Nordson CoolWave 2 User manual

CoolWaver2
410 UV Curing System
Customer Product Manual
Part 1089210A04
Issued 06/10
NORDSON CORPORATION AMHERST, OHIO USA
To order parts call 866-885-1212.
For technical support call 800-524-1322.
Check http://emanuals.nordson.com/finishing for the latest version.
This document is subject to change without notice.

Part 1089210A04 E2010 Nordson Corporation
Address all correspondence to:
North American Sales and Service All other countries
Nordson UV Systems Inc. Nordson UV Systems Ltd.
555 Jackson Street
Amherst, OH 44001
United States
667 Ajax Avenue
Slough
Berkshire UK
SL1 4DB
Tel: [phone]
[phone]
Fax: [phone]
Tel: [phone]
Fax: [phone]
Email: [email protected] Email: [e-mail]
Website: www.uv.curing.com
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2008. No part of this document may be
photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained
in this publication is subject to change without notice.
Trademarks
CoolWave, Nordson and the Nordson logo are registered trademarks of
Nordson Corporation.
DeviceNet is a trademark of ODVA, Inc.
All other trademarks are the property of their respective owners.

Table of Contents i
Part 123456X
E2002 Nordson Corporation Manual XX-XX
Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-2............................................
Regulations and Approvals 1-2................................
Personal Safety 1-3..........................................
Ultraviolet Radiation 1-3......................................
First Aid 1-5..............................................
Microwave Radiation 1-5.....................................
Ozone 1-6..................................................
High Temperatures 1-7.......................................
High Voltage 1-7............................................
Mercury Bulbs (Lamps) 1-7...................................
UV-Curable Inks and Products 1-8.............................
Fire Safety 1-8..............................................
Action in the Event of a Malfunction 1-8........................
Safety Precautions While Servicing 1-9.........................
Control System Cleaning 1-9...............................
High Voltage Connections 1-9..............................
Cabinet Cooling 1-9.........................................
Disposal 1-9................................................
Moving and Storage 1-10......................................
Safety Symbols 1-10..........................................
Description 2-1.............................................
Introduction 2-1.............................................
What is UV Curing? 2-1......................................
The UV Curing System 2-1.................................
How Does it Work? 2-1....................................
System Components 2-2.....................................
Reflectors 2-4...............................................

Table of Contents
ii
Part 123456X E2002 Nordson Corporation
Manual XX-XX
Installation 3-1..............................................
Introduction 3-1.............................................
Inspection and Packaging 3-1.................................
Power Supply Installation 3-1.................................
Mounting Guidelines 3-1...................................
Power Supply Electrical Connections 3-3.....................
Power Connections 3-3..................................
Power Supply Balancing 3-4.............................
Network Connections 3-6..................................
Remote I/O Inputs and Outputs 3-6..........................
Machine Stop Interlock 3-8...............................
Remote Power Level Control 3-8.........................
Idle Mode 3-9..........................................
Remote Standby and Lamp On 3-9.......................
Rapid Cycle Using Idle Mode 3-10.........................
DeviceNet Installation 3-10..................................
Chassis Isolation 3-10....................................
BUS Power 3-10.........................................
Hardware Specifications 3-11.............................
Software Specifications 3-11..............................
Lamphead Installation 3-11....................................
Mounting Guidelines 3-11...................................
Light Shielding 3-11........................................
Internal Blower 3-12........................................
External Blowers −Cooling Air 3-12..........................
Cooling Exhaust Air −Lamphead/Chamber Cooling Air Removal ....
3-12
Monitoring Static Pressure 3-15..............................
Top/Front Pressure Port 3-15..............................
Bottom Pressure Port 3-15................................
Switching Pressure Ports 3-16.............................
Lamphead Cable Connections 3-17..........................
RF Detector Installation 3-18...................................
Power Supply Configuration 3-19...............................
Operation 4-1...............................................
Introduction 4-1.............................................
Display and Controls 4-1.....................................
Additional Functions 4-3...................................
Temperature 4-3........................................
Light Detector 4-3......................................
Starter Bulb Test 4-3....................................
Panel Lock 4-3.........................................
Display Messages 4-4.......................................
Fault Messages 4-4..........................................
Resetting Faults 4-5.......................................
Startup 4-6.................................................
Locally Operated Units 4-6.................................
Remotely Operated Units 4-8...............................
Shutdown 4-9...............................................

Table of Contents iii
Part 123456X
E2002 Nordson Corporation Manual XX-XX
Maintenance 5-1............................................
Power Supply Maintenance and Repair 5-1.....................
Maintenance Schedule 5-1.................................
Power Supply Repair Procedures 5-1........................
Preparation 5-1.........................................
Fuses 5-2.............................................
Power Supply Cooling Fan Cleaning 5-3...................
Lamphead Maintenance and Repair 5-4........................
Lamphead Repair Procedures 5-5...........................
Preparation 5-5.........................................
Bulb Replacement 5-5...................................
Reflector Replacement 5-6...............................
Internal Blower Lamphead Cover Removal 5-9................
Internal Blower Lamphead Cover Replacement 5-10............
Internal Lamphead Component Replacement 5-11.............
Preparation 5-11.........................................
Light Detector Board 5-12.................................
Starter Bulb Replacement 5-13............................
Magnetron Replacement 5-13.............................
Troubleshooting 6-1.........................................
System Software Versions 6-1................................
General Troubleshooting 6-1..................................
Fault Message Troubleshooting 6-2............................
Bulb Troubleshooting 6-6.....................................
Curing Process Troubleshooting 6-6...........................
General Lamphead Troubleshooting 6-7........................
Parts 7-1...................................................
Introduction 7-1.............................................
Using the Illustrated Parts List 7-1...........................
CW-2 Power Supplies 7-2....................................
Repair Parts 7-2..........................................
CW-2 Lampheads 7-4........................................
System Cables 7-6..........................................
RF Detector 7-7.............................................
External Blowers 7-7.........................................
Reflector Conversion Kits 7-7.................................
Accessories 7-7.............................................
Specifications 8-1...........................................
Power Supply 8-1...........................................
Light Output Settings 8-2.....................................
Master/Remote Power Setting Examples 8-2.................
Lamphead 8-3..............................................
Bulb 8-3....................................................
System Schematics 8-3......................................

Table of Contents
iv
Part 123456X E2002 Nordson Corporation
Manual XX-XX
UV Glossary 9-1............................................
DeviceNet Specifications 10-1................................
Introduction 10-1.............................................
Definitions 10-1............................................
Reference Documents 10-1.................................
Governing Body 10-1.......................................
System Operation 10-2........................................
MAC ID / Baud Rate Configuration 10-2.......................
LED Operation 10-3........................................
DeviceNet Interface 10-4......................................
Overview 10-4.............................................
Configuration 10-4.........................................
Initialization 10-4...........................................
Group 2 Only Slave Operation 10-4..........................
Certification 10-4...........................................
Identity Object (01HEX −1 Instance) 10-5.......................
Class Attributes (Instance 0) 10-5............................
Instance Attributes (Instance 1) 10-5..........................
Common Services 10-5.....................................
Message Router Object (02HEX −1 Instance) 10-5...............
DeviceNet Object (03HEX −1 Instance) 10-6....................
Class Attributes (Instance 0) 10-6............................
Instance Attributes (Instance 1) 10-6..........................
Common Services 10-6.....................................
Assembly Object (04HEX – 2 Instances) 10-7....................
Class Attributes (Instance 0) 10-7............................
Instance Attributes (Instances 100 and 112) 10-7...............
Common Services 10-10.....................................
Connection Object (05HEX −2 Instances) 10-11..................
Class Attributes (Instance 0) 10-11............................
Instance Attributes (Instances 1 −2) 10-11.....................
Common Services 10-12.....................................
S−Device Supervisor Object (30HEX −1 Instance) 10-12...........
Class Attributes (Instance 0) 10-12............................
Instance Attributes (Instance 1) 10-12..........................
Common Services 10-13.....................................
Exception Detail Alarm / Warning 10-14........................
Lamp Object (64HEX −16 Instances) 10-15......................
Class Attributes (Instance 0) 10-15............................
Instance Attributes (Instances 1−15) 10-16.....................
Common Services 10-16.....................................

Change Record i
Part 1089210A04
E2010 Nordson Corporation
Change Record
Revision Date Change
A02 8/09 Part Number 1085680 replaced by 772214 under Repair Parts.
A03 06/10 Added Cooling Exhaust Air −Lamphead Cooling Air Removal text on
pages 3−12, 13.
Under lamphead repair parts, part number 1102567 replaces part
number 1088443 for internal blower filter kit, 4 pack.
A04 6/10 Updated UV contact information.
Added information on T3 transformer.
Added pressure table for Monitoring Static Pressure and Light Detector
section.
Updated new part numbers for the main control board (1101815) and the
phase control board (1102449).

Change Record
ii
Part 1089210A04 E2010 Nordson Corporation

Safety 1-1
Part 1089210A04
E2010 Nordson Corporation
Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to all persons operating or servicing equipment.
All equipment is designed and manufactured to International Safety
Standards to ensure that the health and safety of the operator is protected
at all times.
Figure 1-1 Microwave UV Warning
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.

Safety
1-2
Part 1089210A04 E2010 Nordson Corporation
Intended Use
Nordson ultraviolet (UV) equipment is intended specifically for integration
into other machines and should NOT be operated as a standalone system
or without appropriate safety guarding, shielding, and interlocks. It is the
responsibility of the integrator and end user to ensure that the final
assembly fulfills all necessary legislation and is completely safe before
operation.
This equipment is designed for the accelerated curing of UV inks,
adhesives, and coatings. Do not use this equipment to cure alternative
materials unless approved by the material supplier.
The equipment is not flame or explosion proof and is not designed for use in
hazardous areas.
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards, shielding or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
Susing equipment in hazardous areas
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.
Currently there are two organizations that set recommended guidelines for
exposure to occupational microwave radiation exposure, OSHA (U.S.
Department of labor, Occupational Safety and Health Administration −
Directive 29cfr 1910.97) and ANSI (American National Standards Institute −
Directive C95.1−1982). The ANSI directive, which is more stringent and
most commonly referred to, states that individuals should not be exposed to
microwave radiation levels above 5 mW/cm2at 2.45 GHz on a continuous
basis.