Fusion F300S, F300SQ Chapter 1. Safety

Chapter 1. Safety

Fusion UV Systems’ Ultraviolet (UV) Lamp Systems have been designed to operate safely. Many systems are in production in a wide variety of industrial environments without any problems of worker safety or health hazards. However, like most industrial equipment, this equipment can present worker safety problems if care is not taken to install, operate, and maintain it correctly.

The following pages provide information concerning various aspects of worker safety with regard to this equipment. Because some features of the system may be new to personnel using the equipment, an attempt has been made to provide a fairly extensive background on these issues as well as references, where feasible, to further information or U.S. Government Standards.

IMPORTANT: All personnel using the equipment must become familiar with this safety information.

Care in installation and operation, coupled with adequate worker training, should ensure that no unusual safety problems arise.

Installation, Operation, and Maintenance Manual # 509252 Rev R

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Contents

Installation, Operation, and Maintenance Page Page Page Table Of Contents Indications of Note, Caution, Warning, and Danger Reflector and Cavity P300M/P300MQ/P300MT Returned Material Authorization Number Unpacking and Inspection Power Supply Unit(s) Placement Lamps Mounted in Opposing Configuration Installing the External Interlocks Control Settings for Six-PositionSwitch S1 Off/Reset Control Initial Startup Procedure, Multiple-UnitSystems Master/Slave Operation Operating the System Resetting the System After a Fault Page Control Card Removal/Replacement Diode Test Capacitor Test High Voltage Transformer Removal/Replacement Routine Maintenance Control Card Removal/Replacement Blower Air Filters Blower Cover Removal Motor Replacement System Agency Approvals Page Introduction not Document Conventions NOTE: WARNING: Table 1, “Icons,” Table 1. Icons Table 1. Icons (continued) be required to wear goggles with UV certified lenses System Description Figure 1. F300S/F300SQ Lamp System System Components M3 screen retaining screws (4) (2 per side) Cooling air holes Cavity Reflector Figure 2. Reflector Assembly Table 2. Irradiator Models Figure 3. Lamp Bulb RF Detector System Interconnections Figure 4. P300M Front Panel Warranty Policy Shipping Instructions Power Supply Box: Bursting Test: 24 kg/cm2 (350 lbs./sq. in.) Gross Weight Limit: 70 kg (155 lbs.) Page Page Chapter 1. Safety Ultraviolet Radiation Microwave Radiation Personnel Effects of Microwave Radiation Radio Interference Ozone Temperature High Voltage UV Curable Materials Page Chapter 2. Mechanical Installation Mechanical Installation Checklist Table 3. Mechanical Installation Checklist “Shipping Instructions” on page Power Supply Unit(s) Placement Irradiator Mounting Figure 5. Vertical Mounting Design for Irradiators Lamps Mounted in Opposing Configuration Figure 6. Lamps in Opposing Configuration UV Light Shielding RF Detector Mounting Figure 7. Fusion UV Systems RF Detector RF-1 Remote Blowers Irradiator Exhaust Venting Quartz Plates Page Page Chapter 3. Electrical System Electrical Installation/Setup Checklist Table 4. Electrical Installation and Setup Checklist Accessory Parts List Interconnect Cables Appendix B, “Cables and Connectors” Connection and Program Log Appendix D, “Lamp System Maintenance Log” Figure 9. P300M/P300MQ Power Supply Rear Panel Power Supply Programming Figure 10. Location of Programming Switch S1 on PWB Figure 11. Table A: Programming Switch S1 Single Unit Programming and Connections Figure 12. F300/F300SQ Single-unitInstallation Programming Table 5. J105A Inputs In a multi-lampsystem, connections are made to the Master power supply Table 6. J106 Inputs (Remote Operation) Output Ports (J105B) Table 7. J105B Outputs (Customer Interface) Table 7. J105B Outputs (Customer Interface) (continued) Table 8. Alternate Function for K5 Multiple-UnitProgramming and Connections Figure 13. F300S/F300SQ Multiple Unit Programming & Connections NOTES: Power Source “F300S Relay Coil Resistor Assembly Installation” on page Figure 14. Power Supply Front Panel Table 9. High Voltage Transformer Taps Table 9. High Voltage Transformer Taps (continued) Table 10. QRO Transformer Taps (Optional) F300S Relay Coil Resistor Assembly Installation Front B101 L101 T103 Top View Side View Figure 15. K101 and K102 on P300M/P300MQ 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 temperature is 0 to 45°C •Successive short cycles Initial Startup Procedure, Single Unit Table 11. P300M/P300MQ/P300MT Current Requirements Initial Startup Procedure, Multiple-UnitSystems Page Table 12. Routine Operation Remote Operation The following procedure describes how to operate a lamp remotely: 1. Turn all remote switches OFF (open contacts) Table 13. Remote Switch Functions Table 14. Operation with Remote Controls Quick Restart Option (QRO) CAUTION Figure 16. Restart Time Versus QRO State Duration, D-bulb Figure 17. Restart Time Versus QRO State Duration, H-bulb Figure 18. Restart Time Versus QRO State Duration, V-bulb Page Chapter 5. Troubleshooting DANGER: Do not touch any power supply components or wiring while the unit is operating Basic Checks Safety Interlock Tests Fault Indicators Table 15. Unit Faults Table 15. Unit Faults (continued) Table 16. System Faults Fault Diagnosis Tables Failure Diagnosis Cross-Reference Table 17. Fault Diagnosis Cross Reference Table 18. Troubleshooting/Fault Diagnosis Table 18. Troubleshooting/Fault Diagnosis (continued) Page Page Page Page Page Page Page Page Chapter 6. Maintenance I300M Irradiator Cleaning Guidelines Bulb Cleaning Reflector Cleaning Screen Cleaning Figure 19. Reflector Assembly (I300M) Figure 20. RF Screen Screw Tightening Sequence Retaining hole Figure 21. Removing or Replacing the Bulb Figure 22. Gasket Installation Figure 23. Reflector Removal or Replacement (I300M) Figure 24. Reflector Screw Tightening Sequence Figure 25. Correct Reflector Alignment (I300M) 9.Clean the reflector to remove fingerprints 10.Clean and insert the lamp bulb according to “Cleaning Guidelines” on page Figure 26. RF Screen Screw Tightening Sequence (I300M) Air intake plenum Air pressure switch Filament transformer Filament transformer bracket Die casting Photoresistor PWB Photoresistor mating connector Photoresistor UV filter lens Figure 29. Magnetron Fastener Tightening Sequence (I300M) HV Connector (J11) Cover Plate Cover Screws Figure 30. Air Pressure Test Points (I300M) - I300 MB Similar I310M/I311M Irradiator Figure 31. Reflector Assembly (I310M/I311M) Page Figure 32. Removing or Replacing the Bulb (I310M/I311M) Figure 33. Reflector Removal or Replacement (I330M/I311M) Figure 34. Gasket Installation (I330M/I311M) before IMPORTANT: Figure 35. Correct Reflector Alignment (I310M/I311M) Figure 36. Reflector Screw Tightening Sequence (I310M/I311M) Figure 37. RF Screen Screw Tightening Sequence (I310M/I311M) Replacing the RF Gasket Assembly RF SCREEN (Bottom of Irradiator) Figure 38. Gasket Installation with Cross-guide(Short) Gaskets (I310M/I311M) The irradiator enclosure is removed as follows: 3.Remove two M3 flat head screws from each side of irradiator housing Figure 39 on page Figure 39 on page 101 shows the I310M/I311M Irradiator component locations 4.Reverse these steps to replace the photoresistor assembly scatter view assembly Photo resistor direct view assembly Figure 41. Photoresistor Assembly for Direct View (I300M) Figure 42. Magnetron Fastener Tightening Sequence Figure 43. Air Pressure Test Points P300M/P300MQ Power Supply Table 19. Operating Voltages Control Card Removal/Replacement Diode Test Figure 44. P300M/P300MQ Component Identification Capacitor Test WARNING: High Voltage Transformer Removal/Replacement DB2 DB1 Table 20. Transformer Terminal Orientation P300MT Power Supply NOTE: The P300MT cannot be retrofitted for the Quick Restart Option (QRO) Safety Procedures Table 21. Operating Voltages Page CB1 Table 22. Transformer Terminal Orientation Rear Top View Figure 47. P300 MT HV Wiring K300 Modular Blower Blower Air Filters Blower Cover Removal Motor Replacement Page Figure 49. J11 Connections Table 23. J11 Connections Appendix A. Specifications Page Page Page Page Page Appendix B. Cables and Connectors Table 29. Interconnect Cables (continued) Table 30. System Connector Contact Kits Appendix C. Outline Drawings Figure 50. P300M/P300MQ Power Supply Dimensions and Clearances Figure 51. P300MT Power Supply Dimensions and Clearances Figure 52. I300M Irradiator Dimensions Figure 53. I300MB Irradiator Dimensions Figure 54. I310M/I310M-DIrradiator Dimensions Figure 55. I310MB/I310MB-DIrradiator Dimensions Figure 56. I311M/I311M-DIrradiator Dimensions Figure 57. RF-1RF Detector Dimensions Page Appendix D Page Appendix E. Replacement Parts Table 32. Accessory Parts List (continued) I300M/I310M Irradiator Parts List Table 33. I300M/I310M Irradiator Parts List Table 33. I300M/I310M Irradiator Parts List (continued) P300M/P300MT Power Supply Parts List Table 34. P300M and P300MT Replacement Parts Table 34. P300M and P300MT Replacement Parts (continued) P300MQ Quick Restart Option Parts List Table 35. P300MQ Quick Restart Option Parts List K300 Blower Assembly Parts List Table 36. K300 Blower Assembly Parts List Page Appendix F. Ignitor Bulb Table 37. Routine Operations Associated with Ignitor Bulb (Refer to Table 12 on page 59 for other operational information.) Table 38. Troubleshooting and Fault Diagnosis (Refer to Table 18 on page 69 for other operational information.) Ignitor Bulb Removal/Replacement Page Page Appendix G. Schematics