Uvitron SUNRAY 400 SM User manual

UV/Visible Flood
Curing Lamp
INSTRUCTION
MANUAL
PN: UV0446
Uvitron International, Inc. • 150 Front Street, Unit 4 • West Springfield, MA 01089
Phone [phone] • Fax [phone] • http://www.uvitron.com
INFORMATION IN THIS MANUAL IS SUBJECT TO CHANGE WITHOUT NOTICE

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 2 of 23
CONTENTS
Section
Page
1.0 Introduction
……………………………..……….
3
1.1 Purpose of Manual
……………………………..……….
3
1.2 Purpose of Equipment
……………………………..……….
3
1.3 Unpacking
……………………………..……….
3
1.4 List of Included Parts
……………………………..……….
3
2.0 Installation
……………………………..……….
4
2.1 General
……………………………..……….
4
2.2 Mounting
……………………………..……….
5
2.3 Shielding
……………………………..……….
5
2.4 Dimensions
……………………………..……….
6
3.0 Safety Considerations
……………………………..……….
6
3.1 UV Safety Warning
……………………………..……….
6
3.2 Electrical Safety
……………………………..……….
6
3.3 High Temperatures
……………………………..……….
6
3.4 Ozone Safety
……………………………..……….
7
3.5 Lamp Recycling
……………………………..……….
7
4.0 Theory of Operation
……………………………..……….
8, 9
5.0 Controls and Indicators
……………………………..……….
10, 11
6.0 System Operation
……………………………..……….
12
6.1 Startup
……………………………..……….
12
6.2 Shutdown
……………………………..……….
12
7.0 External Interface
……………………………..……….
13
7.1-7.2 External Interface Wiring & Signals
……………………………..……….
13-15
8.0 Maintenance
……………………………..……….
16
8.1 Maintenance Considerations
……………………………..……….
16
8.2 Cleaning of Optics & Lamp Replacement
……………………………..……….
16
8.3 Fan Filter
……………………………..……….
17
8.4 Cleaning of Optional UV Shields
……………………………..……….
17
9.0 Troubleshooting
……………………………..……….
18
10.0 Replacement Parts & Accessories
……………………………..……….
19
11.0 Technical Specifications
……………………………..……….
20, 21
12.0 Block Diagram
……………………………..……….
22
13.0 Warranty Information
……………………………..……….
23

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 3 of 23
INTRODUCTION
1
1.1 Purpose Of Manual
The purpose of this manual is to provide installation, operation and troubleshooting
instructions for the Uvitron International SunRay 400SM Light Cure System. It is important
the manual be read carefully before any attempt is made to install and operate the
equipment.
1.2 Purpose Of Equipment
The system is a bench-top or conveyor mounted light cure source, designed for the rapid
curing of light cure adhesives. The unit is suitable for laboratory use or volume production
applications.
1.3 Unpacking
Visually inspect the shipping carton for physical damage. Damaged shipping cartons should
be reported to the carrier. Carefully open the carton and remove the equipment, being careful
not to lose or damage any separately packed parts.
Check all parts against the parts list. Any damaged or missing parts should be reported to the
carrier and to your UVITRON representative.
All packing material and the shipping carton should be saved in case the unit has to be
returned at some future time.
1.4 List Of Included Parts
1. One (UV0446) SunRay 400SM Lamp Head with Standby power switch and Lamp
Hour Meter.
2. One (UV0320) 400-Watt UVA enhanced metal halide lamp (installed).
3. One (UV2128) glass filter plate (installed).
4. One (UV0495) pair of UV/IR protective OTG glasses, 3.0 shade with case.
5. One (UV0341) Power Cord, 7’6” U.S. version (other types also available).
6. One (UV0503) SunRay 400SM owner’s manual.
Optional Parts
1. One (UV0454) UV Flood Stand, consisting of post, base plate, & 2 screws with nuts.
2. One (UV0455) Wrap-around UV Flood Shield, Front.
3. One (UV1094) UV Flood Shield, Backside

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 4 of 23
INSTALLATION
2
2.1 General
The SunRay 400SM light cure system may be placed on any bench or shelf that has access
to a 120/240V 50/60-cycle single-phase power source in a clean operation area. Since it is an
air-cooled unit, dust or airborne particles can clog the internal cooling passages and cause
overheating. Allow a 6 inch clearance on all sides for unrestricted airflow.
2.2 Mounting
The Lamp Housing Assembly should always be
mounted on a stand, or held away from any flammable
surfaces. Never place the Lamp Housing Assembly
directly on the work surface. The SunRay is designed to
be stand mounted using the optional UV0454 Flood
Stand. The unit’s rear mounted clamping bracket allows
the lamp’s height to be slide adjusted on the Flood
Stand for optimum curing distance (see fig. 1).
For machine or conveyor mounting applications, the
lamp housing assembly can be optionally mounted
using the threaded holes for the clamping bracket
assembly (see fig. 2). Simply remove the clamping
bracket, and reuse its mounting holes and screws to
attach to the desired mounting surface. If longer screws
are required, care should be taken not to exceed the
maximum mounting hole penetration depth of 1.25”.
(See fig. 3 for mounting hole pattern dimensions).
4 x 8-32 mounting
screws at rear side of
SunRay enclosure
Fig. 2, mounting hole locations
Fig. 1, SunRay with
optional Stand & UV Shield

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 5 of 23
INSTALLATION (CONTINUED)
2
The lamp housing assembly can also be placed on a shelf type structure, supporting the unit
by its bottom outside edges. For this type of mounting, a windowed hole must be cut in the
shelf, which would provide adequate clearance for the unit’s bottom-side light exposure
opening, and also for the cooling air exhaust holes.
2.3 Shielding
All installations should incorporate adequate shielding of radiated UV light, in order to prevent
eye and skin burn of the operator or others passing through the work area (refer to UV Safety
Warning in the following Safety Considerations section of the manual). The optional UV0455
Wrap-around Front Flood Shield and the UV1094 Backside Flood Shield can be used with
the SunRay to minimize the amount of stray UV light scattering in the work area. Custom
shielding may be constructed using sheet metal, UV blocking acrylic or polycarbonate to
prevent operator exposure to UV radiation.
WARNING: To prevent risk of eye or skin burn, all personnel must be protected from
direct or indirect exposure to the UV light produced by the SunRay curing system.
Extreme care should be used when designing custom UV shielding to insure
personnel will not be exposed to harmful UV radiation. Additionally, UV protective
glasses and protective clothing should be used at all times while working in the vicinity
of the UV curing system.
2.4 Dimensions
Fig. 3, SunRay overall dimensions

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 6 of 23
SAFETY CONSIDERATIONS
3
3.1 UV Safety Warning
Ultraviolet radiation can cause severe burns to eyes and skin. Do not look at
the light without protective eye shielding (UVITRON UV/IR safety glasses Part
No. UV0495, UV2231 or equivalent).
While thermal burns are felt immediately, UV burns are not felt for several hours. Short
exposure to UV lamp radiation can cause severe burning of skin and eyes. UV burn of eyes
affects the cornea and burning takes several days to heal. UV burn is identical to “Welders
Burn” and will feel like sand in the eyes that cannot be washed out. The discomfort is
temporary and has no lasting effects. Some effects of UV radiation can cause permanent
damage to the eyes. Never look directly at the operating arc lamp, with or without UV
protective glasses.
Exposure to UV radiation of only limited time will cause erythema (redness) on normal skin.
Remember that a few seconds of exposure to direct radiation of the lamp can cause burns
equal to a day in the sun. Such redness is temporary and will not produce blistering, or
tanning, as only a small amount of radiation penetrates deeply. Extended exposure to UV
radiation can lead to skin cancer. When operating the unit in production, the use of protective
clothing and cotton gloves is required.
3.2 Electrical Safety
High voltage and current energize the UV Lamp. A high voltage power supply
and Starter combination are designed to provide lamp-starting voltages, to limit
current, and subsequently provide a uniform output of energy. To avoid the risk
of electrical shock, do not remove the Lamp Access Panel or attempt to replace
the lamp before turning off the Power Input switch, and disconnecting the Input Power Cord.
The electrical system of this unit should be serviced by only UVITRON service personnel.
3.3 High Temperatures
Due to the high output power of this system, high temperatures may be present
on the surfaces of the Lamp, Reflector, and Lamp Housing Assembly. Extreme
care should be taken to prevent touching any of these surfaces before allowing
sufficient time for all temperatures to drop to safely back to room temperature
after power has been removed. Also, the Lamp Housing Assembly should
never be placed on or near any flammable surface while the lamp is on, or before its
temperature has cooled back to room temperature. Never place the lamp head or parts to be
cured on a heat sensitive surface. Always cure parts on a metallic or non-flammable surface.
WARNING: Placing the Lamp Housing Assembly on or near flammable surfaces while the
lamp is on, or still hot could result in fire.

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 7 of 23
SAFETY CONSIDERATIONS (CONTINUED)
3
3.4 Ozone Safety
High concentrations of ozone (O3) can cause discomfort, or at sufficiently
high levels can be dangerous. Arc lamps that are used in light curing
systems may generate ozone when oxygen in the air is exposed to short
wavelengths of light produced by the lamp (<210 nm). This ozone generation
can be avoided by using arc lamps that are constructed with ozone-free
quartz glass, which absorbs the ozone producing wavelengths. This type of
glass is used in Uvitron’s UVA and visible type lamps. Unfortunately, this ozone-free glass
also can reduce the effectiveness of some curing processes that may require the absorbed
short wavelengths (e.g. those for some inks and coatings). For this reason, Uvitron’s UVB
type lamps are not constructed with ozone-free glass, and should be used only in well
ventilated work areas. Another way to cope with the ozone is to exhaust the lamp air
outdoors. Such exhausting involves no danger as the hot ozone containing gas is very
unstable and breaks down to oxygen rapidly in ducting.
Although some SunRay system configurations generate ozone at a level that could barely be
detected by odor and at a level well below the 0.1 parts per million allowable limit for
continuous exposure (American Conference of Government Hygienists), it is recommended
that all SunRay lamps systems be operated in well ventilated areas. For U.S. government
recommended ozone exposure limits and additional ozone safety information, visit the
following OSHA web page:
https://www.osha.gov/dts/chemicalsampling/data/CH_259300.html
3.5 Lamp Recycling
UV curing arc lamps (sometimes referred to as bulbs) all contain some level of mercury, and
should be disposed of responsibly in accordance to local, state and federal
laws. Excellent guidelines for mercury lamp recycling can be obtained at the
following National Electrical Manufacturers Association website:
www.lamprecycle.org
Or call Uvitron customer service at [phone] for more information.

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 8 of 23
THEORY OF OPERATION
4
4.1 Light Curing
Ultraviolet Light (UV) exists around us as one of nature's phenomenon, an example of which
is Ultraviolet (UV) rays produced by natural sunlight. Ultraviolet light can also be artificially
produced by an electrical arc lamp enclosed in special glass to allow it passage (a UV arc
lamp).
Reactive materials called photoinitiators are added to resins for adhesive bonding, coating,
sealing, and printing. Ultraviolet light will cure these adhesives by causing the liquid resin to
polymerize, thus becoming a solid. This could be compared to two part epoxies, which when
mixed in the proper proportions, turn from a liquid to a solid. Light curing resins, on the other
hand, are single component products ready to use as received without measuring or mixing,
and cure on-demand when exposed to UV light.
The photoinitiators added to the adhesive chemistry react to a specific range of light
wavelengths, and the speed of the reaction is governed primarily by the intensity (or
irradiance) of the light source for those wavelengths and by the chemistry of the adhesive.
Approximate adhesive cure time can be calculated as follows:
Curing Time [seconds] = Light Energy [Joules/cm2] / Light Intensity [Watts/cm2]
Adhesive manufactures typically specify the energy required for curing, or the required
intensity and time duration. For some adhesive types, the relationship between the speed of
curing and lamp intensity is not linear (doubling the intensity does not offer half the cure
time). The fastest and most complete reaction may occur at high peak intensity for a relatively
short period of time. This may be a more effective type of curing as compared to a similar (or
even a higher) dose of UV light, which is spread over longer period of time.
NOTE: Various types of adhesives, inks and coatings from different manufacturers
have different levels of reactivity which will require adjusting of exposure times for
proper curing. Consult with the adhesive manufacturer for appropriate cure times for
each type of material.
Light curable adhesives are typically cured using electromagnetic energy in the UV and
visible ranges of 250 to 450 nanometers (nm). It should be noted that ultraviolet light is easily
attenuated when attempting its transmission through any materials that are not extremely
transparent or optically pure. Even window glass will have reduced transmission or block
most UV wavelengths, and this attenuation is greater as wavelengths become shorter. For
this reason, applications that call for deep curing through thick adhesives layers require the
longer light wavelengths in the UV-A and visible ranges for maximum penetration. These
longer wavelengths are also required for curing through more opaque or colored adhesives
and substrate materials to reduce the affect of attenuation. Shorter wavelengths in the UV-B

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 9 of 23
THEORY OF OPERATION (CONTINUED)
4
and UV-C regions have more energy and are effective for curing and removal of surface tack
for thin layers of coatings, inks and paints.
To allow the SunRay curing system to adapt to these different types of curing applications,
multiple replacement lamp types are available which are optimized for each of the visible,
UVA and UVB wavelength ranges. See the Accessories list in section 10.2 for ordering part
numbers of the optional lamp types.
Refer to the chart below for the wavelength ranges of the ultraviolet and visible light curing
bands of the electromagnetic spectrum.
ELECTROMAGNETIC SPECTRUM
Short
Waves
Gamma
Rays
X-
Rays
Ultraviolet
Light
Visible
Light
Infrared
Micro
Waves
Radio
Waves
Long
Waves
Range
Vacuum
UV
UV-C
UV-B
UV-A
Violet
Blue
Green
Yellow
Orange
Red
Wavelength
[nm]
100-200
200-
280
280-
315
315-400
400-
440
440-
490
490-
570
570-
585
585-
620
620-
780
4.2 System Information
The SunRay 400SM has a very high power density light output, which will result in rapid, high
bond strength cures. The light intensity can be controlled somewhat by adjusting the distance
of the lamp head to the substrate being cured (larger distance results in lower light density
and intensity). Intensity can also be adjusted by switching the system’s front panel lamp
power switch between full and standby settings, which will reduce intensity by approximately
one half. The lower power standby setting can be used for very reactive adhesives, or for
temperature sensitive curing substrates.
The SunRay 400SM utilizes a metal halide type arc lamp, which is powered by a tightly
regulated switch-mode power supply. This combination provides high intensity and consistent
light output, resulting in very fast and repeatable product curing.
A system block diagram is shown in Figure 8.

Uvitron International SUNRAY 400SM Instruction Manual, Rev. H
Page 10 of 23
CONTROLS AND INDICATORS
5
Fig. 4, Location of controls and indicators
(1) Handle
(3) Lamp
Full/Standby
Power Switch
(2) Lamp Hour Meter
(8) Height
adjustment knob
(7) Cooling Fan w/
removable filter
(6) Input Power
Switch &
Receptacle
(4) Lamp
Access Panel
(5) DSUB
Interface
Connector