Ushio SugarCube 38000-M03-002 User manual

38000-L01-001_Rev_J_SugarCUBE_Manual 1
SugarCUBE™LED Fiberoptic
Illuminator
Operating and Owner’s Manual
This manual contains important information necessary for the safe and efficient
operation of the LED Fiberoptic Illuminator. Please read the manual in its entirety
and heed all safety warnings before operating the light source.
Necsel IP, Inc., an Ushio Group company
101 Panton Road
Vergennes, VT 05491
USA
Phone [phone]
www.ushio.com

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Follow all safety precautions!
The SugarCUBE™, Model 38000-M03-002 (Red), 38000-M03-003 (Green),
38000-M03-004 (Blue), 38000-M03-005 (White), 38000-M03-010 (QUAD –
Extra High Power White), and 38000-M03-305 (Ultra – High Power White
[Round]) is designed and tested in accordance with ANSI/UL 61010-1, CAN/CSA
C22.2 Number 61010-1, EN 61326-1:2013, EN 55011:2010 and FCC Part 15
Subpart B, Class B.
WARNING:
The SugarCUBE™ contains ultra-intense LED
emitters. DO NOT STARE AT THE LED SOURCE.
Prior to use, carefully unpack and inspect all components for any signs of damage
which may have occurred during shipping. If shipping damage is suspected,
notify Ushio America, Inc or your authorized Ushio distributor immediately.

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Contents
1INTRODUCTION AND INTENDED USE ........................5
2SAFETY...................................................................6
3SYSTEM OVERVIEW.................................................7
4INITIAL SETUP.........................................................9
5ADAPTERS AND LIGHT GUIDES ...............................11
6MAINTENANCE.....................................................13
7REMOTE OPERATION ............................................15
8TROUBLESHOOTING..............................................20
9REPLACING THE FUSES ..........................................23
10 LIMITED WARRANTY .............................................23
11 TECHNICAL DATA ..................................................24
12 REGULATORY COMPLIANCE...................................25
13 APPENDIX A – COMMUNICATION ...........................26

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Special instructions are emphasized as follows:
NOTE:
Notes contain important information regarding
set-up and operation to facilitate ease of use and
obtain effective results.
This symbol indicates critical information regarding
safe handling and use of this system. Device
malfunction or property damage could result if
these instructions are not followed.
WARNING:
Warnings contain critical information by
identifying conditions or practices that may result
in injury or loss of life if these instructions are not
followed.

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1Introduction and Intended Use
The SugarCUBE™is the world’s most powerful single LED light source for general
scientific, industrial and machine lighting. It contains a single, high-power LED,
which is direct coupled to a variety of user interchangeable liquid or fiberoptic
light guides.Models are available in high-power monochromatic red, green,
blue, broad spectrum white, and a high-power “Ultra” broad spectrum white.
The SugarCUBE™ is a very high-power, LED-based illuminator and is a direct
replacement for existing 150W halogen fiberoptic illuminators.
Typical usage is for microscope stands, machine vision, automated inspection,
etc. The unit is designed for continuous operation with minimal maintenance.
The illumination is directed to the target via a fiberoptic light guide or a liquid
light guide (LLG). The light source supports fiberoptic light guides from .0625
inch core up to 1 inch nominal OD, and 3mm through 8mm core diameter liquid
light guides.
Contact the factory for customized units built specifically to suit your needs.
The SugarCUBE™ uses environmentally friendly manufacturing process
components.

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2Safety
The SugarCUBE™uses a high-power LED (Light Emitting Diode) that produces
extremely bright light. Proper care must be taken in the setup and operation to
prevent damage to the unit.
The LEDs are NOT accessible. Please return the unit
to the factory for warranty repair.
The unit requires adequate airflow to maintain proper
cooling. Ensure the ventilation holes are unobstructed
and adequate clearance is provided.
If the unit is used in a manner not specified within
this manual the protection provided by the
equipment might be impaired.
Never open or remove the top cover while the unit
is plugged in. Qualified personnel must perform all
maintenance, including dust removal.
Do not operate the unit near any flammable
materials, including flammable gases or liquids.

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3System Overview
3.1 Front Panel

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3.2 Rear Panel
Main Power
ON/OFF
Switch
AC Power
Connector 5V to 24V
On/STBY
Control Input
Connector
Front Panel /
Analog Control
Switch
RS232
Communications
Connector

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4Initial Setup
4.1 System Components
The SugarCUBE™ is comprised of:
Light Source
Electrical Power Cord
Light Guide Adapter (sold separately) to match optional light guide.
Liquid or Fiberoptic Light Guide (sold separately)
Carefully unpack all components, giving particular attention to the (optional)
light guide and taking care not to touch or contaminate the ends or to exceed its
bend radius. Consult the light guide manual for handling and cleaning
instructions.
4.2 Choosing a Location
Set the SugarCUBE ™ on a flat surface in a place that allows for adequate air
ventilation on all sides. Do not position the unit so that the back or sides of the
unit are obstructed.
NOTE:
For adequate ventilation, maintain at least 4”
of clearance around all sides of the light source
in an unenclosed space.
4.3 Light Guide Connection
Insert the appropriate end of the light guide into the light guide adapter until it
is fully seated. Do not force the light guide. Use the thumbscrew(s) to lock the
light guide in place. Refer to Section 5.1 for light guide selection information.
The light guide adapter provides for the correct
position of the light guide end relative to the LED
emitting surface, therefore no adjustments are
necessary. Ensure the correct adapter is used.

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4.4 Connecting the Power Cord
Insert the appropriate end of the power cord into the AC receptacle in the back
of the unit. Insert the other end of the power cord into a standard AC outlet.
NOTE:
The unit utilizes a universal voltage power
supply. Refer to Section 11 for acceptable
power requirements.
4.5 Operating the Unit
1. On the rear panel, flip the Main Power ON/OFF (I/0) switch to the ON
(I) position.
2. On the front panel, the Power Indicator will flash approximately once
per second to indicate the unit is running and in Standby Mode.
3. The Intensity Indicators will display the current LED intensity level.
4. Adjust the LED intensity to the desired level using the Intensity
Adjustment buttons.
5. Press the On/Stby button to turn the LED on at the previously selected
intensity level.
6. The Power Indicator will be continuously illuminated.
7. Adjust the LED intensity using the Intensity Adjustment buttons if
necessary.

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5Adapters and Light Guides
Use only factory supplied light guide adapters. Use
of non-authorized light guide adapters may
damage the LED and/or light guide and void the
warranty. Consult the factory before attempting to
use non-standard light guides or adapters.
The SugarCUBE™can accept a variety of light guides using standard adapters
specifically designed for optimum performance.
Standard light guides and adapters are listed at www.ushio.com
Other custom adapters are available. Contact the factory for more information.
5.1 Light Guide Selection
The SugarCUBE™ is capable of generating up to 15W of radiometric, or radiant,
power. Check with the factory to select fiber optic and liquid light guides suitable
for use with the SugarCUBE.
NOTE:
The light guide may experience temperatures
at or near 85°C where it comes into contact
with the front panel adapter. The temperature
of the light guide may be more or less,
depending on its construction and ability to
transmit the energy generated by the LED.
NOTE:
Due to the high output and high power
densities emitted from the SugarCUBE™ Ultra,
fiber bundles may be at a higher risk of
damage. Fiber bundles typically have lower
coupling efficiencies than other light guide
technologies which may result in significant
rises in coupling surface temperatures.
Unsuitable light guides may outgas at the end nearest the LED and create a
brown or black residue on the LED and/or the light guide (see image below). In
worst case situations, the deposits will cause the LED to overheat, crack, and fail.
In best case situations, the deposits will cause drastic reductions in LED-to-light-
guide coupling efficiency and LED lifetime. If caught early enough, the deposit
can often be removed via careful mechanical scraping. The SugarCUBE warranty
does not cover mechanical damage to the LED or its surface.

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5.2 Installing/Changing Light Guide Adapters
1. Flip the Main Power ON/OFF (I/0) switch to the OFF (0) position and
remove the power cord from the unit.
2. Using a #1 apex Phillips screwdriver, remove the (2) mounting screws
on the front of the adapter.
3. Remove the adapter.
4. Insert the new adapter and align the mounting holes.
5. Insert and tighten the (2) mounting screws.
6. Connect the power cord to the unit and flip the Main Power ON/OFF
switch to the ON (I) position.

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6Maintenance
All maintenance is to be performed by qualified
personnel only. Ensure electrical power is
disconnected prior to performing maintenance.
Wear OSHA approved safety glasses when
handling and using compressed air or cleaning
chemicals.
Use only OSHA approved compressed air nozzle set
at 29psi or less or electronics-grade (dust-off)
canned compressed air.
6.1 Cleaning the Cooling Fans
The SugarCUBE™ contains two cooling fans. One is used to cool the LED, and
one is used for electronics and power supply cooling. For optimum
performance, both fans must be kept clean of dust and debris.
1. Flip the Main Power ON/OFF (I/0) switch to the OFF (0) position and
remove the power cord from the unit.
2. Remove the (4) top cover screws and remove the top cover.
3. Check for accumulated dust or debris.
4. Using a soft brush or cloth, wipe any dust from LED assembly heat
sink, fans, vent holes and finger guards.
5. Using clean, dry compressed air, blow the remaining dust from heat
sink fins and vent holes.
6. Replace the top cover and secure it using the (4) screws removed in 2.
7. Connect the power cord to the unit and flip the Main Power ON/OFF
switch to the ON (I) position.

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6.2 Cleaning the LED, Light Guide and Light Guide
Adapter
NOTE:
The light guide adapters
are designed to position
selected light guides extremely close to the face of the
LED. Dust
and debris must not be allowed to
accumulate on or around the LED or damage to the LED
and/or light guide may occur.
Use isopropyl alcohol sparingly. Excess isopropyl
alcohol may cause damage to the LED.
1. Flip the Main Power ON/OFF (I/0) switch to the OFF (0) position and
remove the power cord from the unit.
2. Lightly dampen a clean cotton swab with isopropyl alcohol.
3. Gently swab the face of the LED glass to remove debris.
4. Clean around the light guide adapter.
5. Refer to the manufacturer’s recommended cleaning procedure for
cleaning the light guide conducting surface.
6. Allow alcohol to completely dry prior to using unit.
7. Connect the power cord to the unit and flip the Main Power ON/OFF
switch to the ON (I) position.

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7Remote Operation
7.1 Using the Relay Control
NOTE:
Relay Control and the On/Stby button can both be
used to turn the LED on or off. The unit must be in
Standby Mode to ensure proper operation while using
the Relay Control.
The necessary accessory cable can
be purchased at www.ushio.com
1. Flip the Main Power ON/OFF (I/0) switch to the OFF (0) position and
remove the power cord from the unit.
2. Using the Control Cable (P/N 38000-M03-022), apply a 5-24VDC
control voltage (from a PLC, computer I/O device, or equivalent) to the
Input connector on the rear panel. Refer to the image below for
connection information.
Plug – pin end view
RJ10 -
CONTROL
1 - Black
2 - Red
3 - Green
4 - Yellow
5 – 24 VDC
STBY
ON
USER SUPPLIED
TERMINAL STRIP
N/C
N/C
NOTE:
The Relay Control terminals are NOT polarity specific.
NOTE:
For units having the Analog Control option:
Pin 1 – Black is Analog GND
Pin 4 – Yellow is Analog Control Voltage

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3. Connect the power cord to the unit and flip the Main Power ON/OFF
switch to the ON (I) position.
4. The Power Indicator will flash approximately once per second to
indicate the unit is running and in Standby Mode.
5. The Intensity Indicators will display the current LED intensity level.
6. Adjust the LED intensity to the desired level using the Intensity
Adjustment buttons.
7. Apply the control voltage to turn the LED on (5-24V DC).
8. Remove the control voltage to place the unit in Standby Mode.
NOTE:
The Relay Control input is not intended for pulsed
operation of the LED.

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7.2 Operating in Analog Mode
In Analog Mode, the LED intensity is controlled by an external voltage source.
The associated circuit accepts a voltage range from 0V to 10V, which equates to
an intensity adjustment range of 10% - 90%.
1. Flip the Main Power ON/OFF (I/0) switch to the OFF (0) position and
remove the power cord from the unit.
2. Connect the RJ10 end of the (optional) 38000-M03-022 Control Cable to
the Input port on the rear panel.
3. Connect the yellow (+) and black (-) conductors to an appropriately
configured voltage source (0V-10V).
4. Flip the Front Panel/Analog Control switch on the rear panel to the
Analog position.
5. Connect the power cord to the unit and flip the Main Power ON/OFF
switch to the ON (I) position.
6. Adjust the voltage source as necessary to achieve the desired
intensity.
7. Use the On/Stby button to toggle the LED on or off.
NOTE:
In Analog Mode, the Intensity Indicators will be off,
and the Intensity Adjustment buttons will be ignored.
Additionally, all RS-232 commands sent to increase or
decrease intensity will be ignored.
NOTE:
The unit can be powered on or off in either Front
Panel or Analog Mode. Switching between Analog
and Front Panel Modes may be done with the LED
either ON or in Standby. When switching from
Analog Mode to Front Panel Mode, previous Front
Panel Mode settings are restored.
NOTE:
The Analog Mode Input circuit is polarity specific. The
yellow conductor MUST be connected to the positive
terminal of the voltage source. The black conductor
MUST be connected to the negative terminal of the
voltage source.

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7.3 Using RS-232 Commands
The SugarCUBE™ features an RS-232 communications port, which (via
commands) can be used to remotely control all front panel functions.
Additionally, commands exist to provide more precise intensity adjustments as
well as helpful status indicators.
NOTE:
As with Analog Mode and the Relay Control,
associated
optional cables and RS232 interface
adapters are available for purchase at
www.ushio.com
7.3.1 Communications Connection Option 1
1. Flip the Main Power ON/OFF (I/0) switch to the OFF (0) position.
2. Using the Blank Communication Cable (P/N 38000-M03-021), connect
the host computer’s RS-232 port to the SugarCUBE’s RS-232 port. Use
the image below for reference.
3. Flip the Main Power ON/OFF switch to the ON (I) position.
4. The Power Indicator will flash approximately once per second to
indicate the unit is running and in Standby Mode.
5. The Intensity Indicators will display the current LED intensity level.
6. With an appropriate terminal program, computer commands can now
be transmitted to control the unit and query its status. The
communication protocol can be found in Appendix A.

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7.3.2 Communications Connection Option 2
OPTIONAL RJ11 to RJ11 Cable with RJ11 to DB9F Adapter P/N 38000-M03-020
1. Flip the Main Power ON/OFF (I/0) switch to the OFF (0) position.
2. Using the RJ11 to DB9F adapter kit (P/N 38000-M03-020), connect one
end of the RJ11 cable to the SugarCUBE’s RS-232 port.
3. Connect the opposite end of the RJ11 cable to the DB9F adapter.
4. Connect the DB-9F adapter to the host computer’s RS-232 DB9 port.
Refer to the image below for more connection information.
5. Flip the Main Power ON/OFF switch to the ON (I) position.
6. The Power Indicator will flash approximately once per second to
indicate the unit is running and in Standby Mode.
7. The Intensity Indicators will display the current LED intensity level.
8. With an appropriate terminal program, computer commands can now
be transmitted to control the unit and query its status. The
communication protocol can be found in Appendix A.

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8Troubleshooting
Fault Operation
SugarCUBE will not power on.
(Power Indicator LED not
illuminated.)
Check
Ensure the AC power cord is firmly seated in
the receptacle and connected to an
appropriate wall outlet.
Check
Ensure the Main Power ON/OFF (I/0) switch
is in the ON (I) position.
Check
Ensure AC power is available at the wall
outlet the unit is connected to.
Contact
Contact customer service for further
instructions.
No LED light output.
(Power Indicator LED flashes
approx. once per second and
one of the Intensity Indicator
LEDs is on.)
Check
The unit may be in Standby Mode. Press the
On/Stby button to turn the LED on.
Contact
Contact customer service for further
instructions.