Henkel LOCTITE UVALOC 1000 User manual

Operating Manual
Bedienungsanleitung
UVALOC 1000
97055 Curing Chamber Version / Kammerversion
97056 Tunnel Version / Tunnelversion
Order Code / Bestell.
-
Nr. / IDH 805741, 838778

2

3
English
................................
................................
................................
...................
4
-
4
9
Deutsch ................................................................................................................ 50-95
CAUTION!
Store the packing carefully!
The equipment must be shipped in the original packaging in
the case of shipment!
ACHTUNG!
Bewahren Sie die Verpackung sorgfältig auf!
Das Gerät muss bei einem eventuellen Versand in der
Originalverpackung versendet werden!

4
Contents
1
Please observe the following
..........................................................................
6
1.1 Emphasized Sections...................................................................................................6
1.2 Items Supplied .............................................................................................................6
1.3 For your Safety ............................................................................................................7
1.4 General Instructions .....................................................................................................8
1.5 Special Instructions......................................................................................................9
1.6 Field of Application (Intended Use and Foreseeable Abuse) ...................................... 10
2
Description
...........................................................................................................
11
2.1 Theory of Operation ...................................................................................................11
2.2 UV Spectra.................................................................................................................12
2.3 Displays, Operating Elements and Connections......................................................... 14
2.4 User Interface, Touch Display ....................................................................................20
3
Technical Data
....................................................................................................
22
4 Installation............................................................................................................23
4.1 Space Requirements.................................................................................................. 23
4.2 Environmental and Operating Conditions ................................................................... 24
4.3 Connecting the Unit....................................................................................................24
4.4 Installation of the Bulb................................................................................................24
4.5 Start-up ...................................................................................................................... 25
4.6 Display Language ......................................................................................................26
4.7 Adjusting Exposure Time/Cont Mode .........................................................................27
4.8 Switch from 500 W to 1000 W....................................................................................29
4.9 Adjusting the UV Minimum Alarm...............................................................................29
4.10 Working with Parameter Sets..................................................................................... 29
4.11 UV Calibration............................................................................................................30
4.12 Resetting Bulb Operation Hours................................................................................. 30
4.13 Logging in as „Supervisor“ and Special Functions...................................................... 31
5
Cur
ing
....................................................................................................................
3
3
5.1 Part Loading...............................................................................................................33
5.2 Start Exposure Cycle .................................................................................................34
5.3 Shutdown...................................................................................................................34
5.4 No Uncontrolled Shutdown.........................................................................................34
5.6 EMERGENCY Shutdown ...........................................................................................35
5.6 Startup with Bulb in Cold Condition ............................................................................ 35
5.7 Startup with Bulb at Operating Temperature .............................................................. 35
6
Safety devices
....................................................................................................
36
6.1 Temperature Protection..............................................................................................36
6.2 Door Safety Switch.....................................................................................................36
6.3 UV Intensity Monitor...................................................................................................36
7
Environm
enta
l Protection
...............................................................................
36
7.1 Equipment.................................................................................................................. 36
7.2 UV Bulb...................................................................................................................... 36

5
Contents
8
Troubleshooting
.................................................................................................
37
8.1 Error Messages and their Corrective Actions..............................................................37
8.2 General Error Messages and their Corrective Actions ................................................41
8.3 Bulb Replacement ......................................................................................................42
8.4 Filter Pad Replacement ..............................................................................................43
8.5 Change of UV Sensor.................................................................................................43
8.6 Sensor Cable Replacement........................................................................................44
8.7 Change of Reflector....................................................................................................44
9
Annex
....................................................................................................................
46
9.1 Spare Parts and Accessories......................................................................................46
9.2 Pin Connection ...........................................................................................................46
9.3 Declaration of Conformity ...........................................................................................48

6
1 Please Observe the Following
For safe and successful operation of the unit, read these instructions completely. If the
instructions are not observed, the manufacturer can assume no responsibility.
Be sure to keep this manual handy for future reference.
Please refer to the relevant Technical Data Sheet for the adhesive to be processed.
Download from
www
.loc
tite
.com
or contact
the
local
Technical Service.
1.1 Emphasized Sections
DANGER!
Refers to safety regulations and requires safety measures that protect the operator or
other persons from injury or danger to life.
CAUTION!
Emphasizes what must be done or avoided so that the unit or other property shall not be
damaged.
Notice!
Gives recommendations for better handling of the unit during operation or adjustment as
well as for service activities.
The numbers printed in bold in the text refer to the corresponding item numbers in the
illustrations on pages
1
4
-
1
9
.
•The point emphasizes an instruction step.
–
The dash emphasizes a list.
Instruction steps in the illustrations are
indicated with arrows.
Where several instruction steps are
indicated in an illustration, the shading of
the arrow has the following meaning:
Black arrow = 1st step
Grey arrow = 2nd step
White arrow = 3rd step
1.2
Items
S
upplied
UVALOC 1000 97055 (chamber version),
Order no. 805741, comprising:
– Controller
– Lamp housing with UV monitoring
sensor
– Curing cabinet
– UV bulb (Pure mercury vapour)
– Lamp housing connector cords
– Power cord
– Footswitch 97201
–
Operating Manual
UVALOC 1000 97056 (tunnel version),
Order no. 838778, comprising:
– Controller with XS2 PLC interface
– Lamp housing with UV monitoring
sensor
– UV bulb (Pure mercury vapour)
– Lamp housing connector cords
– Power cord
– Operating Manual
Notice!
As a result of technical development, the illustrations and descriptions in this operating
manual may deviate in detail from the actual unit delivered.

7
1 Please Observe the Following
1.3 For your Safety
IMPORTANT! DO NOT OPERATE THE UNIT BEFORE READING THIS SECTION.
DANGER!
Removing, bypassing or putting out of operation of the safety devices can result in
radiation damage to persons and damage to the unit and is therefore prohibited!
Damage to the power cord or the housing can result in contact with live electrical parts.
Check the power cord and the unit before each use. If the power cord or the unit is
damaged, do not operate! Replace a damaged power cord with a new one.
Disconnect power supply before opening the housing!
Never operate system while lamp housing is open!
High voltage is generated by the ignition capacitor inside the lamp housing!
The UVALOC System generates high-intensity UV radiation that, on direct exposure, can
damage skin and eyes in a short time.
In case of malfunctions in the regular operation of the shutter, avoid direct exposure of
the skin under all circumstances, in case of any other shutter malfunction, too!
Broken lamps will release mercury!
Proceed as follows:
Remove all persons at once from the immediate vicinity of the UVALOC System to
prevent breathing of mercury vapours. The room should be thoroughly ventilated
(15 – 20 minutes). When the unit has cooled down, mercury residues should be removed
using absorption systems available from specialty chemicals suppliers.
CAUTION!
The lamps contain mercury. Do not dispose with household trash.
Disposal as hazardous waste required.
To avoid injury, do not touch the shutter while cure chamber is open. This part may reach
up to 90°C during operation.
Only authorized Henkel service staff is permitted to open and repair the unit, except for
replacing the UV bulb and the air filter.
The UV lamp and the air filter must be replaced by qualified personnel only.
Do not touch the glass bulb of the UV lamp. Etched fingerprints on the envelope will
reduce the service life of the lamp significantly.
Cleaners containing ammonium chlorides must never be used to clean the lamp, and not
in the same room as the UVALOC 1000 system, too.
No modifications or other changes to the UVALOC equipment are permitted.
Observe general safety regulations for the handling of chemicals!
Follow the manufacturer's instructions!
Request a safety data sheet for the Loctite®product used!

8
1 Please Observe the Following
1.4
General
I
nstructions
– The UV lamp produces a minor amount of ozone. Under normal operations a
concentration of 0.05 ppm was measured at a distance of 2 cm behind the fan exhaust.
The maximum allowable concentration limit (MAC) for ozone is 0.1 ppm.
– Be sure to pull power plug before opening the equipment!
– Never operate system while housing is open!
– Provided that the system is operated properly, UV radiation is blocked off completely,
eliminating any danger to operators. Make sure to avoid direct exposure of the skin
during set
-
up and installation!
Explanation of Special Labels
1. Electrical Hazard warning
2. UV radiation hazard warning
3. Temperature Hazard warning.
For actions to be taken or avoided:
see section 1.3 For Your Safety.
1 2 3
The following recommendations must be observed for handling UVALOC 1000:
1. Do not operate the unit before reading
the Operating Manual.
2. To protect your skin, wear protective
gloves and long-sleeved clothes.
3. To protect your eyes, wear UV safety
glasses:
– during operation and
– positioning parts or removing them from
the curing chamber.
1 2 3
Ventilation
Cooling air is drawn through ventilation slots in the front panel of the unit, while hot air is
exhausted at the rear. Do not obstruct any of these air vents to make sure that ventilation
air circulates throughout the system. Obstruction of these openings or failure of the fan
will cause the unit to overheat. Replace the filter mat at regular intervals.
Explosive Zones
This unit is
not specified for operation in explosive zones.
Earthquake Zones
If operated in earthquake zones, the unit must be securely fastened.

9
1 Please observe the following
1.5
Special
I
nstructions
Lamp Life
Based on an average power-on time of 8 hours per day and normal service conditions,
the lamp has an expected service life of
– Fe-doped 700 hours,
– Pure mercury vapour 1000 hours (standard lamp), and
– Gallium doped 600 hours.
The lifetime of the bulbs is valid only at the operating condition of 1000 W. They will be
much shorter at 500 W.
To prevent excessive wear of the bulb when operating at 500 W, the bulb must be
operated at 1000 W daily for about 15 minutes.
Notice!
At 500 W the spectrum of the Fe-doped bulb is reduced to the spectrum of the pure
mercury vapour bulb!
All bulbs contain mercury. Other dopings are available for special applications.
UV bulb intensity deteriorates gradually with time. Bulb life depends very much on length
of operating intervals, as
each ignition process subjects the bulb to considerable wear
.
Notice!
Frequent on/off switching results in premature deterioration of the bulb. Do not switch off
for idle periods of less than 3 hours.
How to Handle the Bulb
Any contamination which has not been removed, such as fingerprints on the glass, will
bake to the envelope and result in premature deterioration of performance.
Notice!
Fingerprints can be removed with a lint free wipe and pure alcohol. Before reassembling
the bulb into the unit, the alcohol must have evaporated completely!
In rare cases the envelope may burst – especially if the bulb is very old. The reasons
could be etched fingerprints on the envelope or too frequent on/off switching.
DANGER!
Broken bulbs will release mercury.
Proceed as follows:
Remove all persons at once from the immediate vicinity of the UVALOC System to prevent
breathing of mercury vapours. The room should be thoroughly ventilated (15 – 20 minutes).
When the unit has cooled down, mercury residues should be removed using absorption
systems available from specialty chemicals suppliers.
Overheating
If the maximum operating temperature is exceeded the bulb is automatically switched off
and the shutter closes automatically. After the unit has cooled off sufficiently
(≤55 °C in the lamp housing) the lamp can be ignited again. Overheating may be caused
by obstruction of ventilation slots or excessively high ambient temperatures.
Repair and Servicing
Always disconnect power cord before opening the unit.
Before servicing, always let the unit cool down for 5 minutes. Do not attempt any repairs
except exchanging the bulb and filter mat, see section 8.3 and 8.4. Refer all other repairs
to an authorized Henkel service center.
DANGER!
High voltages are present inside the unit!

10
1 Please observe the following
1.6
Field of
A
pplication (Intended
U
se and
F
oreseeable
A
buse)
The UVALOC 1000 is a 1000 W lamp system designed exclusively for curing Loctite®
UV adhesives or coatings.
It is prohibited to use UVALOC 1000 for drying or curing any other materials or for
heating any flammable or explosive fluids.
The radiation spectrum and p erformance provided is especially matched to the
requirements of Loctite®UV curing adhesives and coating materials, allowing UV
adhesives to cure rapidly to form a dry,
non
-
tac
ky surface.
UVALOC 1000 is a modular system. Version 97055 comprises a controller, a lamp
housing with UC monitoring sensor and a cure chamber. Version 97056 consists of only
a controller and the lamp housing with UV monitoring sensor.
UVALOC 1000 has a pneumatically operated shutter. The time for opening /closing the
shutter is 1 second max. each, which achieves precise and repeatable curing results.
The cure chamber has four rack levels to accommodate the slide-in tray, allowing easy
positioning of parts of various heights at the level of optimum exposure. The tray is
designed as a perforated aluminium plate to allow positioning of customised part holders.
The lamp housing holds the UV radiation source with shutter, fan and ignition device.
T
he controller module holds the control panel, the display
and
the power switch
.
Provided that the shutter operates correctly, the UV bulb is effectively shielded,
eliminating any danger to operators during part loading or unloading. However, it is
recommended that persons with sensitive skin or eyes use gloves, long-sleeved clothes
and UV safety glasses.
The light proof design of the cure chamber ensures a high degree of occupational safety.

11
2 Description
2.1
Theory of
O
peration
UVALOC is a high-performance lamp system for curing UV adhesive. The chamber
version (97055) is a closed system. It is used for applications permitting manual loading
of the cure chamber.
The tunnel version (97056) is the open type designed for integration into semi or fully
automated plants. Both versions offer capability for internal monitoring of the intensity of
UV radiation emitted by the bulb. This function provides additional safety in the
production process as lamp performance is monitored for each exposure.
The parabolically shaped reflector is usable for the most applications because the nearly
parallel radiation generates a uniformly illuminated radiation area.
In contrast the elliptical shaped reflector generates a line of radiation with high intensity
and is more suitable for the use in conveyer systems. The basis is here the tunnel
version 97056.
Radiation spectrum and performance provided by the lamp are especially matched to the
requirements of Loctite®UV curing adhesives and coating materials. Completely dry,
non-tacky surfaces can be achieved rapidly. Exposure times can be preset
in 1 s steps to
ensure precise repeatability of curing results. Exposure time must be determined by
testing to ensure precise results.
As with all UV bulbs of this type, the intensity of light will decline with time as the
electrodes deteriorate and burnt tungsten is deposited on the lamp housing.
The UV minimum output –which is necessary to cure and triggers a warning message
when this value is reached – can be set in the “UV MINIMUM” menu as percentage
value.
The condition for it is a calibration of the integrated UV meter with the bulb. The
”UV CALIBRATION” menu indicates the measured value in terms of percent, e.g. 105%.
This is an absolute value showing the intensity of the bulb. Do not calibrate after
replacing the bulb, to guarantee that the output of the new bulb can be compared with
the old one.
During the installation a measurement should take place with a separate UV measuring
instrument. The measuring should be made at the same position where the work piece
will be inserted into the chamber. An exact relation is received between the %-indication
and absolute intensity (in mW/cm²), for example 100% corresponds to 100 mW/cm²
UV intensity on this position.
However, if you should find out during production that the ”FELL BELOW UV MINIMUM”
warning message is displayed too early or too late, you can adjust the setting on the ”UV
MINIMUM” menu.
For better bulb control, the number of ignitions is recorded for each bulb. When the bulb
is replaced, the count should and the associated bulb operating hours should be reset.
The XS 2 interface (only tunnel version) is used for exchanging the actual system
statuses with a higher
-
ranking controller, see Section 9.2.

12
2 Description
2.2 UV Spectra
DANGER!
Direct exposure of skin and eyes must be avoided by all means!
The ultraviolet spectrum is divided into three sections (Classification according to
CIE S 017:2020 ILV: International Lighting Vocabulary, 2nd edition):
UVA 315 nm - 400 nm (overlapping with UV-Vis from 380 nm on)
UVB 280 nm - 315 nm
UVC
100
nm
-
280
nm
UVA is a part of natural sunlight and its most visible effect on human tissue is the tan. Its
intensity is easily underestimated, as it is not visible. An overdose of UVA will not cause
a UV-induced erythema (sunburn) but a heat-induced erythema, such as it may be
caused by visible light.
UVB is more aggressive than UVA, and also a part of natural sunlight. It has the same
negative effects on human tissue as natural sunlight, the most common being the UV-
induced erythema (sunburn),
UVC is even more aggressive than UVB, it can cause severe tissue damage. The risk of
skin cancer is higher than with UVB.
UV Spectrum – Iron doped Bulb Fe (97347)

13
2 Description
UV Spectrum – Mercury Vapour Bulb Hg (Standard, 97346)
UV Spectrum – Gallium Doped Bulb Ga (97348)

14
2 Description
2.3
Di
splays,
O
perating
E
lements and
C
onnections
Controller, front panel
1
Power switch
2, 3
n/a
4 Display
3.5
’
’
(89 mm) Resistive Col
o
u
r Touch Display
5
Emergency stop button

15
2 Description
Controller, rear panel
6 Power supply
7 F1: Fuse 10A Slow blow
8 XS 1: Start
97055:
Connector for foot switch 97201.
97056:
For external 24 V DC start signal, for assignment see section 9.2.
9 XS 2: PLC connection (97056 only)
External control system for integration into automated plants.
10 XS 3: Data link, lamp housing
11 XS 4: Power supply, lamp housing

16
2 Description
Lamp housing, front panel
12 Ventilation slots (air induction into the interior of the unit)
13 Recessed grip handle (for opening the drawer for bulb replacement)
14 Drawer lock for bulb replacement
15 UV sensor for UV monitoring
15
UVALOC 1000
12 13 14

17
2 Description
Lamp housing, rear panel
16 Compressed air supply for pneumatic tube Ø 6mm calibrated
17 XS 3: Data link to controller
18 Fan (air extraction from the interior of the unit).
If channelled exhaust air is needed a fan flange (Order No. 1045352) can be
mounted instead of the protective grid. At first dismantle the red housing part
and then the grid. Pay attention, the fan is dismantled, too.
19 XS 4: Power supply from controller
P in
4 - 6 bar
60 - 90 PSI
XS3 Lamp Housing
XS4
Power Supply
Lamp Housing
18
16 19
17

18
2 Description
Lamp housing interior
20 Reflector with bulb replacement flap (standard design parabolic).
At the tunnel version 97056 the standard reflector can be replaced by an
elliptical one to achieve better curing when parts are run through.
21 UV bulb with plug-in connection. The unit is equipped by default with the pure
mercury vapour version.
22 Cooling channel
23 Knurled nuts for filter replacement
20
21
22
23

19
2 Description
Cure chamber
24 Rack levels
Allow part positioning at different levels depending on height of part.
25 Perforated aluminium plate
For positioning parts in the radiation area.
26 Door with UV-protective polycarbonate and door safety switch
This switch is a solenoid interlock and prevents opening of the door while the
shutter is open.
27 Carrying handles
DANGER!
Removing, bypassing or putting out of operation of the safety devices can result in
damage to the unit and persons and is therefore prohibited!
24 25 26 27

20
2 Description
2.4 User Interface, Touch Display
The unit has a resistive colour touch display, i. e. it can also be operated with nitrile or
latex protective gloves, for example. The unit is operated by tapping or pressing the
graphically displayed operating elements such as switches, keyboards or option fields.
Notice!
With this version, extended features are available that were previously reserved for
special applications, e. g. setting option for the preheating time for 1000 W exposure,
locking of operating elements for the standard user, automatic exposure when closing
the door and more.
Do not operate the display with hard or sharp-edged objects and avoid contact with
adhesives and solvents.
Functionality of the menus:
Here as an example the language
selection:
The vertical left column is the main
menu. The wide area on the right is the
actual content of the selected menu.
Here, for example, on the left, the
symbol for the globe (language
selection) was pressed. Then, on the
right, the available languages are
displayed accordingly. Here, English
was selected by tapping the flag.
In a few cases, the entire width of the
screen is used to display the selected
content. In this case, the main menu is hidden; tapping the back button takes
you back to the previous screen.
An
input or confirmation dialogue has priority over all other controls. Apart from these two
exceptions, it is possible to switch between the menu items at any time and also change
the language at any time.
Functions of the main menu:
Home: Iginition of the bulb, switch off and cool down, start and cancellation of
an exposure, display and quitting of error messages.
The display of the right-hand area changes depending on the status.
Language selection. Currently available are: English, German, French,
Portuguese, Italian and Spanish.
Setting of the exposure parameters: Continuous or time mode, exposure
time, power selection 500/1000 W, saving and loading these settings under a
name (parameter set, also known as recipe or programme).
Settings: Display brightness, edit parameter sets, UV minimum alarm, UV
calibration, resetting lamp operating hours.
Logging in as "Supervisor", changing the own password, setting permissions
for the standard user, special settings: automatic ignition after power on,
automatic exposure start when closing the door (only chamber version and
time mode), heat-up time for 1000 W exposure, function of the inputs.
Notice!
For the experts: Two digital inputs are available in the chamber version and four in the
tunnel version, which can be freely configured: Start exposure, quit error, ignite lamp or
switch off and cool down. Please remember what you set here!