Fusion F300S manual

F300S/F300SQ Ultraviolet Lamp System Inst allation, Operatio n, and Maintenance Manual No. 5092 52 Rev R 3/04 FUSION UV SYSTEMS, INC. 910 Clopper Road Gaithersburg, MD 20878-1357 USA (301) 527-266 0 • FAX (301) 527-2661[...]

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F300S/F300SQ Ultraviolet Lamp System Inst allation, Operation, and Maintenance Manual No. 5092 52 Rev R 3/04 Applies to systems using P300M/ P300MQ/P300MT power supplies, and I300M/I310M serie s irradiators Serial Numb ers 1001 and late r. (C) Copyright 2004 Fusion UV Systems, Inc. All Rights Reserved. The products cove red herein co nform to EC st[...]

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Installation, Operation, an d Maintenance Manual # 509252 R ev R 5 Table Of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Indications of Note, Caution, Warnin g, and Danger . . . . . . [...]

6 F300S/F300SQ Ultraviolet Lamp System Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 UV Curable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Chapter 2. Mechanical Installa tio[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 7 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 System Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Frequency Tapping of HV Capacitors . . . . . . . . . . . . . . . . . . . 51 QRO HV Capacitors (F or QRO only) .[...]

8 F300S/F300SQ Ultraviolet Lamp System Bulb, Screen, and Reflector Mai ntenance . . . . . . . . . . . . . . . . 79 Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Bulb Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Reflector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 9 Control Card Removal/Replacement . . . . . . . . . . . . . . . 107 Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 High Voltage Transformer Removal/Replacement . . . . . .[...]

10 F300S/F300SQ Ultraviolet Lamp System P300M/P300MT Power Supply Parts List . . . . . . . . . . . . . . . . . . . 144 P300MQ Quick Restart Option Parts List . . . . . . . . . . . . . . . . . . . 146 K300 Blower Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . 147 Appendix F. Ignitor Bulb . . . . . . . . . . . . . . . . . . . . . .[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 11 Introduction This manual is designed to be used, not set aside until problems occur. The following list of chapters and appendixes describes where to find info rmation in this manual. • This Introduction provides a brief descript ion of the total system, and system components. It[...]

12 F300S/F300SQ Ultraviolet Lamp System • Appendix C, “Outline Drawings,” cont ains drawings that provide overview detail s for general reference for Fusion UV Sy stems products. These drawings are not to be used in designing an installation; contact Fusion directly for current specifications. • Appendix D, “Lamp Syst em Maintenance Log,?[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 13 DANGER: Danger indications identify cond itions where deat h or permanent injury to personnel can occur if proper procedures and precautions are not followed. Icon Usage Several icons are used through out the documentation to identify the types of hazardous resources or technologie[...]

14 F300S/F300SQ Ultraviolet Lamp System CAUTION: Ultraviolet Radiation This icon identifies instance s where damaging levels of ultraviolet radiation may be prese nt. Adequate shielding around the equip ment and region must be pro vided, and personnel should be required to wear goggles with UV certified lenses. All personnel within t en feet of the[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 15 System Description The Fusion Ultraviolet Lamp System has b een designed specifically fo r applications involving the industrial curing of inks and coatings and may b e used effectively for a wide variety of applications. An ultraviolet (UV) l amp system for indust rial curing must[...]

16 F300S/F300SQ Ultraviolet Lamp System Figure 1. F300S/F300SQ Lamp System The F300S/F300SQ Fusion UV Lamp System ( Figure 1 ) is modular, consisti ng of independent 6-inch (15.2 cm) lamp un its and corresponding modular power su pplies. Two lamps can be placed end-to-end to form a 12-inch (30.5 cm) lamp system or can be placed in a continuous arra[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 17 Electrical inputs to the lamp module are provi ded by a high voltage/ control cable with a quick-connect fitting which supp lies power for the magnet ron, filament transformer and the interlock circuitry. System Components The basic F300 S/F300SQ system consists of the following it[...]

18 F300S/F300SQ Ultraviolet Lamp System Cooling Proper operation of the lamp requires adequate cooling o f the magnetron an d the bulb. (See Appendix C, page 1 29 , for irradiator cooling requirements.) Coo ling air from a blower goes through the magnetron coolin g fins and into the lamp housing. At this point, the airflow splits into two paths: on[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 19 The following table lists the various irradiator model s manufactured by Fusion UV Systems, and describes th eir high-level differences. Reflector and Cavity The top of the reflector cont ains two rectangular slots wh ich admit microwave en ergy into the cavity. The slots are fed b[...]

20 F300S/F300SQ Ultraviolet Lamp System Mounting The lamps can be mounted over a moving substrate or web, supported by the bottom rails. The lamps should be m ounted so that the rails sit 53 mm (2.1") above the surface to be cured. This allows the elliptical reflector to focus the most intense strip of light very near the substrate. Power Supp[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 21 Figure 4. P300M Front Panel Warranty Policy Items manufactured by Fusion UV Systems In corporated are warranted (under norm al and proper use) to be free from defects in material and workmanship. Fusion UV Systems will repair or replace, at its optio n, any defective part s when re[...]

22 F300S/F300SQ Ultraviolet Lamp System NOTE: Any repairs or alterations, incl uding the use of non-Fusion UV Systems (Fu sion) parts, made by the user of this product without Fusion UV Systems’ prior written consent shal l void all warran ties provided by Fusion UV Systems and such wa rranties shall cease to be in effect. No allowance will be gr[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 23 Irradiators Irradiators should be return ed in their original pa ckaging. If this is n ot available, la mps must be double b oxed, as follows: The lamp is to be placed in an inner box, us ing cardboard fills to assure a snug fit. The RF screen should be protected by taping a piece [...]

24 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 25 Chapter 1. Safety Fusion UV Systems’ Ultravio let (UV) L amp Systems ha ve been designed to operate safely. Many systems are in production in a wide variety of industrial environm ents without any problems of work er safety or health hazar ds. However, like most industrial equipm[...]

26 F300S/F300SQ Ultraviolet Lamp System Ultraviolet Radiation There are no present U.S. government stan dards on wo rker exposure to ultraviolet light. However, there is a NIOSH doc ument, “Criteria for a Recommended Standard...Occupational Exposure to Ult r aviolet Radiation” (No. HSM 73-11009), and several useful publications are availabl e f[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 27 Personnel Effects of Microwave Radiation OSHA (U.S. Department of Labor, O ccupational Safety, an d Health Administrati on - Standard 29CFR 1910 .97) and AN SI (American Natio nal Standards Institute - Standard C95.1-1999) are the only m ajor national organizations with volu ntary [...]

28 F300S/F300SQ Ultraviolet Lamp System Ozone The Fusion UV Lamp System makes less ozone than a conventional arc lamp. For example, a pair of lamps running fo r twelve h ours in a non-vented room resulted in a steady state concentration of less than 0.02 parts per million. This was a level that could barely be detected by od or and a factor of fiv [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 29 High Voltage Insulated electrical cables carry power at 3900 Volt s from the power supply to th e lamp. These voltages can be dangerous, so some precautions should be taken in both the location and protectio n of these lines. High voltage s are exposed within the po wer supply chas[...]

30 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 31 Chapter 2. Mechan ical Installation Mechanical Installation Checklist Before operating the ultraviol et lamp system for the first tim e, be sure the following procedures have been completed. This chapter describes the physical installatio n of the F300S/F300SQ Fusi on UV Lamp Syste[...]

32 F300S/F300SQ Ultraviolet Lamp System Preliminary unpacking and insp ection should be completed im mediately on receipt of equipment to allow time for repair or repl acement if necessary prior to installing the equipment. The P300M/P300MQ power supplies are shipped with six large Ph illips head screws holding the cover to the chassis. There ar e [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 33 Irradiator Mounting The irradiator mounting stru cture must also provide UV shielding and adequate venting for the cooling air. Th is is described on the following pages. Each user will normally design the mounting structure to suit the parti cular application, and the user is resp[...]

34 F300S/F300SQ Ultraviolet Lamp System Lamps Mounted in Opposing Configuration Figure 6. Lamps in Opposing Configuration UV Light Shielding Adequate light shielding must be provid ed for each irradiator in the system. If shielding is not used, or if UV light escapes around the irradiator support , the operator must wear a welder’s helmet or UV b[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 35 The louvers which al low the flow o f cooling air away from the irradiator must be of a light shielding desi gn. (For more inform ation on safety considerations, see Chapter 1, “Safety.” ) RF Detector Mounting Figure 7 illustrates the proper mounting of th e RF Detector. Figure[...]

36 F300S/F300SQ Ultraviolet Lamp System Remote Blowers An optional remote blower package is available from Fusion UV Systems. The package includes an air distri bution plenum (for multi-lamp systems), inlet filter box , and flexible hoses or ducts for cooling the system. The blower d elivers 2.8 m 3 /min (100 cfm) of air to each irradiator inlet at[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 37 Figure 8. Quartz Pla tes - Example Mount ing Design Quartz plate mounting structure Irradiator Removal access for cleaning Quartz plate (pair) P/N 300291 152.4 mm x 152 .4 mm x 2.29 m m (6.00 in x 6.0 0 in. x 0.90 i n.) Irradiator cooling air flow Substrate to be c ure d Irradiator[...]

38 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 39 Chapter 3. Electrical System This chapter discusses the electrical insta llation and electrical se tup aspects of the F300S/F300SQ Ultraviolet Lamp System. Electrical Installation/Setup Checklist Before operating the ultraviol et lamp system for the first tim e, be sure the followi[...]

40 F300S/F300SQ Ultraviolet Lamp System Interconnect Cables The F300S/F300SQ interconn ect cables and connector co ntact kits are listed in Appendix B, “Cables and Connectors” . See this list for the available varieties and lengths. Connection and Program Log To facilitate operation and maintenance, it is advisable to keep a record of the input[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 41 1. Disassemble the strain relief housing by removing th e retaining screws and unscrewing the housin g from the connecto r body. 2. To connect EXT INTLK or SYS BLWR inputs, remove jumper wires and the attached pins as indicated in Table 5 , Table 6 , and Table 7 in this chapter. 3.[...]

42 F300S/F300SQ Ultraviolet Lamp System Figure 10. Locatio n of Programming Switch S1 on PWB K1 J9 J10 J8 J6 J5 JP2 J7 J3 J4 J1 J2 J14 J15 J16 J1 1 K3 K4 K5 K2 TP1 TP2 DS1 S1 S2 S3 F1 F2 F3 q 0 0 0 8 ASSY P /N 32755X OFF/ RST M ASTE R ON MAST ER HI / LO MA STE R UNIT TO SYS RF M ASTER QRO[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 43 Figure 11. Table A: Programming Switch S1 Single Unit Programming and Connections The programming and connections necessary to operate a singl e-unit F300 S/F300SQ system are summarized in Figure 12 . POS6 POS5 POS4 Switch Pos ition 1, 2, and 3[...]

44 F300S/F300SQ Ultraviolet Lamp System Figure 12. F300/F3 00SQ Single-unit Installation Programming Select one unit as the Master. Set S1-1, 1-2, 1-3, and 1-5 of this unit to “YES.” For programming switch S1 setting definitions, see Figure 11 . Irradiator Cable H340 Connections Non-blower version cable H 340 connects to J103 and J1 04 on the p[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 45 Input/Output Connections The P300M/P300MQ/P300MT has three custom er use interlock inputs. A fault condition on any of these inputs will cause the system to shut down; the fault must be corrected before the system can be restarted. There must be one RF detector per sy stem. The rem[...]

46 F300S/F300SQ Ultraviolet Lamp System NOTE: A dry contact (such as a relay contact or a PLC containing a relay contact) with gold contact material shoul d be used to drive the remote inputs. The cable length to the dry contact should be n o more than 6 met ers. Shielded cable should be used to minimize possible electrical inte rference. In a mult[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 47 NOTE: When using circuit currents for K1-K5 belo w 10mA, contact Fusion UV Systems Customer Service. Alternate Function for K5 An alternate K5 function may be selected by inst alling a jumper onto JP2 on the control card. The STANDBY-READY functi on is asserted (K5 closed) when the[...]

48 F300S/F300SQ Ultraviolet Lamp System Multiple-Unit Programming and Connections Programming and connections for mult iple-unit systems are summarized in Fi gure 13 . Typically, one uni t will oper ate as the MASTER and all others as slaves to the ON/OFF commands of this Master unit. Refer to detailed description s in Chapter 4, “Operation” of[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 49 Programming Refer to Figure 11 for programming swit ch S1 settings and set programm ing switches of each power supply as follows: 1. Select one unit as the Master. Set S1-1, 1-2, 1-3 and 1-5 of this unit to YES. 2. Set S1-1, 1-2, 1-3, and 1-5 of all slaves to NO. 3. To shut down al[...]

50 F300S/F300SQ Ultraviolet Lamp System Power Source NOTE: If a lin e voltage greater than 230V and a frequen cy of 50 Hz is used, see the “F300S Relay Coil Resistor Assembly Installation” on page 53 at the end of this chapter. System Power Connections Figure 14. Power Supply Front Pane l Listed current ratings indicate current dema nds during [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 51 North American Appl ications: 3x12 AWG UL listed International A pplications: 3x2.5 mm 2 Harmonized, VDE Both cable types sh ould have mi nimum ratings of 16A, 300V, 0-6 0 °C. Refer to Table 11 on page 57 in Chapter 4, “Operation,” for the leg currents for each power supply/vo[...]

52 F300S/F300SQ Ultraviolet Lamp System QRO Transformer Taps (FOR QRO only) When the Quick Restart Option is installed, the QRO transformers mu st be tapped according to the frequency and voltage spec ifications of the customer. Should these specifications change, or if a transformer is replaced, the transformer should be tapped as follows: 50 Hz 2[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 53 F300S Relay Coil Resistor Assembly Installation The relay coil resistor assembly must be used if the line voltage and frequency used with a P300M/P300MQ/P300MT power supp ly is 230-240 VAC at 50 Hz (nominal voltage). These resistor assemblies prevent th e premature failure of th e [...]

54 F300S/F300SQ Ultraviolet Lamp System Figure 15. K101 and K102 o n P300M/P300MQ T B 1 C101 CB1A CB1B C1 02 TB1 DB1 DB2 T103 L101 T102 T101 B101 J101 C103 S1 S2 S3 To p V i e w Side V iew Rear Front Front Rear K102 K102 K101 K101 K103[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 55 Chapter 4. Operation System Operation Controls The lamp system is operated from the controls on the front of the power supply. NOTE: Ambient system operating tem perature is 0 to 45°C. Lamp Control At STANDBY, power (115 VA C) is applied to the magnetron filam ents without energiz[...]

56 F300S/F300SQ Ultraviolet Lamp System • Bulb producing i nsufficient output t o activate the p hotocell For proper initial ignition, the recommen ded “MINIMUM LAMP ON” time required for this system is “ten (10) seconds” at no rm al air pressure (3.5 inches w.c.) and full power operation (100% power level). As previously mentioned, a “[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 57 3. Press the LAMP ON switch: the green LAMP ON indicator blinks, then stays lit . 4. Check the line currents. The line curren ts should conform to the values in Table 11 . 5. Check RF detector and customer use interlocks as described in Chapter 5, “Troubleshooting.” Initial Sta[...]

58 F300S/F300SQ Ultraviolet Lamp System 4. The LAMP CONTROL switches on the Master may now be used to activate all units in the system at the same time. NOTE: LAMP CONTROL flash ers of slaves will follow LAMP CONTROL on Master. Resetting the System After a Fault If a fault occurs in the system, press th e LAMP OFF/RESET switch on the Master, or cyc[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 59 NOTE: Times indicated are approximate and will vary. The exact interval is determined by conditions within the system. If additional RF detectors are connected to slaves, an RF fault in one of these slaves will automatically be interpreted as a system fault shutting down the entire[...]

60 F300S/F300SQ Ultraviolet Lamp System 2. Turn the Master POWER switch ON and press the LAMP ON switch. 3. The system will now operate from remote switches. Remote switch functions are virtually the same as front panel switch functions. Operation with Remote Controls KEY: S- Switch position does not ma tter. Quick Restart Option (QRO) The Quick Re[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 61 The QRO consists of a high-voltage, low -current power su pply section located in t he P300MQ power supply that allow s the magnetron in the irradiator to maintain an ignited bulb at a very low input power level (approx imately 10%) and a very low UV output level (less than 1%). Th[...]

62 F300S/F300SQ Ultraviolet Lamp System Figure 16. Restart Time Versus QRO State Duratio n, D-bulb Figure 17. Restart Time Versus QRO State Duratio n, H-bulb[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 63 Figure 18. Rest art Time Versus QRO State Dura tion, V-bulb Electrical Installation and Setup For a power supply with the QRO component s installed and properly connected, the QRO can be enabled by setting the control card DIP switch S1-6 (marked QRO) to the YES position. See Chapt[...]

64 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 65 Chapter 5. Troubleshooting Basic Checks Check that input power is conn ected properly. Actual line voltage must be within 10% of the voltage rating shown on the equipment labe l. Labels are located on the rear of the power supply. If the input voltage does not match, cont act Fusio[...]

66 F300S/F300SQ Ultraviolet Lamp System Safety Interlock Tests The fault indicators, RF detector, and external interlocks should be tested at reg ular intervals to assure safe op eration of the UV system. 1. With the power supply ch assis inserted into th e cover and single-phase power applied, depress the IND TEST button on each power supply. All [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 67 System Faults The bottom three LEDs indicat e system faults. These faults always shut dow n ALL units in the system, causing all LAMP CONTROL switches to flash. System interlock switches and the RF detect or may be connected to any unit, but are normally connected to th e master. S[...]

68 F300S/F300SQ Ultraviolet Lamp System Table 18, “Troubleshooting/ Fault Diagnosis,” on pag e 69 covers miscell aneous faults and malfunctions. NOTE: The control card may be responsible fo r any of the fault conditions described following. If the fault can not be determ ined after investig ating all possible causes listed, check the control ca[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 69 Table 18. Troubleshooting/F ault Diagnosis Operation Signal/ Other Symptoms Possible C ause Corrective Action POWER switch from OFF to ON LAMP OFF/RESET button does not light at power up Fuses F1 and F2 Check fuse and replace if blo wn. Power supply wiring If fuse immediately blows[...]

70 F300S/F300SQ Ultraviolet Lamp System Lamp control at OFF, or from OFF to STANDBY EXT INTLK indicator lights Open control input. A jumper or an external circuit between J105A-9 and J105A-10 must be closed by a jumper or an e xternal switch. Poor connection Disconnect all power. Reseat control b oard assembly connections. Try again. Control card R[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 71 Switch from OFF to STANDBY BLWR PRESSURE indicator lights Single-pha se voltage missing phase See “Basic Checks” on page 65 . Air pressure Measure air pressure inside irradiator following the procedure described in Chapter 6, “Mai ntenance” . IF PRESSURE IS LOW: Dirty air f[...]

72 F300S/F300SQ Ultraviolet Lamp System Switch from OFF to STANDBY or from STANDBY to ON PS TEMP indicator lights Power supply fan inoperative Repair or replace fan. Power supply too hot or in poor location Move to cooler location. Temperatur e switch faulty or not connected. With power off, check the T101 and T102 thermal switches, which should be[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 73 Switch from STANDBY to ON LAMP OUT indicator lights after 8 seconds; Lamp bulb does not light High Voltage Cable Check cable connections at J103, J104, J10, and J11. Lamp Bulb Measure the Ph otoresist or output at the photocell test points and magnetron current test points on the f[...]

74 F300S/F300SQ Ultraviolet Lamp System Switch from STANDBY to ON (continued) LAMP OUT indicator lights after 8 seconds; Lamp bulb does not light (continued) Diodes, capacito rs If the readings are not different, a power supply fault is indicated. Disconnect all power and inspect for wiring damage. Test diodes and capacitors according to the proced[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 75 Switch from STANDBY to ON (continued) LAMP OUT indicator lights after 8 seconds; Lamp Bulb does not light (continued) Dirty surface Inspect lamp bulb and reflector. Clean or replace as necessary. Try to start again. Line voltages out of specification NOTE: If the magnetron needs to[...]

76 F300S/F300SQ Ultraviolet Lamp System Switch from STANDBY to ON (continued) PWR IMBAL indicator lights Power Supply Usually, a diode or cap acitor failure will reduce magnetron current by one-half. Test the diodes and capacitors according to Chapter 6, “Maintenance” . The voltage to the primary coils ONLY of the high voltage transformers shou[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 77 Lamp Control at LAMP ON LAMP OUT indicator does not light, or UV lamp does not light Control card Replace control card. Arcing sound from irradiator, a grinding noise Damaged Reflector Disconnect all power. Inspect reflector for pitting near large slots. Replace reflector if necess[...]

78 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 79 Chapter 6. Maintenance This chapter provides m aintenance procedures for th e I300M irradiator, the I310M/311M Irradiator, the P300MT power supp ly, and the K300 modular blower. I300M Irradiator Bulb, Screen, and Re flector Maintenance Cleaning Guidelines At least every 500 hours o[...]

80 F300S/F300SQ Ultraviolet Lamp System If cleaning reflectors while a ssembled in the irradiator, drying with compressed air is NOT recommended because particles or resi dues can be driven into spaces between components and into opti cal sensing elements. Screen Cleaning Screens may be cleaned with the same clean ers cited previously, soaking if n[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 81 1. Refer to Figure 19 . Loosen the four M3 screen retaining screws three turns each. Repeat, this time removing screws. Gras p the screen frame by both ends, taking care not to twist or bend the screen itself, and remove screen assembly. 2. To replace existing screen or install a n[...]

82 F300S/F300SQ Ultraviolet Lamp System CAUTION: Do not apply be nding force to the lamp bulb. Do not touch the bulb with bare fingers or allow it to contact dirty or greasy surfaces. Contaminants can be burned into the quartz envelope, causing premature bulb failur e. 3. Clean any deposits from the surface of the bulb (see “Cleaning Guidelines?[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 83 3. Referring to Figure 23 , remove an d discard the two end reflectors and the gaskets underneath. If evidence of arcing is presen t, clean the gasket grooves with emery cloth to remove all oxide. 4. Insert both end reflectors, ensuring that they both seat fully and evenly. The rep[...]

84 F300S/F300SQ Ultraviolet Lamp System 7. Align the reflector squarely over the opening. With gentle pressure and a rocking motion, slide the reflector down in place. It should not bind against the end reflectors as it goes into place. As a fina l motion, grasp the si des of the reflector and gently force them together a small amount, then settle [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 85 CAUTION: Do not use the flathead screws to pull the reflector into place. Excessive pull on these scre ws will de form the re flector face at it s bend radius or loosen it s rivets. This would res ult in a failure of the screen assembly to seat properly and subseq uent damage to th[...]

86 F300S/F300SQ Ultraviolet Lamp System 11. Replace the screen assembly. After re placing the screen assembly, refer to Figure 26 ; hand-tight en the four M3 screws as shown until snug. Tighten them in sequence to 0.9 N-m (8 inch-lbs.) using a torque-controlled screwdriver. Repeat tightening the fasteners according to the sequence and torque specif[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 87 Figure 27. I300M/I301M Irrad iator Component Loca tion Direct View Photoresistor Removal/Replacement 1. Remove the housing as described in the prev ious section. 2. Unplug the photoresistor 3-circuit connecto r (P30) from the photoresistor PWB. 3. Remove the two M4 screws securing [...]

88 F300S/F300SQ Ultraviolet Lamp System 5. Remove and discard the PWB and inspect th e UV filter lens for damage. 6. Replace the photoresistor and UV filter lens assembly. 7. Reinstall the housing. Figure 28. Photoresist or Assembly for Direct Vie w (I300M) Filament Transformer Removal/Re placement 1. Remove the irradiator housing. 2. Cut the cable[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 89 5. Reconnect the fil ament transformer wires to the magnet ron and tighten the terminal screws to 0.9 N-m (8 inch-l bs) using a torque-limitin g screwdriver. Reposition the tubing over the terminal screws an d install cable ties. 6. Install the irradiator housing as described in ?[...]

90 F300S/F300SQ Ultraviolet Lamp System Air Pressure Verification To test air pressure inside the irradiator, remove one cover plate screw and, using a magnehelic, place the end of th e tube over the screw hole ( Figure 30 on page 90 ). For the I300M, the pressure should be 447-596 Pa (1.8-2.4” H 2 O) with respect to o utside (ambient) air. For t[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 91 Air Pressure Switch Replacement 1. Remove the irradiat or cover. 2. Pull the silicone tubing off the low pressure port of the switch. 3. Disconnect the two electri cal leads from the switch. 4. Reach inside the air distri bution plenum and remove the short length of silicone tubing[...]

92 F300S/F300SQ Ultraviolet Lamp System Bulb Cleaning Handle bulbs with a lint-fr ee cloth or tissue taking care not to leave fingerprints. Baked-on material can b e removed from b ulb s with a mild abrasive cleaner such as Soft Scrub®, followed by a thorough rinse with water. If al cohol is allowed, do a final wipe with alcohol. Harsh abrasives a[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 93 Screen Assembly Removal/Replacement 1. Refer to Figure 31 . Loosen the four M3 screen retaining screws, u sing three turns each. Repeat, this time removing screws . Grasp the screen frame by both ends, taking care not to twist or b end the screen itself, and remove the screen assem[...]

94 F300S/F300SQ Ultraviolet Lamp System CAUTION: Do not apply bending force to lamp bulb. Do not touch the bulb with bare fingers or allow it to contact dirty or greasy surfaces. Contaminants can be burned into the quartz envelope, causing premature bulb failur e. Figure 32. Removing or Replacing th e Bulb (I310M/I3 11M) 3. Clean any deposits from [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 95 2. Remove the six flat head screws and lift the reflector out. Examine the cross-guide gaskets for wear and/or arcing; replace if th ere is any sign of either. Replace as described in “Replacing the RF Gasket Assembly” on page 99 . 3. Refer to Figure 33 on page 95 , and remove [...]

96 F300S/F300SQ Ultraviolet Lamp System Figure 34. Gasket Installa tion (I330M/I311M) 4. Insert both end reflectors, ensuring that they both seat fully and evenly. The replacement end reflectors must be installed befo re the new RF Gasket. 5. Install the two pre-cu t (long) RF gaskets int o the grooves for the end reflectors. Insert one end flush w[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 97 Figure 35. Correct Reflector Alignme nt (I310M/I311M) 7. Align the reflector squarely over the opening. With gentle pressure and a rocking motion, slide the reflector down in place. It shoul d not bind against the end reflectors as it goes into place. As a fina l motion, grasp the [...]

98 F300S/F300SQ Ultraviolet Lamp System Figure 36. Reflector Scre w Tightening Sequence (I310M/I31 1M) 8. When the reflector is properly installed, the face should be flush and even with the outer face of the two end reflectors as shown in Figure 35 . 9. Clean the reflector to remove fingerprints. 10. Clean and insert the lamp bulb as instructed ea[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 99 Replacing the RF Gasket Assembly 1. If you detect evidence of arcing on the back of the reflector caused by the RF gasket assemblies (behind the reflector ), then you will need to replace the two RF gasket assemblies with the main reflector removed. Figure 38. Gasket Installation w[...]

100 F300S/F300SQ Ultraviolet Lamp System 4. Remove the extrusions. While holding th e extrusion inside the casting, remove the four screws securing the extrusion to the casting. Repeat for the extrusion on the opposite side. Discard the old extrusions and the RF gaskets behind each . 5. Install the gasket assemblies (with extrusio ns) with the mesh[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 101 Figure 39. I310M/I311M Irradiator Component Loca tion (Scatter View) Direct View Photoresistor Removal/Replacement 1. Remove the housing as described in the prev ious section. 2. Unplug the photoresistor 3-circuit connecto r (P30) from the photoresistor PWB. 3. Remove the two M4 s[...]

102 F300S/F300SQ Ultraviolet Lamp System 6. Replace the photoresistor and UV filter lens assembly. 7. Reinstall the housing. Figure 40. I310M-D/I311M- D Irradiator Component Loc ation (Direct View) Air intake pl enum Air pressure swit ch Magnetron Fi l a m e n t tran sfor mer bracket Fila me nt t r an sf o r me r Die c ast ing RF sc reen Phot o re [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 103 Figure 41. Photoresistor As semb ly for Direct View (I300M) Filament Transformer Removal/Replacement 1. Remove irradiator housing . 2. Cut the cable ties and slide the PV C tubing off the magnetron connections. Remove the filament terminal screws. Disconnect the lead s at the prim[...]

104 F300S/F300SQ Ultraviolet Lamp System Magnetron Removal/Replacement 1. Remove the irradiator housing as described previous ly. 2. Disconnect the filament transformer wires from magn etron by removing the cable ties and sliding back the tubing. Remove the termin al screws. 3. Remove the filament transf ormer bracket and air plenum. 4. Remove the [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 105 Air Pressure Verification To test air pressure inside the irradiator, remove one cover plate screw and, using a magnehelic, place the end of the tube over the screw hole (see Figure 43 ). For the I310M/I311M and I31 0M-D/I311M-D, the pressure should be 447-596 Pa (1.8-2.4 ” H 2 [...]

106 F300S/F300SQ Ultraviolet Lamp System 2. Pull the silicone tubing off the low pressure port of the switch. 3. Disconnect the two electri cal leads from the switch. 4. Reach inside the air distri bution plenum and remove the short length of silicone tubing which secures the pressure switch to the plenum wall. 5. Insert the high pressure port (lon[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 107 Test Point Voltages Control Card Removal/Replacement This unit must be di sconnected and retu rned to Fusion U V Systems for repair or direct replacement. The control card can not be repaired in the field. 1. Remove the six screws from the power sup ply cover. Remov e the cover. 2[...]

108 F300S/F300SQ Ultraviolet Lamp System Diode Test An ohmmeter can be used to check for a sh orted or open capacitor. (Isolate the component before making con tinuity tests.) Ohmmeters having less than a 6V battery can give erroneous indi cations of high resistance in both directions when t esting these hi gh voltage diodes. 1. With an insulated s[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 109 Figure 44. P300M/P3 00MQ Co mpone nt Identification[...]

110 F300S/F300SQ Ultraviolet Lamp System Capacitor Test CAUTION: An ohmmeter can be used to check for a shorted or open capacitor. (Isolate the component be fore performing continuity tests.) The ohmmeter should have a minimu m 6V battery, and should be set on the high resistance scale. 1. Remove all power, discharge the capac ito r, and disconnect[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 111 1. Disconnect all power, discharge the high voltage capacito rs, and disconnect all leads from the transformer terminals. 2. Unbolt the transformer from the pow er supply chassi s. 3. To replace the transformer, reverse the steps, being cer tain that terminals are in the correct l[...]

112 F300S/F300SQ Ultraviolet Lamp System NOTE: When colors are indicated, the first is the wire color and the second is the stripe color. P300MT Power Supply The P300MT power su pply is electrically identical to the standard P300M power supply except that the ch assis is 7 inches (184 mm) sh orter than the st andard P300M. NOTE: The P30 0MT cannot [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 113 Test Point Voltages. Control Card Removal/Replacement This unit must be returned to Fusion UV Sy stems for repair or di rect replacement. The control card cannot be repaired in the field. 1. Remove the six screws from the power supply cover. 2. Remove the cover. WARNING : Before t[...]

114 F300S/F300SQ Ultraviolet Lamp System 3. Remove all connectors. 4. Remove three screws at the top of the card. Slide the card approximately an inch away from the front panel and raise it up out of its bottom track. 5. To install a replacement card, reverse th is procedure. Note the location of the connectors in Figure 46 on page 115 and reinstal[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 115 Capacitor Test The ohmmeter should have a minimum 6V bat tery, and should be set on the high resistance scale. 1. Remove all power, d ischa rge the capacitor, and disc onnect all leads from the capacitor terminals. Figure 46. P300MT Com pone nt Identification An ohmmeter can be us[...]

116 F300S/F300SQ Ultraviolet Lamp System 2. With an ohmmeter set on the highest scale, measure the resistance between the two outside capacitor terminals and the cent er terminal. The meter needle sh ould momentarily deflect upward to in dicate continuity , and should then return to infinity. Reversing the meter leads should giv e the same indicati[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 117 NOTE: When colors are indicated, the first is the wire color and the second is the stripe color. Figure 47. P300 MT HV Wiring K300 Modular Blower Routine Maintenance The following sections discu ss maintenance for the various part s of your blower system . Blower Air Filters The b[...]

118 F300S/F300SQ Ultraviolet Lamp System The filters pull out easily. New filters should be tucked in at the edges. The white side belongs outside, so the blue side should face in. CAUTION: Do not operate the modular blowe r without a properly installed air filter. Un filtered cooling air can reduce lamp bulb and reflector life. Blower Cover Remova[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 119 Figure 48. Blower Components Blo wer Cov er Ground Connections Capacitor Housing J1 1 Ground Screw Blower Wheel Mot or (B 10 ) F3e0 017 Gr ound Strap[...]

120 F300S/F300SQ Ultraviolet Lamp System Figure 49. J11 Conne ctions 8. Connect the replacement J11 connector to the chassis. The black and white leads from the blower motor have pins installed; these pins must be inserted into th e back of J11 as indicated in Figure 49 . 9. Connect the ring terminals on the green/yellow wire from J11 and the green[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 121 Appendix A. Specifications This appendix outlines th e various characteristics of major componen ts of F300S and F300SQ systems. System Power Supply The following table provide s the F300S and F300SQ system power su pply specifications. Table 24. System Oper ating Requirements Amb[...]

Specifications 122 F300S/F300SQ Ultraviolet Lamp System Front Panel Controls System Power ON /OFF - 2 position switch Lamp Control ON/ STANDBY/OFF - 3 illumin ated pushbu tton switches Interlocks Unit HV Cable Disconnect Lamp Out Power Imbalance Power Error Power Supply Overtemperature Lamp Cooling Air Underpressure System System Blower Underpressu[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 123 Irradiators Irradiators Table 26 lists the variou s Fusion UV Syst ems Irradiator models an d cooling met hod. NOTE: All air flow sp ecifications assume stan dard air density of 1.20 kg/ m 3 (0.075 lbs/ft 3 ). Remote blower specification mu st be corrected for air density variatio[...]

Specifications 124 F300S/F300SQ Ultraviolet Lamp System Exterior: Brushed aluminum. Mechanical (wit hout Blower): Length: 260.4 mm (10.25") Height: 276.9 mm (10.9") Width: 167.6 mm (6.6") Mechanical (with Blower): Length: 260.4 mm (10.25") Height: 505.5 mm (19.9") Width: 167.6 mm (6.6") Blower Mechanical: Length 260 .4[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 125 Irradiators System Agency Approvals Table 28 lists the quality standard s and agency regulatory guidelines against which the Fusion UV System s products described in this document have b een certified/validated. Table 28. System Ag ency Approv als Quality Measured St an da r d Ele[...]

Specifications 126 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 127 Appendix B. Cables and Connectors This appendix provides information on th e interconn ect cables and system conn ector contact kits used with the F300S/F300SQ Ultraviolet Lamp System. Interconnect Cables Fusion UV Systems irradiators use the interconnect cables descri bed in Tabl[...]

Cables and Connectors 128 F300S/F300SQ Ultraviolet Lamp System System Connector Contact Kits Each kit includes pins and contact s for referenced connections. See Table 32 on page 141 for the proper cont act extraction tool. Power Supply RF-1 H790 RF Cable 2 329281 4 329282 6 329283 8 329284 11 329285 14 329286 17 329287 21 329288 26 329289 31 32929[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 129 Appendix C. Outline Dr awings The drawings in this appendix provide overview details for general reference for Fusion UV Systems produc ts. These drawings are not to be used in designing an installation; co ntact Fusion dire ctly for current specifications. • Figure 50 , P300M/P[...]

Outline Drawings 130 F300S/F300SQ Ultraviolet Lamp System Figure 50. P300M/P300MQ Power Supply Dimensions and Clearan ces[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 131 Figure 51. P300M T Power Supply Dimensions and Clearances[...]

Outline Drawings 132 F300S/F300SQ Ultraviolet Lamp System Figure 52. I300M Irradiat or Dimensions 3. Air pressure measured at la mp inlet 6 95Pa (2.8"H O) a t 2.8m /min (1 00 cfm) 2 3 4. Air pressure measured at ve nt holes 447-5 96Pa (1.8-2.4" H O) 2 Notes: 2. Standard d ensity 1.2 kg /m (0.075 lb/ft ) 33 1. Dimensi ons in mm (in)[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 133 Figure 53. I300MB Irradiat or Dimensions Notes: 1. D imensio ns in mm ( i n) 2. Air pressure at vent holes 447- 822 Pa (1.8 - 3.3"H O) 2[...]

Outline Drawings 134 F300S/F300SQ Ultraviolet Lamp System Figure 54. I310M/I310M- D Irradiator Dimensions 3. Air pressure measured at l amp inl et 695P a (2.8"H O) a t 2.8m /min (1 00 cfm) 2 3 4. Air pressure measured at ve nt holes 4 47-5 96Pa (1.8 -2.4"H O) 2 Notes: 2. Stand ard densi ty 1.2 kg /m (0.075 lb/ ft ) 33 1. Dime nsions in m [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 135 Figure 55. I310MB/I310MB- D Irrad iator Dimensions Notes: 1. Dimen sions in mm (in) 2. Air pressure at ve nt holes 447- 822 Pa (1.8 - 3.3"H O) 2[...]

Outline Drawings 136 F300S/F300SQ Ultraviolet Lamp System Figure 56. I311M/I311M- D Irradiator Dimensions Opt i mum su bs t ra te location f or focusi ng UV to maximum peak irradiance 3. Air pressur e measured at lamp inle t 695Pa (2. 8"H O) at 2.8m /min (100 cfm) 2 3 4. Air press ure mea sured a t v ent ho les 4 47-596Pa (1.8- 2.4" H O) [...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 137 Figure 57. RF-1 RF Detector Dimensions[...]

Outline Drawings 138 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 139 Appendix D . Lamp System Maintenance Log Table 31 gives an example of a Fusion UV Syst ems form to use for tracking lamp system maintenance. Table 31. Lamp System Maint enance Log Lamp System Log FUSION UV SYSTEMS, INC. Irradiator Serial Number _______ __ 910 Clopper Road Bulb Ser[...]

Lamp System Maintenance Log 140 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 141 Appendix E. R eplacement Parts Table 32 lists the various accessory replacemen t parts available for Fusion UV Systems F300S/F30 0SQ Lamp Systems. Table 32. Accessory Parts List Description Ref P/N Quantity F300S/F300SQ Modular Blower Remote Cooling Cable, irradiator w/K300M modul[...]

Replacement Parts 142 F300S/F300SQ Ultraviolet Lamp System I300M/I310M Irradiator Parts List Table 33 lists the various replacement parts av ailable for Fusion UV Systems I300M and I310M Irradiators. Kit, RF detector RF-1 079961 1 Kit, retrofit, relay coil resistor assemblies — 528641 1 Tool, contact removal — 043041 1 Table 33. I300M/I310M Irr[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 143 I300M/I310M Irradiator Parts List Kit, reflector assembly, I300M, R500 (includes main reflector, 2 end reflectors and gaskets — 292161 Kit, reflector assembly, I300M, R350 (includes main reflector, 2 end reflectors and gaskets) — 292162 Kit, reflector assembly, I300M, dichroic[...]

Replacement Parts 144 F300S/F300SQ Ultraviolet Lamp System P300M/P300MT Power Supply Parts List Table 34 lists the various replacement parts av ailable for Fusion UV Systems P300M and P300MT power supplies. Table 34. P300M and P300MT Replacement Part s Description Reference Designator Part Number Capacitor, Oil filled 0.85/0.43 MFD (50 /60 Hz) C101[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 145 P300M/P300MT Power Supply Parts List HV transformer, 230V, 50/60 Hz T101, T102 341371 HV wire assembly, 8", Wh ite — 340701 HV wire assembly, 3.5", Black — 340704 HV wire assembly, 3.5" White — 340702 HV wire assembly, 8" Black — 340703 HV wire assembly[...]

Replacement Parts 146 F300S/F300SQ Ultraviolet Lamp System P300MQ Quick Restart Option Parts List Table 35 lists the various replacement parts available for the Fusion UV Systems P300MQ Quick Restart Option. Table 35. P3 00MQ Quick Restart Opt ion Parts Lis t Description Refe rence Designat or Part Number Bracket, Mtg, 1.75 oval For C103 222 291 In[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 147 K300 Blower Assembly Parts List K300 Blower Assembly Parts List Table 36. K3 00 Blower Assemb ly Parts Lis t Description Reference Designator Part Number Capacitor, Fld. Fill, 4.0 MFD C200 0419 81 Connector, 4 CKT (Use Contact Kit 201675) J11 025802 Contact Kit, SKT, 16-18GA (set [...]

Replacement Parts 148 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 149 Appendix F . Ignitor Bulb NOTE: This appendix applies to lamps manufactured before July 1, 2002. Ignitor The ignitor bulb is designed to provide positiv e instant ignition of the main bulb . As shown in Figure 58 , the ignitor is a UV bulb with a probe which projects into th e wav[...]

Ignitor Bulb 150 F300S/F300SQ Ultraviolet Lamp System Ignitor Bulb Removal/Replacement 1. Replace the ignitor bulb only if the lamp does not start consistently and all other indications are normal. Table 37. Routine Operations Ass ociated with Ignitor Bulb (Refer to Table 12 on page 59 for other operational information.) Tim e Power Switch Lamp Con[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 151 Ignitor Bulb Remov al/Replacement 2. Remove the irradiat or housing as described in Chapter 6, “Maintenance” . 3. Pull the defective bulb out and push th e new bulb into the mountin g clip. make sure the stem of the bulb fits into th e wavegui de so that the outer Teflon sleev[...]

Ignitor Bulb 152 F300S/F300SQ Ultraviolet Lamp System[...]

Installation, Operation, an d Maintenance Manual # 509252 R ev R 153 Appendix G. Schematics The following schematics are locat ed within the F300 folder on your product documentation CD in a subfolde r or director y entitled “Schematics”. These files are in PDF format. They illustrate various wi ring diagrams an d other schematics forF300S/F300[...]

Schematic s 154 F300S/F300SQ Ultraviolet Lamp System[...]