Page 1 2 610 UV Curing System Customer Product Manual Part 1105120-03 Issued 04/15 To order parts call 866-885-1212. For technical support call 800-524-1322. This document is subject to change without notice. Check http://emanuals.nordson.com/uvsystems for the latest version. NORDSON CORPORATION • AMHERST, OHIO • USA...
Page 2: Part
Notice inquiries about its products. General information about Nordson can be This is a Nordson Corporation publication which is protected by copyright. found on the Internet using the following address: Original copyright date 2013. No part of this document may be http://www.nordson.com.
Page 3 Change Record Change Record Revision Date Change 09/14 Replaced light detector board part number 1077320 with 1605735 for internal blower. 04/15 Updated part number 1083258 to 1607248 in Parts List. Part 1105120-03 E 2015 Nordson Corporation...
Page 4 Change Record Part 1105120-03 E 2015 Nordson Corporation...
Page 5: Table Of Contents
..........Part 1105120-03 E 2015 Nordson Corporation...
Page 6 ..........4-13 Part 1105120-03 E 2015 Nordson Corporation...
Page 7 Mounting Kit Installation ....... . 7-13 Part 1105120-03 E 2015 Nordson Corporation...
Page 8 ........... Part 1105120-03 E 2015 Nordson Corporation...
Page 9: Safety
Figure 1-1 Microwave UV Warning Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks.
Page 10: Intended Use
Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. Part 1105120-03...
Page 11: Personal Safety
UV−A is at the lower limit of sensitivity to the human eye. UV-B (315−280 nanometers) − most responsible for reddening and burning of the skin and damage to the eyes. UV-C (280−100 nanometers) Part 1105120-03 E 2015 Nordson Corporation...
Page 12 Duration of Exposure (Per Day) Effective Irradiance (E Micro Watts/cm sq) 8 hours 4 hours 2 hours 1 hour 30 minutes 15 minutes 10 minutes 5 minutes 1 minute 30 seconds 10 seconds 1 second 3000 Part 1105120-03 E 2015 Nordson Corporation...
Page 13: First Aid
This system complies with EN55011 (CISPR-1, Group 2, Class A). NOTE: Nordson UV lamps operate at a fundamental frequency of 2.45 GHz. They may cause interference with wireless local area networks (WLANs) that also operate at this frequency.
Page 14: High Temperatures
The UV curing equipment operates at high voltages up to 5000 Vdc. If any electrical faults develop, the operator should: 1. Switch the equipment off immediately. 2. Make no attempt to service the equipment. 3. Call a qualified electrician trained to service this type of equipment. Part 1105120-03 E 2015 Nordson Corporation...
Page 15: Mercury Bulbs (Lamps)
Do not store or handle bulbs near food or beverages. Nordson Corporation will dispose of UV bulbs free of charge provided the customer covers all shipping costs associated with returning the bulbs. For bulb disposal, please clearly mark on the all bulb containers and shipping packages: BULBS FOR DISPOSAL ONLY.
Page 16: Action In The Event Of A Malfunction
Moving and Storage Moving or storing of the Nordson UV curing system must comply with all applicable local and state regulations. The lamphead and system controller should be shipped or stored in the original container or an equivalent and kept dry and clean at all times.
Page 17: Safety Symbols
Controllers should be properly fastened to an appropriate fixture such as a pallet for handling and storing. Shipping of Nordson UV curing systems and their component parts must be done in accordance with all applicable shipping regulations including requirements for shipping of magnetic materials and mercury lamps.
Page 18 1-10 Safety Part 1105120-03 E 2015 Nordson Corporation...
Page 19: Description
Description Section 2 Description Introduction This manual covers the Nordson CoolWave 2 610 Ultraviolet Microwave Curing System. It provides safety, installation, operation, and troubleshooting and repair information for the system and its components. What is UV Curing? Ultraviolet curing is achieved by a chemical reaction in special inks and coatings when intense UV energy is focused on them.
Page 20: System Components
Use genuine Nordson replacement bulbs with this system. Alternative bulbs may damage the controls or overheat the reflector system. NOTE: The system warranty is void if genuine Nordson UV bulbs are not used. Contact a Nordson UV representative for ordering information.
Page 21: Issued
Forced air is used to cool the UV bulb and magnetrons. If external External Blowers blowers are used, they must be sized appropriately to provide the required air flow. Contact Nordson UV engineering for external cooling Internal Blower air guidance.
Page 22: Magnetron Operation And Life
An imbalance in the frequency output from the magnetrons can shorten their life as they then try to couple energy into one another. This typically causes the ceramic antenna cap to break, permanently damaging the magnetron. Part 1105120-03 E 2015 Nordson Corporation...
Page 23: Reflectors
The focal point is measured from the bottom of the lamphead. See Figures 2-2 and 2-3. The flood reflectors produce a wider band of UV light. See Figure 2-4. 2.1 Inch Focus Reflector Figure 2-2 2.1 Inch Focus Reflectors Part 1105120-03 E 2015 Nordson Corporation...
Page 24: 3.1 Inch Focus Reflector
Description 3.1 Inch Focus Reflector Figure 2-3 3.1 Inch Focus Reflectors Part 1105120-03 E 2015 Nordson Corporation...
Page 25: Flood Reflector
Description Flood Reflector Figure 2-4 Flood Reflector Diagram Part 1105120-03 E 2015 Nordson Corporation...
Page 26: Options
LightTite Shutter: Installed on the lamphead, the pneumatically powered proprietary Nordson LightTite shutter opens and closes instantly to block UV light without turning off the lamp head and system controller. The LightTite shutter is ideally suited for systems running manually loaded and unloaded parts, or heat-sensitive parts where accurate control of UV exposure is required.
Page 27: Installation
Inspection and Packaging The Nordson CoolWave system has been carefully tested, inspected, and packaged prior to shipping. Upon receipt, inspect the shipping materials and components for visible damage. Report any damage immediately to the shipper and to your Nordson representative.
Page 28 If the system controller is mounted in an enclosure, there must be free and unobstructed ventilation from top to bottom and side to side within the enclosure. Contact your Nordson representative for enclosure cooling requirements. 453.50 [17.854] MPS2−610...
Page 29: Power Connections
To connect power to the system controller, remove the voltage cover on the back of the enclosure. Connect power wiring to the terminals labeled A (L1), B (L2), C (L3), and Ground. Part 1105120-03 E 2015 Nordson Corporation...
Page 30: Power Load Balancing
Only the network configuration settings are shown in the following diagrams. All other settings are optional and depend on the application. Refer to Table 3-6 for all configuration settings. Unicable Connection: Refer to page 3-21. RF Detector Installation: Refer to page 3-22. Part 1105120-03 E 2015 Nordson Corporation...
Page 31 ID : 01 FLT: A RFD: N NT: CAN or 485 CTRM: Y Last unit on network L2 (A) L3 (B) L1 (C) Figure 3-4 System Diagram − Two Systems, One RF Detector, One Network Part 1105120-03 E 2015 Nordson Corporation...
Page 32 FLT: A RFD: N NT: CAN or 485 L1 (A) L2 (B) CTRM: Y L3 (C) Last unit on network System Controller Figure 3-5 System Diagram − Four Systems, Two RF Detectors, One Network Part 1105120-03 E 2015 Nordson Corporation...
Page 33: Network Connections
Section 10 of this manual. DETECTOR MSTOP INTERFACE RETURN LAMP ON STDBY ADDRESS OFF/RESET READY FAULT RATE ACOM SHLD AOUT DEVICENET NOT USED ACOM STATUS NETWORK INDICATORS REMOTE I/O Figure 3-6 Remote I/O Connections Part 1105120-03 E 2015 Nordson Corporation...
Page 34 System Controller Configuration on page 3-24 for instructions. Analog (ACOM) − Common Ground Shield (SHLD) Earth ground Output Analog Output (AOUT) Not used. Do not connect. Analog Common Not used. Do not connect. (ACOM) Part 1105120-03 E 2015 Nordson Corporation...
Page 35: Machine Stop Interlock
Both jumpers must be set to one of the two positions as shown in Figure 3-7. CAUTION: Any other jumper combination is invalid and will cause damage. NORMAL Figure 3-7 Machine Stop Interlock Jumper Settings − Shown Set To NORMAL Part 1105120-03 E 2015 Nordson Corporation...
Page 36: Remote Power Level Control
Power is applied to the magnetron filament to prepare it for operation. 2. After approximately 15 seconds the magnetron filament is warmed up. The system goes into standby mode and remains there indefintely. Part 1105120-03 E 2015 Nordson Corporation...
Page 37: Quick Cycle Using Idle Mode
The system controller can be hot plugged into a DeviceNet network. Inrush current is limited to less than 500 milliamps for less than 50 microseconds. Mis-Wiring Protection The system controller supports mis-wiring protection as defined in the DeviceNet Specification (Section 10 of this manual). Part 1105120-03 E 2015 Nordson Corporation...
Page 38: Hardware Specifications
Each application has different constraints and therefore requires custom-designed enclosures and light shielding. Contact Nordson UV systems engineering department for help with designs. Mounting Guidelines Figures 3-9 and 3-10 provide the physical dimensions of the CoolWave 2 lampheads.
Page 39 NOTE: Refer to page 3-18 for top and bottom pressure port usage. It is important that the pressure port being used to measure differential pressure not be blocked, and that the appropriate port be used depending on the cooling air and exhaust air arrangements. Part 1105120-03 E 2015 Nordson Corporation...
Page 40 9.50 (0.374) 182.0 Bottom (7.165) Pressure Port * All measurements in mm (in.) * DO NOT BLOCK PRESSURE PORTS WHEN MOUNTING LAMPHEADS M4 Threaded Mounting Holes (8) (5.24) Figure 3-10 Lamphead Dimensions − Internal Blower Part 1105120-03 E 2015 Nordson Corporation...
Page 41: Optional Mounting Kit For Lampheads
If an AirShield ventilation system or any type of exhaust-restricting devices are used, the exhaust air must be evacuated to ensure adequate cooling air flow. Refer to the AirShield Ventilation System instructions on page 3-17. Part 1105120-03 E 2015 Nordson Corporation...
Page 42: External Blower Lampheads
The duct connection is for 6-in. ID ducts. If you plan on using variable speed external blowers, contact Nordson UV engineering for advice on the design of the air handling system. The following specifications must be maintained for all applications at all...
Page 43: Airshield Ventilation System
(1.0 in.) Port for Bottom Pressure Reading 8−M4 x 35 Screws (Std Kit) 8−M4 x 50 Screws (High Flow Kit) Quartz Plate (included in kits) Figure 3-12 AirShield Kit Installation (External Blower Lamphead Shown) Part 1105120-03 E 2015 Nordson Corporation...
Page 44: Monitoring Lamphead Air Pressure
2. Disconnect the pressure hose and unscrew the barbed fitting from the top or front pressure port. 3. Install the barbed fitting in the bottom pressure port, then feed the hose through the lamphead and connect it to the barbed fitting. Part 1105120-03 E 2015 Nordson Corporation...
Page 45 3-19 Installation Top Pressure Port (Factory Connection) Port B Hose Connection Hose Barbed Fitting Bottom Pressure Port Figure 3-13 Pressure Port Connections − External Blower Version Part 1105120-03 E 2015 Nordson Corporation...
Page 46 3-20 Installation Port B Hose Connection Front Pressure Port (Factory Connection) Hose Bottom Pressure Port Barbed Fitting Figure 3-14 Pressure Port Connections − Internal Blower Version Part 1105120-03 E 2015 Nordson Corporation...
Page 47: Lamphead Cable Connections
DIN1810B hook wrench (spanner wrench) to insure that the connection is secure. There are four holes in the screw ring for the wrench pin. Red Indicator: Incorrectly Installed No Red Indicator: Correctly Installed 30−32 DIN1810B Spanner Wrench (Customer-Supplied) Figure 3-15 Unicable Connection Part 1105120-03 E 2015 Nordson Corporation...
Page 48: Rf Detector Installation
One RF detector is normally required for every 16 networked units within one curing enclosure. However, some applications and systems may require a RF detector on each unit. Contact your Nordson representative for more information. Do not mount the RF detector directly below the lamphead.
Page 49: System Controller Configuration
OFF. 2. Press the Nordson Logo for 5−15 seconds to enter the configuration menu. The configuration settings are displayed in the order listed in Table 3-5.
Page 50 Remote control source IO = Use discrete remote DN = Use DeviceNet for I/O terminal remote control Refer to Table 3-3 on page 3-8 for discrete remote I/O connections. IO is the default setting. Part 1105120-03 E 2015 Nordson Corporation...
Page 51 PWROFF POWER OFF No selection No selection This is a message instructing you to turn the power supply switch OFF to save your settings in flash memory. Part 1105120-03 E 2015 Nordson Corporation...
Page 52 3-26 Installation Part 1105120-03 E 2015 Nordson Corporation...
Page 53: Operation
The startup procedures documented in this manual are strictly for the UV equipment. Display and Controls See Figure 4-1 and Table 4-1. MPS2-610V Figure 4-1 CoolWave 2 System Controller Displays and Controls Part 1105120-03 E 2015 Nordson Corporation...
Page 54 20% the control will stay at 40% until the calculated value is again above 20%. This will not set an error but the unit power will not go below 20%. Part 1105120-03 E 2015 Nordson Corporation...
Page 55: Additional Functions
20 seconds. LOCK is displayed momentarily. The period at the left of the display remains on as long as the system is locked. To unlock the system press REMOTE for approximately 20 seconds. UNLOCK displays and the unit returns to normal operation. Part 1105120-03 E 2015 Nordson Corporation...
Page 56: Operating Messages
NO LIGHT DETECTED There was insufficient output from the lamp when the system controller energized the magnetrons in the Lamp On mode. HARDWARE FAILURE The system controller is not communicating with the light board. Part 1105120-03 E 2015 Nordson Corporation...
Page 57: Resetting Faults
NOTE: Once the fault has been corrected you can reset a fault on a unit operating in Remote Mode from the host controlling the master unit through either a discrete I/O or DeviceNet. Part 1105120-03 E 2015 Nordson Corporation...
Page 58: System Timing Sequences
Idle is a configurable mode. If not enabled, only the Standby mode is active. Changing system status from IDLE to LAMP ON Total Seconds Display reads IDLE. ~ 2 seconds Press SYSTEM ON button. Display reads LMPDLY. Display reads LAMPON. Part 1105120-03 E 2015 Nordson Corporation...
Page 59 Changing system status from LAMP ON to OFF Display reads LAMPON. Total Seconds 60 seconds Press SYSTEM OFF button. Display reads C DELY. Display reads OFF. Shutdown timing at completion of process allows for proper cooling. Part 1105120-03 E 2015 Nordson Corporation...
Page 60: Timing Sequence With Idle = N
Changing system status from LAMP ON to OFF Total Seconds Display reads LAMPON. 60 seconds Press SYSTEM OFF button. Display reads C DELY. Display reads OFF. Shutdown timing at completion of process allows for proper cooling. Part 1105120-03 E 2015 Nordson Corporation...
Page 61: Correcting A Fault Condition
FAULT EXT INTERLOCK will be displayed. On the NETWORK selector, press LOCAL. Set the NETWORK configuration. On the master unit NETWORK selector, press LOCAL. On the remote unit NETWORK Selectors, press REMOTE. Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 62 External Blower Units: Turn on the external blower. If there is insufficient pressure the system faults and FAULT LOW LAMPHEAD PRESSURE is displayed. (Check for proper pressure with the appropriate instrumentation.) The internal blower automatically turns on and off as required. Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 63 4. To return to curing, initiate LAMPON command (locally or remotely). 5. The lamp is ready to cure within approximately 5−7 seconds. NOTE: After 10 minutes in Idle mode, the unit automatically switches to Standby mode. Part 1105120-03 E 2015 Nordson Corporation...
Page 64: Remotely Operated Units
Turn on the external blowers. If there is insufficient pressure a system fault occurs and the message FAULT LOW LAMPHEAD PRESSURE appears in the display. (Check for proper pressure.) The internal blower automatically turns on and off as required. Part 1105120-03 E 2015 Nordson Corporation...
Page 65: Shutdown
Turn off main power to all units. Part 1105120-03 E 2015 Nordson Corporation...
Page 66 4-14 Operation Part 1105120-03 E 2015 Nordson Corporation...
Page 67: Troubleshooting
These troubleshooting procedures cover only the most common problems. If you cannot solve a problem with the information given here, contact your local Nordson representative for help or call 800−524−1322 for technical support. System Software Versions If you call for technical support, you may be asked to provide the version numbers for the software installed in your system.
Page 68: Fault Message Troubleshooting
Fault on remote unit. Fault 6: Phase control board has failed. Replace phase control board. FAULT MAG POWER WHEN OFF Phase control board failure Magnetron current detected when in Standby or Off mode. Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 69 FAULT NETWORK COMM connected to network. connections. Damaged network cables. Replace the network cables. Network Fault Improper network setup. Refer to Network Connections and Master/remote network System Controller Configuration in connection lost. Section 3, Installation. Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 70 Check the continuity of the RF cable. Replace the cable if necessary. See RF Fault. Figure 8-1, System Schematic. System does not sense the RF detector is damaged. Replace the RF detector. RF detector. Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 71 FAULT RF DETECTOR detector has been permanently Detector Installation on page 3-22. FAILED damaged by a very high RF field. NOTE: This failure is only RF Fault. possible under extreme conditions. RF Detector failed self-test. Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 72: Bulb Troubleshooting
Refer to page 6-7 in the Section 6, Maintenance and Repair for installation instructions. Replace the reflectors if necessary. Wrong bulb used. Make sure the proper bulb for the lamp is installed. Part 1105120-03 E 2015 Nordson Corporation...
Page 73: Curing Process Troubleshooting
The lamphead is Loose component or debris in the Tighten all fasteners. Clean the showing signs of lamphead. lamphead interior. electrical arcing Refer to Section 6, Maintenance and Repair to replace any damaged lamphead parts. Part 1105120-03 E 2015 Nordson Corporation...
Page 74: Diode Block Testing
GND to pin 10 open, over 20 M ohm TP− to pin 2 short, less than 0.2 ohm TP− to TP+ 200 ohm ±1% C to FB 1000 ohm ±1% C to GND 4.9 ohm ±1% Part 1105120-03 E 2015 Nordson Corporation...
Page 75: Maintenance And Repair
System Controller Maintenance and Repair Maintenance Schedule Recommended maintenance for the system controller consists of removing dust from the enclosure and components. This should be done as necessary. Part 1105120-03 E 2015 Nordson Corporation...
Page 76: System Controller Repair Procedures
Refer to the Section 7, Parts for ordering information. F1: Blower, 3A, slow blow, 250V F2: Blower, 3A, slow blow, 250V F3: Board Power, 160mA, slow blow, 250V F4: Filament Transformers, 2A, slow blow, 250V Part 1105120-03 E 2015 Nordson Corporation...
Page 77: Cleaning System Controller Cooling Fans
2. The system controller cooling fans are located on the front and rear panels. Make sure the safety covers are clean and free of debris. 3. Examine the fan blades for contamination or damage. Clean the blades or replace the fan if necessary. Part 1105120-03 E 2015 Nordson Corporation...
Page 78: Lamphead Maintenance And Repair
Internal blower filters cannot be cleaned. They are coated with a tacky material that traps contaminants. NOTE: Nordson does not supply filters on the system controller or external blowers. Filters must be supplied by the customer. For Internal blower lampheads, a filter is provided (refer to page 6-5 for replacement instructions ).
Page 79: Internal Blower Lamphead Filter Replacement
5. If necessary, loosen the lamphead mounting fasteners and remove the lamphead from its mounting. Bulb Replacement CAUTION: Use only the Nordson bulbs listed in this manual. Equipment damage may occur if bulbs from any other source are used. 1. Perform the Preparation procedure in this section.
Page 80 Refer to the Section 1, Safety section for the bulb return policy. 7. Install the RF screen on the lamphead base with the eight M4 screws. Torque the screws to 1.18−1.57 NSm (0.87−1.16 lb-ft). Figure 6-4 Bulb Removal and Replacement. Part 1105120-03 E 2015 Nordson Corporation...
Page 81: Reflector Replacement
Note that two retainers are stamped into the flood bracket. 253.8 mm (9.99 in.) Springs 32.732 mm (1.28 in.) Focus Reflector Bracket 253.8 mm (9.99 in.) Retainers Springs 42.338 mm (1.66 in.) Flood Reflector and Bracket Figure 6-6 Reflector Brackets Part 1105120-03 E 2015 Nordson Corporation...
Page 82 NOTE: The outside edges of the reflectors are printed with the part number. 6. Slide the new reflectors into the lamphead base and slide the inside edges into the notches in the white supports. Part 1105120-03 E 2015 Nordson Corporation...
Page 83 Figure 6-10 Flood Reflector Installation 8. Torque the six retaining bracket screws to 1.8−1.57 NSm (0.87−1.16 lb-ft) to secure the retaining brackets. 9. Install the bulb and RF screen as described on page 6-6. Part 1105120-03 E 2015 Nordson Corporation...
Page 84: Internal Blower Replacement
7. Install the blower cover and secure it with the six M4 x 10 screws. Torque the screws to 1.35 NSm (12 in-lbs). Blower Connector Blower Harness Ground Wire Receptacle M4 x 10 Screws M6 x 20 Screws Figure 6-11 Removing Blower Cover Part 1105120-03 E 2015 Nordson Corporation...
Page 85: Internal Blower Lamphead Complete Cover Removal
− 4 Front and 4 Rear Figure 6-13 Removing Blower Plug and Screws 6. See Figure 6-14. Lift the bottom cover straight up and then push the unicable receptacle into the cover until it clears the cover housing. Part 1105120-03 E 2015 Nordson Corporation...
Page 86: Internal Blower Lamphead Cover Replacement
4. See Figure 6-12. Replace the top blower cover and secure with 6 screws (3 front and 3 rear). Tighten the screws to 1.35 NSm (12 in-lbs). 5. Refer to page NO TAG. Reconnect the unicable to the lamphead. Part 1105120-03 E 2015 Nordson Corporation...
Page 87: External Blower Lamphead Cover Removal
3. Remove the lamphead cover as described in the Internal Blower or External Blower Lamphead Cover Removal procedures. 4. Remove the two M4 screws shown in Figure 6-16. Bracket Screws Figure 6-16 Transformer Bracket Screws Part 1105120-03 E 2015 Nordson Corporation...
Page 88: Magnetron Replacement
3. Remove the two terminal screws and disconnect the cables from the magnetron pigtails. Remove the sleeves and discard them. Save the screws for re-use. HV Insulation Sleeves Terminal Screws Figure 6-18 Magnetron Removal Part 1105120-03 E 2015 Nordson Corporation...
Page 89: Filament Transformer Replacement
3. Remove the two terminal screws and disconnect the cables from the magnetron pigtails. Remove the sleeves and discard them. Save the screws for re-use. 4. Remove the transformer bracket from the wave guide assembly. Part 1105120-03 E 2015 Nordson Corporation...
Page 90 8. Secure the transformer to the bracket with the M4 screws and nuts, securing the green transformer ground wire to the bracket with the screws. Secondary Ground Cables Wire Screws Figure 6-21 Transformer Installation Part 1105120-03 E 2015 Nordson Corporation...
Page 91 Secure the top and bottom of the sleeves with cable ties. 15. Slide the transformer bracket all the way into the wave guide assembly. Secure the bracket with the two M4 screws shown in Figure 6-16. Part 1105120-03 E 2015 Nordson Corporation...
Page 92: Light Detector Board Replacement
2. See Figure 6-24. Cut the RTV sealant at the bulb base and unscrew the bulb. 3. Screw the new bulb into the socket. Apply a small dot of RTV sealant between the bulb and socket. The RTV sealant keeps the bulb from vibrating out of the socket. Part 1105120-03 E 2015 Nordson Corporation...
Page 93: Re-Assembly
1. Check all wiring connections and make sure they are secure and that insulation is intact. 2. Install the cover on the lamphead. 3. Install the bulb and RF screen as described in Bulb Replacement on page 6-6. Part 1105120-03 E 2015 Nordson Corporation...
Page 94 6-20 Maintenance and Repair Part 1105120-03 E 2015 Nordson Corporation...
Page 95: Parts
Parts Section 7 Parts Introduction To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. CW2 610 System Controllers Part Description Note 60 Hz Applications: 1084113 System controller, 480V...
Page 96: System Controller Repair Parts
160 microamp, 250 volt control board fuse; one 2 amp, 250 volt fuse for the filament transformer. C: This part is a 4 pole, 600V, 20A, 24V coil contactor. D: Choose correct I/O board kit for your application. NS: Not Shown Part 1105120-03 E 2015 Nordson Corporation...
Page 97 Parts 12 (Cover) Figure 7-1 CoolWave 2 610 System Controller and RF Detector Part 1105120-03 E 2015 Nordson Corporation...
Page 98: Cw-2 Internal Blower Lampheads
S SCREW, slotted pan head, 6−32 x .250 in. 984101 S NUT, hex, machine, 6−32, steel, zinc 983044 S WASHER, lock, internal, 6, steel, zinc −−−−−− S NUT, lock, nylon, M3, steel, zinc 984727 S NUT, hex, M4, brass Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 99: Torque Specifications For Lamphead Fasteners
SCREW, pan head, phillips, M4 x 40, steel 1.18−1.57 NSm (0.87−1.16 lb-ft) NUT, hex, w/external toothed washer, M4 1.18−1.57 NSm (0.87−1.16 lb-ft) SCREW, truss, M4 x 10, Phillips, steel, zinc 1.35 NSm (12 lb-in) Part 1105120-03 E 2015 Nordson Corporation...
Page 100: Parts Illustration − Internal Blower Lamphead Parts
Parts Parts Illustration − Internal Blower Lamphead Parts 3A, 3B (Cover Screws) Figure 7-2 CoolWave 2 Internal Blower Lamphead (shown with cover removed) Part 1105120-03 E 2015 Nordson Corporation...
Page 101: Cw-2 External Blower Lampheads
S SCREW, pan head, Phillips, M4 x 40, steel −−−−−− S NUT, hex, w/external toothed washer, M4 −−−−−− S SCREW, truss, M4 x 6, Phillips, steel, grade 8 −−−−−− S SCREW, pan head, slotted, M4 x 8, brass Continued... Part 1105120-03 E 2015 Nordson Corporation...
Page 102: Torque Specifications For Lamphead Fasteners
1.18−1.57 NSm (0.87−1.16 lb-ft) NUT, hex, w/external toothed washer, M4 1.18−1.57 NSm (0.87−1.16 lb-ft) SCREW, truss, M4 x 10, Phillips, steel, zinc 1.6−1.8 NSm (14−16 lb-in) SCREW, socket, M5 x 50, black 4.6−5.1 NSm (40−45 lb-in) Part 1105120-03 E 2015 Nordson Corporation...
Page 103: Parts Illustration − External Blower Lamphead Parts
Parts Parts Illustration − External Blower Lamphead Parts 3A, 3B (Cover Screws) Figure 7-3 CoolWave 2 External Blower Lamphead (shown with cover removed) Part 1105120-03 E 2015 Nordson Corporation...
Page 104: Bulbs
2 bulb retainer springs, 4 screws, 4 locknuts. You must also order a 775061 flood reflector retainer bracket kit (contains 2 brackets). RF Detector Part Description Note 1086731 Detector, RF NOTE A: Refer to System Cables on page 7-11 for proper length RF Detector cables. Part 1105120-03 E 2015 Nordson Corporation...
Page 105: System Cables
12 ft CABLE, RF detector 775029 25 ft CABLE, RF detector 775050 50 ft CABLE, RF detector 775051 75 ft CABLE, RF detector 775052 100 ft CABLE, RF detector 775031 NETWORK CABLE, 6 ft Figure 7-4 System Cables Part 1105120-03 E 2015 Nordson Corporation...
Page 106: Accessories
ThruCure Continuous Coating System − A hinged aluminum chamber equipped with customer-machinable entrance and exit vestibules and additional reflectors for a 360 degree cure that mounts on the lamphead. 1100919 Chamber, ThruCure, 10 in. External Blowers − Contact your Nordson representative for information on external blowers. Standard Closed Open...
Page 107: Optional Lamphead Mounting Kit
3. Mount the bracket on a suitable surface or rack, using the extra four 5/16−18 socket-head screws (3). Use the bracket handles to tighten and loosen the pivot joints and position the lamphead as desired. Part 1105120-03 E 2015 Nordson Corporation...
Page 108 7-14 Parts Part 1105120-03 E 2015 Nordson Corporation...
Page 109: System Controller
Refer to Table 8-2 Environmental Operating Conditions Ambient Temperature 5−40 _C (41−104 _F) Altitude Contact Nordson UV Engineering Relative humidity 80% up to 31 _C (88 _F), decreasing linearly to 50% at 40 _C (104 _F) Ingress Protection Rating IP−21 RF Detector Max.
Page 110: Current Draw
Amps @ 440 Vac Table 8-3 Power Line Current for 610 Internal Blower Line 60 Hz 50 Hz Amps @ 440 Vac Amps @ 480 Vac Amps @ 380 Vac Amps @ 440 Vac Part 1105120-03 E 2015 Nordson Corporation...
Page 111: Light Output Settings
Specifications Light Output Settings Nordson CW2 UV Output Remote Input 4 mA 8 mA 12 mA 16 mA 20 mA 10 V Remote Input ⎯ mA/VDC Figure 8-1 Light Output Settings Master/Remote Power Setting Examples If the Master Unit is set at...
Page 112: Lamphead
RF leakage detection Bulb Table 8-5 Bulb Specifications Item Specification Length 254 mm (10 in.) Power 600 watts/in. maximum Types Mercury, Mercury +, Iron, Gallium, Indium, Lead System Schematic See Figures 8-1 and 8-2. Part 1105120-03 E 2015 Nordson Corporation...
Page 113 24V COM. SHIELD CONN3−3 CONN6−3 CONN3−4 CONN6−4 CONN3−5 SHIELD CONN3−5 CONN6−5 CONN2−6 SHIELD/DRAIN CONN3−6 CONN6−6 CONN6−7 CONN2−1 STARTER BULB CONN2−3 14 13 12 11 10 9 SHIELD/DRAIN LAMP HEAD Figure 8-1 External Blower System Schematic Part 1105120-03 E 2015 Nordson Corporation...
Page 114 CONN3−5 CONN6−5 SHIELD/DRAIN CONN2−6 BULB CONN3−6 CONN6−6 CONN6−7 CONN2−1 CONN2−3 CONN1−3 CONN2−8 CONN1−4 14 13 12 11 10 9 CONN1−1 CONN1−2 TEMP SENSOR INTERNAL SHIELD/DRAIN BLOWER LAMP HEAD Figure 8-2 Internal Blower System Schematic Part 1105120-03 E 2015 Nordson Corporation...
Page 115: Uv Glossary
Low powered UV composed of wavelengths in the UVA band. Usually powered with several 100-watt power supplies or less instead of several 1000-watt power supplies. Nordson’s UV Star and CoolWave product lines are much higher in irradiance and energy density than black light UV products.
Page 116 417 nm and a spectral concentration between 400 and 450 nm. They are often used when deeper cure is required or with white coatings containing titanium oxides. In some industries, microwave gallium bulbs are referred to as V bulbs. Part 1105120-03 E 2015 Nordson Corporation...
Page 117 Low-powered UV in the UVC band. Usually powered with several 100-watt power supplies or less instead of several 1000-watt power supplies. Nordson’s UV Star and CoolWave product lines are much higher in irradiance and energy density than germicidal UV products.
Page 118 When a lamphead is located further away from the substrate or closer to the substrate than the focal distance. oxidizing When the coating or ink reacts with oxygen and slows the polymerization process of the cure. Part 1105120-03 E 2015 Nordson Corporation...
Page 119 To further reduce heat, the quartz can be coated with a material that passes UV light and absorbs infrared energy. Part 1105120-03 E 2015 Nordson Corporation...
Page 120 Typically, the concentration is provided as a normalized percentage where the energy is integrated over 10-nanometer bands to reduce the difficulty of quantifying the effects of line emission spectra. Part 1105120-03 E 2015 Nordson Corporation...
Page 121 The portion of the electromagnetic spectrum ranging between 200 and (200−280 nanometers) 280 nm. UVC is typically referred to as short UV. The portion of the electromagnetic spectrum ranging between 400 and (400−445 nanometers) 445 nm. The V stands for visible UV. Part 1105120-03 E 2015 Nordson Corporation...
Page 122 One joule per second. watt density Refer to irradiance. waveguide Directs microwaves toward the bulb in microwave UV systems. wavelength The measured cycle length of a wave in the direction of propagation. Part 1105120-03 E 2015 Nordson Corporation...
Page 123: Devicenet Specifications
DeviceNet Interface Module Revision 0.62. This specification describes the unit configuration, unit initialization, the DeviceNet Network Model and the interface to the Nordson Coolwave2 module. It describes the functionality required of the network interface module. It does not describe implementation details or specify the requirements for the PCB or enclosure.
Page 124: System Operation
2 set the baud rate to the last baud rate the device was powered up at and allow software configuration tools to modify the baud rate. DATA RATE 500 Kb 250 Kb 125 Kb Figure 10-2 Baud Rate Switch S1 Part 1105120-03 E 2015 Nordson Corporation...
Page 125: Led Operation
Red, DeviceNet Power is not present Baud Rate / Mac ID switch value changed, next power up uses a new configuration Green Solid Normal Operation Red/Green Flashing Device is in self test mode LEDs Figure 10-3 DeviceNet Status LEDs Part 1105120-03 E 2015 Nordson Corporation...
Page 126: Devicenet Interface
Group 2 Unconnected message port. Certification The unit must be certified as a compliant DeviceNet device through an ODVA certified testing facility. This device is not required to pass SEMI-SIG optional conformance testing. Part 1105120-03 E 2015 Nordson Corporation...
Page 127: Identity Object (01Hex − 1 Instance)
Normal: Class 1, Instance 1, 1 byte data = 0 Out of Box: Class 1, Instance 1, 1 byte data = 1 Message Router Object (02 1 Instance) HEX − No supported attributes or services. Part 1105120-03 E 2015 Nordson Corporation...
Page 128: Devicenet Object (03Hex − 1 Instance)
Baud Rate Switch Changed BOOL (since last power up) Actual MAC ID Switch Value (0−99) USINT Actual Baud Rate Switch Value (0−9) USINT Common Services Implemented for Service Code Class Level Instance Level Service Name Get_Attribute_Single Set_Attribute_Single Part 1105120-03 E 2015 Nordson Corporation...
Page 129: Assembly Object (04Hex - 2 Instances)
Polled Output Assembly Instance UINT Get / Set (valid values are 112) Polled Output Size UINT Instance Attributes (Instances 100 and 112) Attribute DeviceNet Data Access Name Data Type Value Rule Data USINT Get / Set Part 1105120-03 E 2015 Nordson Corporation...
Page 130 9 – Lamp Cool 10 – Test 11 – Start Power Delay Lamp Power Level: USINT 0x64 varies 0 −100% 10 – 13 Lamp Fault: UDINT 0x64 varies 32−bits Defined in S−Device Supervisor Object Part 1105120-03 E 2015 Nordson Corporation...
Page 131 5 – Lamp On 6 – Fault 7 – Reset 8 – Cool Off 9 – Lamp Cool 10 – Test 11 – Start Power Delay Slave 2 Lamp Power Level: USINT 0x64 0 −100% Part 1105120-03 E 2015 Nordson Corporation...
Page 132: Common Services
NOTE: Receive_Idle condition (0 byte length message) is treated as a DeviceNet fault condition by the CoolWave2 unit. NOTE: Commands other than those listed are not implemented, and will be ignored by the CoolWave2 unit. Common Services Implemented for Service Code Class Level Instance Level Service Name Get_Attribute_Single Set_Attribute_Single Part 1105120-03 E 2015 Nordson Corporation...
Page 133: Connection Object (05Hex − 2 Instances)
Produced UINT Connection Path Length Produced USINT Array NULL 20h 04h 24h Connection Path 65h 30h 03h Consumed UINT Connection Path Length Consumed USINT Array NULL 20h 04h 24h Connection Path 70h 30h 03h Part 1105120-03 E 2015 Nordson Corporation...
Page 134: Common Services
Hardware Revision Level SHORT “Rev A“ STRING6 Device Status USINT Exception Status BYTE Exception Detail Alarm STRUCT 0…0 Exception Detail Warning STRUCT 0…0 Alarm Enable BOOL Get / Set Warning Enable BOOL Get / Set Part 1105120-03 E 2015 Nordson Corporation...
Page 135 Stop Abort Recover Perform_Diagnostics The Coolwave2 enters the “Nordson Off State” as a result of S−Device Supervisor commands “Reset”, “Stop” or “Abort”. The S−Device Supervisor “Start” command transitions to the S−Device “Executing” state which allows the Nordon commands: “On, Ready, Standby and Stop”...
Page 136 Detector Detector Unit over Interlock Lamphead Detail Byte 2 Fault missing temp Pressure Manufacturer’s Unassigne Unassigne Unassigne Phase Phase Exception Filament Controller Detector Control at magnetron Detail Byte 3 Open Fault Failed Limit current Part 1105120-03 E 2015 Nordson Corporation...
Page 137: Lamp Object (64Hex − 16 Instances)
Master Magnetron Power Level Actual (0−100%) USINT Master Lamp Command: USINT Get / Set 1 – Off 2 – On 3 – Standby 5 – Reset Light Intensity Command USINT Get / Set 20−100% (0−255% accepted) Part 1105120-03 E 2015 Nordson Corporation...
Page 138: Instance Attributes (Instances 1−15)
See S−Device Supervisor for bit definitions Slave Light Intensity Level Set (0−100%) USINT Slave Magnetron Power Level Actual (0−100%) USINT Common Services Implemented for Service Code Class Level Instance Level Service Name Get Attribute Single Set Attribute Single Part 1105120-03 E 2015 Nordson Corporation...
Page 139: Index
3-5 network, 3-7 system connection, 3-4 power, 3-3 connections, two systems, 3-5 remote I/O, 3-7 Dimensions bulb, 8-4 lamphead, external blower, 3-13 lamphead, internal blower, 3-14 System Controller, 3-2, 8-1 Display, messages, operation, 4-1 Part 1105120-03 E 2015 Nordson Corporation...
Page 140 FAULT PHASE CTRL AT LIMIT, 5-5 FAULT POWER CTRL AT LIMIT, 5-4 FAULT POWER UNIT OVER TEMP, 5-4 FAULT RF DETECTOR FAILED, 5-5 FAULT RF DETECTOR MISSING, 5-4 Faults, resetting, 4-5 Filament transformer, replacement, 6-15 Filters Part 1105120-03 E 2015 Nordson Corporation...
Page 141 AirShield Ventilation System, 2-8 description, 2-8 Machine stop interlock, 3-8 LiteTite Shutter, 2-8 connection, 3-9 Output Magnetron fault, 3-8 description, 2-1, 2-3 Ready, 3-8 replacement, 6-14 Ozone, definition, exposure, 1-5 Magnetrons, Description, 2-4 Maintenance Part 1105120-03 E 2015 Nordson Corporation...
Page 142 1-5 Rapid startup, using, 3-10 safety, UV inks, 1-7 symbols, 1-9 Ready output, 3-8 UV inks, 1-7 Reflector, replacement, 6-7 Schematic external blower, 8-5 internal blower, 8-6 Schematics, 8-4 Servicing, safety while, 1-8 Part 1105120-03 E 2015 Nordson Corporation...
Page 143 3-3 remote I/O, 3-7 Voltage, specifications, 8-1 repair, 6-2 specifications, 8-1 System controllers, part numbers, 7-1 System off, function, 4-2 WARMUP, message, 4-4 System on, function, 4-2 Wave guide, description, 2-3 Wiring, diagram, 8-5 Part 1105120-03 E 2015 Nordson Corporation...
Page 144 Index Part 1105120-03 E 2015 Nordson Corporation...
Page 145 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, CW2I-410V, CW2+I-410V Description: Applicable Directives: Standards Used for Compliance: Product Certificates: Quality System Certificate – ISO9000 through...

Nordson Coolwave 2610 Manual

Safety

Description

Installation

Operation

Troubleshooting

Maintenance and Repair

Parts

UV Glossary

Devicenet Specifications

Index

Quick Links

Troubleshooting

Need help?

Questions and answers

Summary of Contents for Nordson Coolwave 2610

Table of Contents