacement . . . . . . 110
P300MT Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Test Point Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Control Card Removal/Replacement . . . . . . . . . . . . . . . . . . . 113
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
High Voltage Transformer Removal/Replacement . . . . . . 116
K300 Modular Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 118
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Appendix A. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
RF Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
System Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . 125
Appendix B. Cables and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
System Connector Contact Kits . . . . . . . . . . . . . . . . . . . . . . 128
Appendix C. Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Appendix D. Lamp System Maintenance Log . . . . . . . . . . . . . . . . . . . . 139
Appendix E. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
I300M/I310M Irradiator Parts List . . . . . . . . . . . . . . . . . . . . . . . 142

10 F300S/F300SQ Ultraviolet Lamp System
P300M/P300MT Power Supply Parts List . . . . . . . . . . . . . . . . . . . 144
P300MQ Quick Restart Option Parts List . . . . . . . . . . . . . . . . . . . 146
K300 Blower Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . 147
Appendix F. Ignitor Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Ignitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Ignitor Bulb Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 150
Appendix G. Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Installation, Operation, and Maintenance Manual # 509252 Rev R 11
Introduction
This manual is designed to be used, not set aside until problems occur. The following
list of chapters and appendixes describes where to find information in this manual.
• This Introduction provides a brief description of the total system, and system
components. It also contains the Fusion UV Systems warranty policy and shipping
instructions for returning equipment.
•Chapter 1, “Safety,” contains important information! This chapter should be read
by all persons who will operate or troubleshoot system equipment.
•Chapter 2, “Mechanical Installation,” gives unpacking instructions, and
instructions for equipment placement, mounting, shielding and exhaust venting.
•Chapter 3, “Electrical System,” explains the power supply software setup,
including single and multiple unit programming and connections. HV capacitor
frequency tapping instructions are also provided.
•Chapter 4, “Operation,” describes steps for initial startup for both single and
multiple unit systems, how to operate master/slave and remote systems, and how
to reset the system after a fault. It also contains setup and operations instructions
for the Quick Restart Option (QRO).
•Chapter 5, “Troubleshooting,” consists mainly of information in table form. There
is a reference table for faults and indications, tables describing unit and system
fault indications, and a fault diagnosis table. The fault diagnosis table provides
faults, causes, and corrective actions.
•Chapter 6, “Maintenance,” covers routine maintenance and removal/replacement
instructions for the irradiator, power supply and modular blower. There is a
maintenance procedure page locator at the front of the chapter.
•Appendix A, “Specifications,” outlines the various characteristics of major
components of the F300S/F300SQ Ultraviolet Lamp System. It also lists agency
approvals and certificates for the relevant systems and components.
•Appendix B, “Cables and Connectors,” provides information on the interconnect
cables and system connector contact kits used with the F300S/F300SQ Ultraviolet
Lamp System.

12 F300S/F300SQ Ultraviolet Lamp System
•Appendix C, “Outline Drawings,” contains drawings that provide overview details
for general reference for Fusion UV Systems products. These drawings are not to
be used in designing an installation; contact Fusion directly for current
specifications.
•Appendix D, “Lamp System Maintenance Log,” contains an example of a Fusion
UV Systems form to use for tracking lamp system maintenance.
•Appendix E, “Replacement Parts,” lists the various accessory replacement parts
available for Fusion UV Systems Irradiators.
•Appendix F, “Ignitor Bulb,” applies to lamps manufactured before July 1, 2002. It
describes the operation of the ignitor bulb that provides ignition to the main bulb.
•Appendix G, “Schematics,” contains figures that illustrate the various wiring
diagrams for Irradiator components.
Document Conventions
The products and components discussed in this document are designed and tested for
safe operation; however, they use technologies and resources that have inherent risks.
This section describes the conventions used throughout this manual when discussing
such technologies, so that users can plan and act accordingly when installing,
operating, or troubleshooting equipment.
Indications of Note, Caution, Warning, and Danger
Four categories of notice are indicated in this document; descriptions and examples of
their formatting are provided next.
NOTE: Notes serve to point out additional information about a subject or
process that is important, but not hazard-related.
CAUTION: Cautions generally indicate areas where a user should take
special care to avoid minor or moderate injury. It may also indicate
unsafe practices that could damage equipment or materials.
WARNING: Warnings indicate actions that can cause recoverable physical
harm; or destruction of equipment, data, or products.

Installation, Operation, and Maintenance Manual # 509252 Rev R 13
DANGER: Danger indications identify conditions where death or
permanent injury to personnel can occur if proper procedures and
precautions are not followed.
Icon Usage
Several icons are used throughout the documentation to identify the types of hazardous
resources or technologies used when working with a particular aspect of the system.
Table 1, “Icons,” lists these and their definitions. Exercise extreme care by reading the
material thoroughly and following all procedures when working with the various
components.
Table 1. Icons
Icon Definition
CAUTION:
Exclamation Mark: This icon is used for other instances and
items for which a standard symbol does not exist.
CAUTION: Risk of Electric Shock
This icon identifies instances where dangerous or lethal
voltages might be present when working with various
components of the irradiator or site power.
CAUTION: Microwave Radiation
The Fusion UV Lamp System is powered by high
energy RF microwave power which can be dangerous if
misused or inadequately shielded. The lamp system
should never be turned on if the lamp housing and
screen are not intact, or if the microwave leak detector
and interlock are not functioning.

14 F300S/F300SQ Ultraviolet Lamp System
CAUTION: Ultraviolet Radiation
This icon identifies instances where damaging levels of
ultraviolet radiation may be present. Adequate shielding
around the equipment and region must be provided, and
personnel should be required to wear goggles with UV
certified lenses. All personnel within ten feet of the lamp
should wear gloves and long sleeves to protect their hands
and arms, and ensure that their legs are covered.
CAUTION: Radio Interference
Fusion lamps operate at a fundamental frequency of
2.45 GHz. The unit may cause interference with some
local area networks (LANs) that also operate at this
frequency. Please check with your LAN manufacturer
for compatibility. Ensure that the equipment is properly
maintained and shielded.
CAUTION: Ozone
High concentrations of ozone can cause discomfort, or at
sufficiently high levels be dangerous. Although Fusion lamp
systems make ozone at a level that could barely be detected
by odor and at a factor of five below the level of 0.1 parts per
million allowable for continuous exposure (American
Conference of Governmental Hygienists), all Fusion UV Lamp
Systems should be exhausted to the outdoors.
CAUTION: Hot Temperature, Do Not Touch
Surface temperatures of the lamp during normal
operation may exceed 120o F. Metal components near
the lamp will also be hot. Observe appropriate
precautions to avoid burns.
Table 1. Icons (continued)
Icon Definition

Installation, Operation, and Maintenance Manual # 509252 Rev R 15
System Description
The Fusion Ultraviolet Lamp System has been designed specifically for applications
involving the industrial curing of inks and coatings and may be used effectively for a
wide variety of applications.
An ultraviolet (UV) lamp system for industrial curing must generate extremely intense
radiation in the 200-400 nanometer region. Such radiation, when properly generated
and focused, and used in conjunction with specially formulated UV sensitive inks and
coatings, causes virtually instantaneous curing (drying) of the exposed materials.
The unique properties of the Fusion UV Lamp System are obtained by using
microwave radiation to energize the lamp. Microwave energy at 2450 MHZ is
generated by a power tube (magnetron) of the type widely available for commercial
microwave cooking ovens. The patented Fusion UV Systems lamp has no electrodes,
and consequently overcomes many of the basic limitations of conventional mercury
arc lamps.
Protective Conductor Terminal
Earth (ground) Terminal
Three Phase Alternating Current
Table 1. Icons (continued)
Icon Definition

16 F300S/F300SQ Ultraviolet Lamp System
Figure 1. F300S/F300SQ Lamp System
The F300S/F300SQ Fusion UV Lamp System (Figure 1) is modular, consisting of
independent 6-inch (15.2 cm) lamp units and corresponding modular power supplies.
Two lamps can be placed end-to-end to form a 12-inch (30.5 cm) lamp system or can
be placed in a continuous array to form lamps of 18-inch (45.7 cm), etc. This is
possible because the illumination of the lamp is a full 6". When two 6" lamps are
placed end-to-end forming a 12" lamp, material being irradiated in the focal plane
53.3mm (2.1") below the lamp bottom, and at the juncture between the two lamps,
receives sufficient radiation from each 6" module to provide uniform curing over the
entire region.
Microwave energy from a single magnetron is directed into the cavity formed by an
aluminum reflector and a screen over the bottom of the reflector. The lamp bulb is
located inside this chamber. The screen keeps microwaves inside the chamber but
allows UV light to pass through onto the material to be cured.

Installation, Operation, and Maintenance Manual # 509252 Rev R 17
Electrical inputs to the lamp module are provided by a high voltage/control cable with
a quick-connect fitting which supplies power for the magnetron, filament transformer
and the interlock circuitry.
System Components
The basic F300S/F300SQ system consists of the following items:
• A P300M/P300MQ/P300MT power supply
• An HV Cable H340 (no modular blower)
• An HV Cable H341 (with modular blower)
• An I300 series irradiator
• An RF detector cable H790
• An RF-1 detector
In addition, the user must supply the following if not provided by Fusion UV Systems:
• Cooling for the irradiator, if no modular blower is provided. (See Appendix A,
“Specifications” and Appendix C, “Outline Drawings” for irradiator cooling
requirements.)
• Mechanical mounting of the lamp modules over a substrate, conveyor, or other
transport mechanism
• Light shield surrounding the lamps
• Exhaust system for the light shield
• Any desired interlock mechanisms (see Chapter 3 on page 39)
• Electrical wiring of the power supply into the plant electrical system
Control
The control system of the F300S/F300SQ provides precise control of high voltage and
filament voltage supplies. The control board also monitors cooling air pressure,
detection of RF, power levels, bulb ignition, and interlocks such as transformer
thermal switches. If a problem arises, the control system turns off all high voltage
power to the lamp and flashes a fault LED indicator on the power supply control panel.
Inputs for customer ON/OFF control are available. Outputs allow detection of
STANDBY or LAMP ON operation, or of interlock failures.

18 F300S/F300SQ Ultraviolet Lamp System
Cooling
Proper operation of the lamp requires adequate cooling of the magnetron and the bulb.
(See Appendix C, page 129, for irradiator cooling requirements.) Cooling air from a
blower goes through the magnetron cooling fins and into the lamp housing. At this
point, the airflow splits into two paths: one path exhausts through the irradiator
housing vent holes, and the rest of the air flows into the cavity through cooling holes
in the reflector. This airflow cools the bulb and exhausts through the RF screen.
Irradiators
The I300M irradiator family is the heart of the UV system. For example, the model
I300M contains both the 15.2 cm (6") long electrodeless lamp bulb mounted in the
elliptical reflector and the magnetron which energizes the bulb. The reflector is
elliptical in cross-section and the lamp bulb is mounted at the focus of the ellipse,
producing an intense strip of light at the other focus of the reflector (53 mm [2.1"]
below the bottom rails of the lamp).
Figure 2. Reflector Assembly
M3 screen retaining
screws (4) (2 per side)
RF screen
Cooling air holes
Lamp bulb
Cavity
Reflector

Installation, Operation, and Maintenance Manual # 509252 Rev R 19
The following table lists the various irradiator models manufactured by Fusion UV
Systems, and describes their high-level differences.
Reflector and Cavity
The top of the reflector contains two rectangular slots which admit microwave energy
into the cavity. The slots are fed by one 1800 W, 2450 MHz magnetron located in the
top half of the lamp enclosure and connected to the cavity by a waveguide launcher.
Lamp Bulb
The lamp bulb (Figure 3) is made of quartz and has a tapered shape which optimizes
its UV, thermal, and microwave properties. The short quartz stubs at either end of the
15.3 cm (6") bulb provide mechanical support for quick mounting into spring-loaded
receptacles at the cavity ends. They are not electrodes and have no electrical function.
Figure 3. Lamp Bulb
Access to the cavity for changing the bulb or routine cleaning of the bulb and reflector
is easily accomplished by removing the screws which secure the screen assembly to
the bottom of the lamp. This procedure is explained in detail in Chapter 6,
“Maintenance”. The fine mesh screen must be intact and firmly secured to the lamp if
the system is to work properly and safely. The RF leakage interlock automatically
shuts the system off if excess microwave energy passes through the screen.
Table 2. Irradiator Models
Irradiator Model Photoresistor Assembly RF Gasket Air Delivery
I300M Direct View Standard Front Connect Plenum
I301M Direct View Standard Top Connect Plenum
I300MB Direct View Standard Modular Blower
I310MP Scatter View I6 Front Connect Plenum
I311MP Scatter View I6 Top Connect Plenum
I310MB Scatter View I6 Modular Blower
I310MP-D Direct View I6 Front Connect Plenum
I311MP-D Direct View I6 Top Connect Plenum
I310MB-D Direct View I6 Modular Blower

20 F300S/F300SQ Ultraviolet Lamp System
Mounting
The lamps can be mounted over a moving substrate or web, supported by the bottom
rails. The lamps should be mounted so that the rails sit 53 mm (2.1") above the surface
to be cured. This allows the elliptical reflector to focus the most intense strip of light
very near the substrate.
Power Supply
Each lamp system has its own power supply to house the high voltage circuits
necessary to energize the magnetron, as well as all control and interlock electronics,
and the built-in cooling fan.
The power supply is fully modular. Up to six units may be interconnected and
controlled from a single master unit. Any power supply may assume either Master or
Slave status in a multi-unit installation.
P300M/P300MQ/P300MT
The power supply high voltage circuit consists of a dual half-wave voltage doubler
circuit which supplies a regulated source of high voltage power (approximately
3900V, 700 mA DC) to the magnetron in the irradiator. The capacitors and diodes
provide regulation and rectification to the high voltage transformer outputs.
RF Detector
The system includes a detection device which shuts the system down if microwave
energy in excess of permissible levels is in danger of being released into the work
environment. This might be caused by a faulty RF screen or some other type of damage
to the lamp, or by inadequate or damaged shielding.
The power supply fault detection circuitry searches the system for a functioning RF
detector by means of the System Interconnections Bus. A multi-unit installation must
have at least one RF detector, which is usually connected to the master power supply.
Additional detectors may be connected to slave units.
During the startup sequence, each power supply will automatically perform a
functional test on any installed RF detector (if switch S1-5 is set to “YES”). The
operator may also verify detector operation by pushing a test button on the RF-1
module for 4 seconds. Complete information appears in Chapter 5, “Troubleshooting”.
System Interconnections
All electrical connections to the power supply are made through connectors at the rear.
Instructions for wiring are provided in Chapter 3, “Electrical System”. The power
supply does not require any routine maintenance other than occasional cleaning of the
interior with compressed air (depending on the environment).