Sharp R-610D Manuel

Coolwaver 2 610 UV Curing SystemCustomer Product ManualPart 1105120-01Issued 4/13NORDSON CORPORATION  AMHERST, OHIO  USATo order parts call 866-885-

Safety1-4Part 1105120-01E 2013 Nordson CorporationExposure to UV radiation can result inS reddening of skinS headachesS sore eyesX RAYSULTRAVIOLETINFR

Parts7-8Part 1105120-01E 2013 Nordson CorporationNoteQuantityDescriptionPartItem31 −−−−−−S SCREW, flat head, phillips, M3 x 10, steel, zincAR32 760529

Parts7-9Part 1105120-01E 2013 Nordson CorporationParts Illustration − External Blower Lamphead Parts 1291011357812141343A, 3B1516652123302122232820311

Parts7-10Part 1105120-01E 2013 Nordson CorporationBulbs Order the correct bulb for your application. Keep spare bulbs on hand toavoid unplanned downt

Parts7-11Part 1105120-01E 2013 Nordson CorporationSystem Cables See Figure 7-4. Order the correct cable length for your system.Item Part Description Q

Parts7-12Part 1105120-01E 2013 Nordson CorporationAccessories Part DescriptionAirShield Ventilation System − Captures the heated exhaust air from the

Parts7-13Part 1105120-01E 2013 Nordson CorporationOptional Lamphead Mounting Kit See Figure 7-6.Item Part Description Quantity Note− 1106333 KIT, brac

Parts7-14Part 1105120-01E 2013 Nordson Corporation

Specifications8-1Part 1105120-01E 2013 Nordson CorporationSection 8SpecificationsSystem Controller Specifications Table 8-1 Standard and Enclosure Mo

Specifications8-2Part 1105120-01E 2013 Nordson CorporationCurrent Draw Table 8-2 Power Line Current for 610 External Blower Line60 Hz 50 HzAmps @ 440

Specifications8-3Part 1105120-01E 2013 Nordson CorporationLight Output Settings Nordson CW2 UV OutputRemote InputRemote Input  mA/VDC% of UV Light Ou

Safety1-5Part 1105120-01E 2013 Nordson CorporationFirst Aid Seek immediate medical attention for skin burns and direct UV exposure tothe eyes.Microwav

Specifications8-4Part 1105120-01E 2013 Nordson CorporationLamphead Table 8-4 Lamphead Specifications Item SpecificationDimensions Refer to Section 3,

Specifications8-5Part 1105120-01E 2013 Nordson CorporationCONN6−1PLC INTF −− CANLPLC INTF −− CANHFAULTREADYREMOTE STDBYREMOTE OFF/RESETI/O BOARDREMOTE

Specifications8-6Part 1105120-01E 2013 Nordson CorporationCONN6−1PLC INTF −− CANLPLC INTF −− CANHFAULTREADYREMOTE STDBYREMOTE OFF/RESETI/O BOARDREMOTE

UV Glossary9-1Part 1105120-01E 2013 Nordson CorporationSection 9UV Glossaryabsorption Not reflecting. The partial loss in energy that results when lig

UV Glossary9-2Part 1105120-01E 2013 Nordson Corporationdose (dosage) Refer to energy density.dose rate (dosage rate) Refer to irradiance.dynamic expos

UV Glossary9-3Part 1105120-01E 2013 Nordson Corporationgermicidal UV Low-powered UV in the UVC band. Usually powered with several100-watt power suppli

UV Glossary9-4Part 1105120-01E 2013 Nordson Corporationlouver A part of a UV shutter system or shielding section that blocks the UVlight while allowin

UV Glossary9-5Part 1105120-01E 2013 Nordson Corporationoxygen inhibition Oxygen slows the cure response of UV curable coatings. The higherthe ratio of

UV Glossary9-6Part 1105120-01E 2013 Nordson Corporationquartz tube (1) A sealed tube made from a silicate material that is filled with aprecise mixtur

UV Glossary9-7Part 1105120-01E 2013 Nordson Corporationstarter bulb Used in the start up of microwave systems to ignite the mercury vaporin the bulb.s

Safety1-6Part 1105120-01E 2013 Nordson CorporationOzone readily reverts to breathable oxygen when mixed with atmosphericair. Ozone should be removed f

UV Glossary9-8Part 1105120-01E 2013 Nordson Corporationvacuum UV (100−200 nanometers)The portion of the electromagnetic spectrum ranging between 100 a

DeviceNet Specifications10-1Part 1105120-01E 2013 Nordson CorporationSection 10DeviceNet SpecificationsIntroduction This section covers the specificat

DeviceNet Specifications10-2Part 1105120-01E 2013 Nordson CorporationSystem Operation MAC ID / Baud Rate Configuration Three rotary switches are defin

DeviceNet Specifications10-3Part 1105120-01E 2013 Nordson CorporationLED Operation There are two LEDs on the rear panel. The first bicolor LED indicat

DeviceNet Specifications10-4Part 1105120-01E 2013 Nordson CorporationDeviceNet Interface Overview DeviceNet is a low cost and open industrial network

DeviceNet Specifications10-5Part 1105120-01E 2013 Nordson CorporationIdentity Object (01HEX − 1 Instance) The Identity Object provides descriptive inf

DeviceNet Specifications10-6Part 1105120-01E 2013 Nordson CorporationDeviceNet Object (03HEX − 1 Instance) Class Attributes (Instance 0) AttributeIDNa

DeviceNet Specifications10-7Part 1105120-01E 2013 Nordson CorporationAssembly Object (04HEX – 2 Instances) Class Attributes (Instance 0) AttributeIDNa

DeviceNet Specifications10-8Part 1105120-01E 2013 Nordson CorporationInstance 100 – Input Assembly 1 (Common)ByteIndexDescriptionDeviceNetData TypeCla

DeviceNet Specifications10-9Part 1105120-01E 2013 Nordson CorporationInstance 101 – Input Assembly 2 (Master/Slave 1−2)ByteIndexDescriptionDeviceNetDa

Safety1-7Part 1105120-01E 2013 Nordson CorporationMercury Bulbs (Lamps) The bulbs used in UV lamp systems contain mercury. Mercury is a toxicsubstance

DeviceNet Specifications10-10Part 1105120-01E 2013 Nordson CorporationSystem Bitmap (default in bold)BitValueBit7Bit6Bit5Bit4Bit3Bit2Bit1Bit01(ON)Mast

DeviceNet Specifications10-11Part 1105120-01E 2013 Nordson CorporationConnection Object (05HEX − 2 Instances) Class Attributes (Instance 0) AttributeI

DeviceNet Specifications10-12Part 1105120-01E 2013 Nordson CorporationCommon Services Service CodeImplemented forService NameClass Level Instance Leve

DeviceNet Specifications10-13Part 1105120-01E 2013 Nordson CorporationCommon Services Service CodeImplemented forService NameClass Level Instance Leve

DeviceNet Specifications10-14Part 1105120-01E 2013 Nordson CorporationException Detail Alarm / Warning Both the Exception Detail Alarm and the Excepti

DeviceNet Specifications10-15Part 1105120-01E 2013 Nordson CorporationLamp Object (64HEX − 16 Instances) Class Attributes (Instance 0) AttributeIDName

DeviceNet Specifications10-16Part 1105120-01E 2013 Nordson CorporationInstance Attributes (Instances 1−15) AttributeIDNameDeviceNetData TypeDataValueA

IndexiPart 1105120-01E 2013 Nordson CorporationIndexAAccessories, part numbers, 7-12Airshield ventilation systeminstallation, 3-17parts, 7-12BBalancin

IndexiiPart 1105120-01E 2013 Nordson CorporationEElectricalconnections, system controller, 3-3requirements, 3-3Exhaust, requirements, 3-16External blo

IndexiiiPart 1105120-01E 2013 Nordson CorporationLL COOL, message, 4-4Lamp on input, 3-8Lampheadair pressure, 4-2blowers, 3-15cable connection, 3-21de

Safety1-8Part 1105120-01E 2013 Nordson CorporationAction in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off

IndexivPart 1105120-01E 2013 Nordson CorporationPPanel lock, using, 4-3Partsaccessories, 7-12bulbs, 7-10cables, 7-11external blower lampheads, 7-7lamp

IndexvPart 1105120-01E 2013 Nordson CorporationShutdownfault, 4-13Normal, 4-13Shutter system, part number, 7-12Specificationsbulb, 8-4current draw, 8-

IndexviPart 1105120-01E 2013 Nordson Corporation

Product: Cool Wave, Cool Wave 2 and Cool Wave 2 Plus Models: CW-610V, CW2-610V, CW2+-610V, CW2I-610V, CW2+I-610V CW2-410V, CW2+-410V, CW2

Safety1-9Part 1105120-01E 2013 Nordson CorporationAll electrical power and other services must be disconnected and thelamphead must be cool before mov

Safety1-10Part 1105120-01E 2013 Nordson Corporation

Description2-1Part 1105120-01E 2013 Nordson CorporationSection 2DescriptionIntroduction This manual covers the Nordson CoolWave 2 610 Ultraviolet Micr

Description2-2Part 1105120-01E 2013 Nordson CorporationIn addition to ultraviolet light, the UV bulbs radiate heat. A constant flow ofcooling air thro

Description2-3Part 1105120-01E 2013 Nordson CorporationDescriptionComponentItem6 Magnetrons The magnetrons are 3 KW, 2450 MHz generators that convert

Part 1105120-01E 2013 Nordson CorporationAddress all correspondence to:Nordson UV Systems Inc.555 Jackson StreetAmherst, OH 44001United StatesTel:(80

Description2-4Part 1105120-01E 2013 Nordson CorporationMagnetron Operation and Life Magnetrons consist of a cathode built into the center of a circula

Description2-5Part 1105120-01E 2013 Nordson CorporationReflectors The reflectors are manufactured from borosilicate glass with a proprietarycoating to

Description2-6Part 1105120-01E 2013 Nordson Corporation3.1 Inch Focus Reflector Figure 2-3 3.1 Inch Focus Reflectors

Description2-7Part 1105120-01E 2013 Nordson CorporationFlood Reflector Figure 2-4 Flood Reflector Diagram

Description2-8Part 1105120-01E 2013 Nordson CorporationOptions Each CoolWave system lamp head can be fitted with optional patentedcomponents for maxim

Installation3-1Part 1105120-01E 2013 Nordson CorporationSection 3InstallationWARNING: Allow only qualified personnel to perform the following tasks.F

Installation3-2Part 1105120-01E 2013 Nordson CorporationS Leave at least six inches of ventilation clearance on all four sides of thesystem controller

Installation3-3Part 1105120-01E 2013 Nordson CorporationPower Connections NOTE: Power must be supplied from a dedicated source with a disconnectswitc

Installation3-4Part 1105120-01E 2013 Nordson CorporationPower Connections (contd)CW2-610 External BlowerT3 Control TransformerHigh VoltageT2T1480VH44

Installation3-5Part 1105120-01E 2013 Nordson CorporationL1L2 L3RF DetectorLamphead UnicableLampheadSystem ControllerInput PowerSourceNetwork SettingsM

Table of ContentsiPart 1105120-01E 2013 Nordson CorporationTable of ContentsSafety 1-1...Introduction 1

Installation3-6Part 1105120-01E 2013 Nordson CorporationPower Connections (contd)L1L2 L3RJ45 Network CableLamphead UnicableLamphead UnicableLamphead

Installation3-7Part 1105120-01E 2013 Nordson CorporationNetwork Connections See Figures 3-3, 3-4, and 3-5. Up to 16 system controllers can beconnected

Installation3-8Part 1105120-01E 2013 Nordson CorporationTable 3-3 Remote Inputs and Outputs ConnectorTypePin Function DescriptionInput16 Machine stop

Installation3-9Part 1105120-01E 2013 Nordson CorporationMachine Stop Interlock CAUTION: Allow only qualified personnel to service the equipment. Allp

Installation3-10Part 1105120-01E 2013 Nordson CorporationRemote Power Level Control The Remote Power Level Control (AIN inputs 4 and 5) function adjus

Installation3-11Part 1105120-01E 2013 Nordson CorporationNOTE: Do not leave the system controller in the standby mode for longerthan 30 minutes. Prol

Installation3-12Part 1105120-01E 2013 Nordson CorporationHardware Specifications The hardware design of the DeviceNet Interface follows ODVArecommenda

Installation3-13Part 1105120-01E 2013 Nordson Corporation115(4.53)150(5.906115(4.53)53.3 (2.1 Focus)78.8 (3.1 Focus)199.2 (7.84)266.4 (10.48)370(14.56

Installation3-14Part 1105120-01E 2013 Nordson Corporation265.00 [10.433]267.00 [10.512]63.20[2.488]115.00[4.528]200.96[7.91]667.00[26.260]FrontPressur

Installation3-15Part 1105120-01E 2013 Nordson CorporationOptional Mounting Kit for Lampheads An optional adjustable bracket, mounting plate, and screw

Table of ContentsiiPart 1105120-01E 2013 Nordson CorporationInstallation 3-1...Introduction 3-1...

Installation3-16Part 1105120-01E 2013 Nordson CorporationExternal Blower Lampheads For lampheads without internal blowers, the customer must supply co

Installation3-17Part 1105120-01E 2013 Nordson CorporationThe exhaust blower and duct size for each application will depend on manyvariables. Size all

Installation3-18Part 1105120-01E 2013 Nordson CorporationMonitoring Lamphead Air Pressure See Figures 3-13 and 3-14. The lamphead pressure sensor on t

Installation3-19Part 1105120-01E 2013 Nordson CorporationTop Pressure Port(Factory Connection)HoseBarbedFittingBottomPressurePortPort BHose Connection

Installation3-20Part 1105120-01E 2013 Nordson CorporationFrontPressurePortHoseBarbedFittingBottomPressurePort(FactoryConnection)Port BHose ConnectionF

Installation3-21Part 1105120-01E 2013 Nordson CorporationLamphead Cable Connections CAUTION: The unicable conducts high and low voltage between thesy

Installation3-22Part 1105120-01E 2013 Nordson CorporationRF Detector Installation See Figures 3-3 and 3-6 for RF Detector connections and Figure 3-16

Installation3-23Part 1105120-01E 2013 Nordson CorporationSystem Controller Configuration Once the system controller and lamphead are mounted and all c

Installation3-24Part 1105120-01E 2013 Nordson CorporationTable 3-5 Power Supply Configuration Settings Display Function Configuration 1 Configuration

Installation3-25Part 1105120-01E 2013 Nordson CorporationConfiguration 2Configuration 1FunctionDisplayPCTL Power control algorithm Y = Enable Power Co

Table of ContentsiiiPart 1105120-01E 2013 Nordson CorporationTroubleshooting 5-1...System Software Versions 5-1

Installation3-26Part 1105120-01E 2013 Nordson Corporation

Operation4-1Part 1105120-01E 2013 Nordson CorporationSection 4OperationWARNING: Allow only qualified personnel to perform the following tasks.Follow

Operation4-2Part 1105120-01E 2013 Nordson CorporationTable 4-1 CoolWave 2 Displays and Controls Item Control Description1 Main Power Switch Turns sy

Operation4-3Part 1105120-01E 2013 Nordson CorporationDescriptionControlItem9 Digital Display Displays power levels, operation and fault messages.10 PO

Operation4-4Part 1105120-01E 2013 Nordson CorporationOperating Messages Table 4-2 lists the messages that indicate operating status.Table 4-2 Display

Operation4-5Part 1105120-01E 2013 Nordson CorporationDescriptionFault MessageNo.10 DEVICENET ERROR There is a DeviceNet communication fault.11 DEVICEN

Operation4-6Part 1105120-01E 2013 Nordson CorporationSystem Timing Sequences NOTE: Refer to Section 5, Troubleshooting if the system fails duringstar

Operation4-7Part 1105120-01E 2013 Nordson CorporationChanging system status from LAMP ON to STANDBYTotal Seconds20 secondsDisplay reads LAMPON.Press S

Operation4-8Part 1105120-01E 2013 Nordson CorporationTiming Sequence with Idle = N (Also see Table 3-5)Powering ON the System ControllerTotal Seconds1

Operation4-9Part 1105120-01E 2013 Nordson CorporationCorrecting a Fault Condition Correcting a fault conditionTotal SecondsMax 60 seconds25 secondsDis

Table of ContentsivPart 1105120-01E 2013 Nordson CorporationSpecifications 8-1...System Controller 8-1...

Operation4-10Part 1105120-01E 2013 Nordson CorporationMultiple Units Networked to a Master UnitOperated LocallySingle Unit Operated LocallyStep5 Set t

Operation4-11Part 1105120-01E 2013 Nordson CorporationMultiple Units Networked to a Master UnitOperated LocallySingle Unit Operated LocallyStep7 Press

Operation4-12Part 1105120-01E 2013 Nordson CorporationRemotely Operated Units NOTE: The system can be wired to initiate lamphead start from either th

Operation4-13Part 1105120-01E 2013 Nordson CorporationShutdown CAUTION: Do not shut off the system with the main power switch while thelamps are oper

Operation4-14Part 1105120-01E 2013 Nordson Corporation

Troubleshooting5-1Part 1105120-01E 2013 Nordson CorporationSection 5TroubleshootingWARNING: Allow only qualified personnel to perform the following t

Troubleshooting5-2Part 1105120-01E 2013 Nordson CorporationFault Message Troubleshooting Problem Possible Cause Corrective ActionFault 0:FAULT NETWORK

Troubleshooting5-3Part 1105120-01E 2013 Nordson CorporationCorrective ActionPossible CauseProblemFault 7:FAULT NO LIGHTDETECTEDLamp FaultThe light det

Troubleshooting5-4Part 1105120-01E 2013 Nordson CorporationCorrective ActionPossible CauseProblemFault 15:FAULT POWER CTRL ATLIMITPower control at lim

Troubleshooting5-5Part 1105120-01E 2013 Nordson CorporationCorrective ActionPossible CauseProblemFault 20:FAULT RF DETECTORTRIPRF Fault.High RF field

Safety1-1Part 1105120-01E 2013 Nordson CorporationSection 1SafetyIntroduction Read and follow these safety instructions. Task- and equipment-specificw

Troubleshooting5-6Part 1105120-01E 2013 Nordson CorporationCorrective ActionPossible CauseProblemFault 27:FAULT PHASECONTROLLER ERRORControl does not

Troubleshooting5-7Part 1105120-01E 2013 Nordson CorporationCuring Process Troubleshooting Problem Possible Cause Corrective ActionSystem running corre

Troubleshooting5-8Part 1105120-01E 2013 Nordson CorporationDiode Block TestingWARNING: Shut off power to the system controller, allow the capacitorst

Maintenance and Repair6-1Part 1105120-01E 2013 Nordson CorporationSection 6Maintenance and RepairWARNING: Allow only qualified personnel to perform t

Maintenance and Repair6-2Part 1105120-01E 2013 Nordson CorporationSystem Controller Repair Procedures Preparation 1. Turn off the UV system from the p

Maintenance and Repair6-3Part 1105120-01E 2013 Nordson CorporationFuse F3160 mAFuse F13 AFuse F23 AFuse F42 AFigure 6-1 Main Control Board FusesF130 A

Maintenance and Repair6-4Part 1105120-01E 2013 Nordson CorporationLamphead Maintenance and Repair Table 6-1 lists typical maintenance guidelines and r

Maintenance and Repair6-5Part 1105120-01E 2013 Nordson CorporationInternal Blower Lamphead Filter Replacement WARNING: Turn off the lamp and allow th

Maintenance and Repair6-6Part 1105120-01E 2013 Nordson CorporationBulb Replacement (contd)Figure 6-3 RF Screen RemovalCAUTION: Do not touch the bulb

Maintenance and Repair6-7Part 1105120-01E 2013 Nordson CorporationReflector Replacement Two types of reflectors may be used in the lamphead: Flood or

Safety1-2Part 1105120-01E 2013 Nordson CorporationIntended Use Nordson ultraviolet (UV) equipment is intended specifically for integrationinto other m

Maintenance and Repair6-8Part 1105120-01E 2013 Nordson CorporationReflector Replacement (contd)NOTE: Great care should be taken when replacing refle

Maintenance and Repair6-9Part 1105120-01E 2013 Nordson Corporation7. Set the retaining brackets in place. The placement of the retainingbrackets diffe

Maintenance and Repair6-10Part 1105120-01E 2013 Nordson CorporationInternal Blower Replacement 1. See Figure 6-11. Remove the blower cover by removing

Maintenance and Repair6-11Part 1105120-01E 2013 Nordson CorporationInternal Blower Lamphead Complete Cover Removal 1. Disconnect the unicable from the

Maintenance and Repair6-12Part 1105120-01E 2013 Nordson CorporationInternal Blower Lamphead Complete Cover Removal (contd)Lifting Bottom CoverUnicabl

Maintenance and Repair6-13Part 1105120-01E 2013 Nordson CorporationExternal Blower Lamphead Cover Removal See Figure 6-15. Remove the 11 screws (3 top

Maintenance and Repair6-14Part 1105120-01E 2013 Nordson CorporationPreparation (contd)5. See Figure 6-17. Pull the the transformer bracket from the w

Maintenance and Repair6-15Part 1105120-01E 2013 Nordson Corporation4. See Figure 6-19. Remove the four nuts that secure each magnetron tothe wave guid

Maintenance and Repair6-16Part 1105120-01E 2013 Nordson CorporationFilament Transformer Replacement (contd)5. See Figure 6-20. Note the colors of the

Maintenance and Repair6-17Part 1105120-01E 2013 Nordson Corporation9. See Figure 6-22. Arrange the secondary cable ferrites of bothtransformers as sho

Safety1-3Part 1105120-01E 2013 Nordson CorporationPersonal Safety To prevent injury follow these instructions.S Do not operate or service equipment un

Maintenance and Repair6-18Part 1105120-01E 2013 Nordson CorporationLight Detector Board Replacement 1. Follow steps 1−5 under Preparation. 2. See Figu

Maintenance and Repair6-19Part 1105120-01E 2013 Nordson CorporationSocketRTVFigure 6-24 Starter Bulb ReplacementRe-Assembly 1. Check all wiring connec

Maintenance and Repair6-20Part 1105120-01E 2013 Nordson Corporation

Parts7-1Part 1105120-01E 2013 Nordson CorporationSection 7PartsIntroduction To order parts, call the Nordson Industrial Coating Systems CustomerSuppor

Parts7-2Part 1105120-01E 2013 Nordson CorporationSystem Controller Repair Parts See Figure 7-1.Item Part Description Quantity Note− - - - - - - 50/60

Parts7-3Part 1105120-01E 2013 Nordson CorporationT2T3T1ABCCR1CR2T1T2T3T3CR112344256789A9B9c9d1052112(Cover)1315141617181920242223Figure 7-1 CoolWave 2

Parts7-4Part 1105120-01E 2013 Nordson CorporationCW-2 Internal Blower Lampheads See Figure 7-2.Item Part Description Quantity Note− 1103923 LAMPHEAD,

Parts7-5Part 1105120-01E 2013 Nordson CorporationNoteQuantityDescriptionPartItem28 −−−−−−S WASHER, flat, regular, M4, brassAR29 −−−−−−S WASHER, lock,

Parts7-6Part 1105120-01E 2013 Nordson CorporationParts Illustration − Internal Blower Lamphead Parts 1033A, 3B212265323334303135(CoverScrews)578121413

Parts7-7Part 1105120-01E 2013 Nordson CorporationCW-2 External Blower Lampheads See Figure 7-3.Item Part Description Quantity Note− 1074677 LAMPHEAD,