OAI TRI-SOL User manual

OPERATION MANUAL
TRI-SOL
SOLAR SIMULATOR
1-1.6KW
685 RIVER OAKS PARKWAY
SAN JOSE, CA 95134
www.oainet.com
[email protected]
408/232-0600
P/N 0131-7024-01 Rev. D
01/21/14

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 1
TRI-SOL SOLAR SIMULATOR
Definitions of the following Symbols and Words should be understood
before working with this manual and/or the equipment with this
manual.
The definitions are:
“Caution”- Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
“Warning”- Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
“Danger”- Indicates an eminently hazardous situation which, if not
avoided, will result in death or serious injury.

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 2
TABLE OF CONTENTS
PURPOSE, SCOPE AND REVISION HISTORY...................................................3
SECTION 1: INTRODUCTION .............................................................................5
1.1. GENERAL DESCRIPTION…………………………………………...……….5
1.1.1. SOLAR SIMULATION LIGHT SOURCE SYSTEMS……………..….5
1.2 APPLICATION....……………………………..……….…………….…...……...6
1.3 GETTING HELP…..…………………………………………………….………7
SECTION 2: RECEIVING AND UNPACKING THE EQUIPMENT….…...………..8
2.1 CHECK SHOCK WARNING LABEL.........................................................8
2.2 OPEN CRATE AND UNPACK EQUIPMENT……………………………….9
SECTION 3: SAFETY PRECAUTIONS..............................................................10
3.1 HAZARDS TO PERSONNEL………..………………………………………10
3.1.1 UV HAZARD BURN.……………………………………………………11
3.1.2 HEAT BURN HAZARD....................................................................11
3.1.3 HAZARDS DUE TO LAMP EXPLOSION ........................................11
3.1.4 HAZARDS DUE TO ELECTRICAL SHOCK....................................12
SECTION 4: LAMP INSTALLATION AND CLEANING.....................................13
4.1 INSTALL OR CHANGE THE LAMP..………………………………………13
4.2 ADJUSTING THE LAMP POSITION………...……………………………. 17
4.3 CLEANING OPTICAL COMPONENTS...................................................17
4.4 INSTALLING THE AIR MASS FILTER...................................................18
SECTION 5: SYSTEM OPERATION..................................................................19
5.1 STARTING AND OPERATING THE SOLAR SIMULATOR ...................19
5.2 MEASURING UNIFORMITY ...................................................................23
5.3 ADJUSTING UNIFORMITY.....................................................................24
5.4 OPERATING THE SOLAR SIMULATOR REMOTELY...........................25
SECTION 6: SYSTEM INTERLOCKS................................................................27
6.1 SOLAR SIMULATOR INTERLOCKS.......................................................27
6.1.1 THE PERSONAL SAFETY INTERLOCK .........................................28
6.1.2 THE AIR-FLOW SYSTEM SAFETY INTERLOCK............................28
SECTION 7: HAZARDOUS MATERIALS USED WITH THE SYSTEM .............29
7.1 ISPROPYL ALCHOL................................................................................29
SECTION 8: SYSTEM SPECIFICATIONS AND DRAWINGS............................30
8.1 SYSTEM SPECIFICATIONS...................................................................30
8.2 SYSTEM DRAWINGS.............................................................................30

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 3
PURPOSE SCOPE AND REVISION HISTORY
PURPOSE. To provide instructions on how to receive/ship, install, handle, use,
trouble-shoot and maintain the UV LIGHT SOURCE hereinafter referred to as the
EQUIPMENT.
SCOPE. The user of this document should have a complete understanding of
the EQUIPMENT.
OBJECTIVE. To ensure that this document provides as much information as
possible on the Equipment so that few, if any, questions will be raised relative to
its operation and functionality over the short and long-term.
REVISION HISTORY.
Purpose Rev
Level Release Date
New Release ECO 10670 A 10/06/10
Change Company Logo & Text Colors, Updated Lamp Instr. ECO
10826 B 07/07/11
Add Constant Intensity operation description, ECO 10867 C 08/11/11
Add section 4.4 Installing the Air Mass Filter per ECO 11359 D 01/21/14
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Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 4
Copyright 2010 by OAI
All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in
a retrieval system or translated into any language or computer language, in any
form or by any means, electronic, mechanical, magnetic, optical, chemical,
manual or otherwise, without the prior written permission of OAI.
Disclaimer:
OAI makes no representations or a warranty with respect to the contents hereof
and specifically disclaims any implied warranties or merchantability or fitness for
any particular purpose. Further, OAI reserves the right to revise this publication
and to make changes from time to time in the content hereof, without obligation
of OAI to notify any person of such revision or changes.
WARNING!
The high intensity energy produced by systems employing xenon arc lamps can
cause serious eye or skin damage. Personnel working with this equipment
must wear eye protection with suitable filtration to block ultraviolet and infrared
radiation, and avoid directly exposing skin for extended periods. OAI will not be
responsible for injuries arising from incorrect or unprotected work with these
Light sources. They should not be adjusted or serviced by personnel lacking
specific training on them. Before installing or operating this equipment, be sure
to read Section 3, on safety. Due to the high voltage to start xenon arc lamps, the
light source power supply starter circuit may create RF noise during the start up
cycle that might possibly have an effect on sensitive electronic equipment in the
immediate area. Noise may also be created on the power supply AC input line
during the start up cycle. To eliminate this potential problem, it is recommended
that the power supply and lamp be started before turning on any sensitive
electronics in the immediate area. If this is not possible, it is also recommended
that the power supply and cabling be placed at a distance from any sensitive
electronics that has not been adequately shielded.
Before installing or operating this equipment, be sure to read
Section 4, SAFETY PRECAUTIONS

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 5
SECTION 1:
INTRODUCTION
This manual is intended to provide instructions and recommendations for the
proper use and maintenance of the EQUIPMENT.
1.1 GENERAL DESCRIPTION
1.1.1 SOLAR SIMULATION LIGHT SOURCE SYSTEMS
Solar simulation light sources produce an intense, uniform, collimated beam of
broad band energy. The radiation from the xenon arc lamp is collected by an
ellipsoidal reflector and directed to an aluminum “turning” mirror. The beam
converges onto the optical integrator made up of arrays of 49 or more closely-
spaced lenses. The exit beam diverges through the open shutter to the second
mirror, where it is reflected through the output (collimating) lens onto the
exposure plane. The light is filtered to match the required solar spectrum just
after it exits the optical integrator.
Controls for adjusting the lamp’s position within the main reflector housing are
located inside one of the access doors of the light source system. Typically,
power for the blower, shutter, lamp power supply and accessories is supplied via
a multi-conductor cable which is located on the rear of the housing.

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 6
1.2 APPLICATION
The EQUIPMENT is designed to emit collimated broad band light. OAI’s Tri-Sol
Solar Simulator Systems are high performance systems intended for solar
simulation, with applications including solar cell testing and weathering.
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Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 7
1.3 GETTING HELP
Assistance in answering questions relating to the operation of the EQUIPMENT
can be obtained by calling OAI’s customer support at 1 [phone] between
the hours of 8:00 A.M. and 5:00 P.M., Pacific Standard Time. Outside normal
business hours, or at any other time, written questions may be Faxed to 1 (408)
433-9904 to the attention of the Optical Products Group Customer Support, or
emailed to [email protected].
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Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 8
SECTION 2:
RECEIVING AND UNPACKING THE
EQUIPMENT
Normal receiving inspection procedures should be followed prior to unpacking
the EQUIPMENT including the inspection of the Shock Warning label on the front
of the crate.
Then, use a copy of these guidelines when ready to unpack and prepare the
Equipment for installation. Be sure to follow all safety precautions used during
the handling of packaging and related materials.
2.1 CHECK SHOCK WARNING LABEL
The color of the liquid capsule on the Shock Warning label affixed to the side of
the SOLAR SIMULATOR crate (shown in Figure 3-1) should be clear; if it’s red,
the shipment should be inspected for physical damage. If damage is found,
reject the shipment.
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Figure 3-1. Warning label, straps and clips
on front of crated Solar Simulator.
Check per
para. 3.1
Remove
clips.
Cut straps using
metal shears.

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 9
2.2 OPEN CRATE AND UNPACK EQUIPMENT
CAUTION! WEAR SAFETY GLASSES AND GLOVES AS
PROTECTION FROM CUTS OR DAMAGE TO EYES WHEN
CUTTING STRAPS AND REMOVING CLIPS!
1) If the shipment is accepted, cut and remove any straps securing
the crate to the pallet (shown in Figure 3-1).
2) Remove any bolts along the bottom of the front of the crate.
3) If clips are used on the crate, use one hand loosely cupped over
each clip to prevent damage to the eyes, pop off the clips around
the edges of the front of the crate (shown in Figure 3-1). Use either
the claw side of a hammer or a screwdriver to loosen same.
Note: Some of the crated items are very heavy. Use proper
lifting techniques when handling this unit

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 10
SECTION 3:
SAFETY PRECAUTIONS
There are several major hazards to personnel:
Ultraviolet light or non-ionizing radiation exposure
Lamp explosion
Electrical shock
UV Burn Hazard
Heat Burn Hazard
There is also a hazard to the equipment:
Risk of damage to the light source during handling and shipping
3.1 HAZARDS TO PERSONNEL
Personnel using the SOLAR SIMULATOR should be aware of the hazards that
stem from the SOLAR SIMULATOR. This section of the manual describes
precautions that help avoid personal injury while using the equipment. Also, be
sure to read the Section entitled, SYSTEM INTERLOCKS.
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Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 11
WHEN IN THE VACINITY OF A LIGHT SOURCE WITH ITS
COVER REMOVED, ALWAYS WEAR UV FILTERED
GLASSES TO PROTECT EYES AND LIMIT EXPOSURE
TIME TO UV RADIATION.
3.1.1 UV BURN HAZARD
Prolonged exposure to diffused reflection from the output
beam, illuminated surfaces in the beam, exposures of even a
few seconds to the direct output beam or to the lamp itself, can
cause ultraviolet skin burns or burns to the outer layers of the
eye. Prolonged skin exposure can cause burns similar to
severe sunburn. WARNING!
3.1.2 HEAT BURN HAZARD
When the XE lamp is on, the lamp end caps and other metal
pieces near the lamp get very hot. The outside of the lamp
main housing is safe to touch.
3.1.3 HAZARDS DUE TO LAMP EXPLOSION
Xe lamps are under high pressure, even at room temperature.
Do not handle a Xe lamp without wearing proper face and eye
protection, long sleeves, and gloves as the lamp could explode.
During operation, the lamp is subjected to very high internal
pressure; thus there is always the possibility of a lamp exploding
due to internal strains or physical abuse. A lamp explosion can
also be caused by contamination of the quartz envelope. Handle the lamps only
by the metal end caps. Do not touch the quartz with bare hands. A lamp
explosion inside the closed light source housing can damage its internal
components such as its ellipsoidal reflector, mirror, etc.
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Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 12
3.1.4 HAZARDS DUE TO ELECTRICAL SHOCK
Before changing the lamp or working on the light source, turn off the
main power breaker at the rear of the SOLAR SIMULATOR.
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Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 13
SECTION 4:
LAMP INSTALLATION AND CLEANING
The EQUIPMENT consists of a single housing containing components of the
SOLAR SIMULATOR.
4.1 INSTALL OR CHANGE THE LAMP
WARNING!
Again, be sure to wear face protection, safety goggles, and gloves when handling lamps.
And this is the large upper door of the lamp housing we will mention in step 3).
Be sure to wear face protection, safety goggles, and gloves
when handling lamps.
If the lamp has been operating, turn it off and allow the housing
to cool for 20 minutes before proceeding
Always turn off the main power to the system via the circuit
breaker at the rear of the SOLAR SIMULATOR and unplug the
main power cord from the wall before changing a lamp

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 14
1) If the lamp has been operating, turn it off while leaving the main breaker
switch at the rear of the light source on to keep the blower operating and allow
the housing to cool for 20 minutes before proceeding.
2) Turn off the main power breaker and unplug the main power cord from the
wall socket.
The main power breaker should be turned off like the left picture instead of the right one.
3) Remove the captive screw(s) securing the large upper door of the lamp
housing and set door aside.
WARNING!
When the access door is removed, an interlock switch will open, preventing
operation of the lamp.
Do not attempt to defeat this interlock.
* Never o
p
erate the lam
p
with this door removed
!

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 15
4) On those models equipped with a hinged primary mirror assembly, unscrew
the thumb screws holding the mirror in place and swing the hinge plate clear to
provide access to the lamp.
NOTE
5) Carefully remove the flying lead from the clamp on the end-cap of the
lamp. Unscrew the screw on the clamp counterclockwise while holding the
wire and the flying lead to prevent it from falling down, then slip off the
wire with attached lug. Gently unscrew the lamp counterclockwise and
carefully remove the lamp from the housing. Gently remove the clamp on
the old lamp’s end-cap. Only handle the Anode (+) side of the lamp, not
the Cathode (-) side, this will prevent lamp breakage. Do not pull or push
too hard on the clamp when handling.
Please use the other hand to hold the wire and flying lead to prevent them from falling
down. In the picture, I did not do that since my other hand was holding the camera. The
yellow one on the top is the clamp.
WARNING!
6) Put the clamp on the new lamp’s end-cap Anode (+) side and screw it down
tightly. Gently screw in the new lamp with the Anode (+) side up, then reattach
the flying lead to the anode of the lamp.
When installing the lamp, do not touch the quartz envelope. Handle the lamp
only at the bases, by the metal end-caps. If fingerprints are inadvertently
transferred to the lamp, clean with isopropyl alcohol before reinstalling.
Since most lamps contain toxic materials,
they should be disposed of in an ecological manner

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 16
Put the clamp on and tighten the screw on it first before you screw the new lamp in.
7) On those models equipped with a hinged primary mirror, return the mirror to
the normal location and secure with thumb screws.
8) Replace the large door of the lamp housing and tightened the screw that
secures the door.
The lamp’s positioning should be adjusted to achieve maximum output. This is
referred to as “peaking” a lamp. See adjusting the lamp position.

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 17
4.2 ADJUSTING THE LAMP POSITION
Be sure that the large upper door of the lamp housing is closed before you adjust
the lamp position. The lamp positioning should be adjusted to achieve maximum
output. With a lamp warmed-up to normal operating temperature, removed the
small door of the lamp main housing. Open the shutter, place a reference cell
measurement probe at the center of the exposure area, and vary the adjustments
for maximum intensity. Due to subtle differences between the lamps, the X, Y,
and Z adjustment should be a readjusted every time a lamp is replaced. This is
referred to as "peaking" a lamp.
XYZ lamp position adjustment knobs shown with lower panel removed.
4.3 CLEANING OPTICAL COMPONENTS
Periodic cleaning of optics is recommended to maintain light intensity and
uniformity. Items to be cleaned include the mirrors and lens. Do not attempt to
clean the condensing lens array (integrator), elliptical reflector or feedback
probes. These should only be disassembled and cleaned at OAI.
With the light source fully cooled, gently clean the optics with a soft, lint-free,
lens tissue and a small amount of isopropyl alcohol.
NOTE
Dispose of the alcohol soaked lens tissue as described in Section 7
HAZARDOUS MATERIALS USED WITH THE SYSTEM

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 18
4.4 INSTALLING THE AIR MASS FILTER
The system comes equipped with an air mass filter, usually air mass 1.5G,
but it may be something else depending on the desired specifications. To
install the air mass filter, locate the filter holder assembly in the lens
housing as shown in the figure below. Unscrew the 2 thumb screws that
hold the filter holder in place and lift the filter holder out of the lens
housing. Once you have the filter holder removed, slide the supplied filter
into place by placing it on the surface near the thumb screws and tipping
the filter holder down to allow the filter to slide into position as shown. Its
orientation is unimportant.
Once the filter is in place, replace the filter holder in the lens housing of the
unit and tighten the 2 thumb screws to hold it in the correct position.
Thumb screws holding the
filter holder in place.

Manual PN: 0131-7024-01, Rev: D MANUAL MDL TRI-SOL 1-1.6KW SOLAR SIM OPER 19
SECTION 5:
SYSTEM OPERATION
5.1 STARTING AND OPERATING THE SOLAR
SIMULATOR
To start the solar simulator, press the LAMP START button on the conrol panel.
After the lamp has been operating for 5 minutes and is sufficiently warmed up,
adjust the lamp current via the knob on the control panel as necessary to achieve
the desired beam intensity. Lamp current and voltage can be read from the LED
display.
The shutter can be opened by pressing the SHUTTER OPEN button, and the
lamp intensity can be dimmed by pressing the LOW INTENSITY button. The
LOW INTENSITY button is set at the factory to drop the lamp intensity by
approximately 20%.
The numer of hours the simulator has operated can be read from the hour meter.
Solar simulator
standard control
panel
Solar simulator
control panel for
systems with
constant intensity
option.