Page 1 F300S/F300SQ Ultraviolet Lamp System Installation, Operation, and Maintenance Manual No. 509252 Rev R 3/04 FUSION UV SYSTEMS, INC. 910 Clopper Road Gaithersburg, MD 20878-1357 USA (301) 527-2660 • FAX (301) 527-2661...
Page 3 Manual No. 509252 Rev R 3/04 Applies to systems using P300M/P300MQ/P300MT power supplies, and I300M/I310M series irradiators Serial Numbers 1001 and later. (C) Copyright 2004 Fusion UV Systems, Inc. All Rights Reserved. The products covered herein conform to EC standards. See Appendix A for details.
Page 5: Table Of Contents
Table Of Contents Introduction ..........11 Document Conventions .
Page 6 Temperature ........28 High Voltage .
Page 7 Power Source ........50 System Power Connections .
Page 8 Bulb, Screen, and Reflector Maintenance ....79 Cleaning Guidelines ......79 Bulb Cleaning .
Page 9 Control Card Removal/Replacement ....107 Diode Test ....... . . 108 Capacitor Test .
Page 10 P300M/P300MT Power Supply Parts List ....144 P300MQ Quick Restart Option Parts List ....146 K300 Blower Assembly Parts List .
Page 11: Introduction
• This Introduction provides a brief description of the total system, and system components. It also contains the Fusion UV Systems warranty policy and shipping instructions for returning equipment. •...
Page 12: Document Conventions
• Appendix C, “Outline Drawings,” contains drawings that provide overview details for general reference for Fusion UV Systems products. These drawings are not to be used in designing an installation; contact Fusion directly for current specifications. • Appendix D, “Lamp System Maintenance Log,”...
Page 13: Icon Usage
CAUTION: Microwave Radiation The Fusion UV Lamp System is powered by high energy RF microwave power which can be dangerous if misused or inadequately shielded. The lamp system...
Page 14 CAUTION: Radio Interference Fusion lamps operate at a fundamental frequency of 2.45 GHz. The unit may cause interference with some local area networks (LANs) that also operate at this frequency.
Page 15: System Description
UV sensitive inks and coatings, causes virtually instantaneous curing (drying) of the exposed materials. The unique properties of the Fusion UV Lamp System are obtained by using microwave radiation to energize the lamp. Microwave energy at 2450 MHZ is generated by a power tube (magnetron) of the type widely available for commercial microwave cooking ovens.
Page 16 Figure 1. F300S/F300SQ Lamp System The F300S/F300SQ Fusion UV Lamp System (Figure 1) is modular, consisting of independent 6-inch (15.2 cm) lamp units and corresponding modular power supplies. 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 array to form lamps of 18-inch (45.7 cm), etc.
Page 17: System Components
• An RF detector cable H790 • An RF-1 detector In addition, the user must supply the following if not provided by Fusion UV Systems: • Cooling for the irradiator, if no modular blower is provided. (See Appendix A, “Specifications”...
Page 18: Cooling
Cooling Proper operation of the lamp requires adequate cooling of the magnetron and the bulb. (See Appendix C, page 129, for irradiator cooling requirements.) Cooling air from a blower goes through the magnetron cooling fins and into the lamp housing. At this point, the airflow splits into two paths: one path exhausts through the irradiator housing vent holes, and the rest of the air flows into the cavity through cooling holes in the reflector.
Page 19: Reflector And Cavity
The following table lists the various irradiator models manufactured by Fusion UV Systems, and describes their high-level differences. Table 2. Irradiator Models Irradiator Model Photoresistor Assembly RF Gasket Air Delivery I300M Direct View Standard Front Connect Plenum I301M Direct View...
Page 20: Mounting
Mounting The lamps can be mounted over a moving substrate or web, supported by the bottom rails. The lamps should be mounted 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.
Page 21: Warranty Policy
The purchaser will be charged for the representative’s time and expense. The two consumable items in a Fusion UV lamp system are the lamp bulb and the microwave power tube (magnetron). The special warranties on these components are detailed on the sales contract.
Page 22: Shipping Instructions
No person, agent, representative, or distributor is authorized to give any warranties on behalf of Fusion UV Systems, or to accept for Fusion UV Systems any other liability in connection with any of Fusion UV Systems’ products.
Page 23: Irradiators
UV Bulbs Place the bulb in a rigid tube (use Fusion UV Systems’ plastic lamp bulb replacement shipping tube if available.) Secure ends to prevent impact against the tube and wrap the tube in three layers of plastic “bubble wrap”...
Page 24 F300S/F300SQ Ultraviolet Lamp System...
Page 25: 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.
Page 26: Ultraviolet Radiation
Fusion UV equipment is interlocked to shut down if microwave leakage in excess of 5 mW/cm (milliwatts per square centimeter) is detected.
Page 27: Personnel Effects Of Microwave Radiation
Fusion lamps operate at a fundamental frequency of 2.45 GHz. The unit may cause interference with some local area networks (LANs) that also operate at this frequency.
Page 28: Ozone
At high concentrations it can cause discomfort or at sufficiently high levels be dangerous. The Fusion UV Lamp System makes less ozone than a conventional arc lamp. For example, a pair of lamps running for twelve hours in a non-vented room resulted in a steady state concentration of less than 0.02 parts per million.
Page 29: High Voltage
A high quality cable, rated at 10,000 Volts, is used in all high voltage cables manufactured by Fusion UV Systems, and can be supplied to users for any additional connections that may be required. UV Curable Materials Please consult your UV materials supplier for recommended precautions regarding the proper handling and use of these products.
Page 30 F300S/F300SQ Ultraviolet Lamp System...
Page 31: Chapter 2. Mechanical Installation
Before unpacking, examine all shipping containers for damage. After unpacking, examine the equipment for damage. Any damage should be reported immediately to the shipper and to Fusion UV Systems Incorporated. A delay of more than 10 days may invalidate future claims for damages.
Page 32: Power Supply Unit(S) Placement
After the inspection is completed, all components must be carefully re-packed and stored until actual installation. Save the packing materials. They will be valuable if any component must be returned to Fusion UV Systems for service. See “Shipping Instructions” on page 22 for more information.
Page 33: Irradiator Mounting
Irradiator Mounting The irradiator mounting structure must also provide UV shielding and adequate venting for the cooling air. This is described on the following pages. Each user will normally design the mounting structure to suit the particular application, and the user is responsible for providing the required shielding and ventilation.
Page 34: Lamps Mounted In Opposing Configuration
(as shown in Figure 6 on page 34), lamp performance and operation may be impaired. Contact Fusion UV Systems Technical service department for consultation. Figure 6. Lamps in Opposing Configuration UV Light Shielding Adequate light shielding must be provided 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 blocking eye wear.
Page 35: Rf Detector Mounting
Figure 7 illustrates the proper mounting of the RF Detector. Figure 7. Fusion UV Systems RF Detector RF-1 One RF detection device must be installed for each light shield. The antenna should point toward the irradiator screen, which is the potential source of RF leakage.
Page 36: Remote Blowers
Remote Blowers An optional remote blower package is available from Fusion UV Systems. The package includes an air distribution plenum (for multi-lamp systems), inlet filter box, and flexible hoses or ducts for cooling the system. The blower delivers 2.8 m /min (100 cfm) of air to each irradiator inlet at 695 Pa (2.8"...
Page 37 Irradiator Irradiator mounting structure support 53.3mm (2.10) Quartz plate (pair) P/N 300291 152.4 mm x 152 .4 mm x 2.29 mm (6.00 in x 6.00 in. x 0.90 in.) Irradiator Substrate cooling to be cured Removal access air flow for cleaning Quartz plate mounting structure Figure 8.
Page 38 F300S/F300SQ Ultraviolet Lamp System...
Page 39: Chapter 3. Electrical System
Chapter 3. Electrical System This chapter discusses the electrical installation and electrical setup aspects of the F300S/F300SQ Ultraviolet Lamp System. Electrical Installation/Setup Checklist Before operating the ultraviolet lamp system for the first time, be sure the following items have been reviewed and/or tested. Table 4.
Page 40: Interconnect Cables
Interconnect Cables The F300S/F300SQ interconnect cables and connector contact 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/output connections and programming used on each unit.
Page 41: Power Supply Programming
1. Disassemble the strain relief housing by removing the retaining screws and unscrewing the housing from the connector body. 2. To connect EXT INTLK or SYS BLWR inputs, remove jumper wires and the attached pins as indicated in Table Table 6, and Table 7 in this chapter.
Page 42 OFF/RST MASTER ON MASTER HI / LO MASTER UNIT TO SYS RF MASTER ASSY P/N 32755X F3q0008 Figure 10. Location of Programming Switch S1 on PWB F300S/F300SQ Ultraviolet Lamp System...
Page 43: Single Unit Programming And Connections
Switch Position POS4 POS5 POS6 1, 2, and 3 Figure 11. Table A: Programming Switch S1 Single Unit Programming and Connections The programming and connections necessary to operate a single-unit F300S/F300SQ system are summarized in Figure Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 44: Programming
Figure 12. F300/F300SQ 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 Irradiator Cable H340 Connections Non-blower version cable H340 connects to J103 and J104 on the power supply; and to J10 on the irradiator.
Page 45: Input/Output Connections
Input/Output Connections The P300M/P300MQ/P300MT has three customer 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 system. The remaining interlock inputs are optional.
Page 46: Output Ports (J105B)
NOTE: A dry contact (such as a relay contact or a PLC containing a relay contact) with gold contact material should be used to drive the remote inputs. The cable length to the dry contact should be no more than 6 meters. Shielded cable should be used to minimize possible electrical interference.
Page 47: Alternate Function For K5
(K5) (10mA minimum) no unit or system error exists. NOTE: When using circuit currents for K1-K5 below 10mA, contact Fusion UV Systems Customer Service. Alternate Function for K5 An alternate K5 function may be selected by installing a jumper onto JP2 on the control card.
Page 48: Multiple-Unit Programming And Connections
Multiple-Unit Programming and Connections Programming and connections for multiple-unit systems are summarized in Figure Typically, one unit will operate as the MASTER and all others as slaves to the ON/OFF commands of this Master unit. Refer to detailed descriptions in Chapter 4, “Operation”...
Page 49: Programming
Programming Refer to Figure 11 for programming switch S1 settings and set programming 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.
Page 50: Power Source
(rear panel of power supply). Available line voltage should be within 10% of the nominal operating voltage. Fusion UV equipment must be connected in accordance with local wiring codes. Use applicable standards for wire sizes, fuse sizes, and disconnect box locations.
Page 51: Frequency Tapping Of Hv Capacitors
North American Applications: 3x12 AWG UL listed International Applications: 3x2.5 mm Harmonized, VDE Both cable types should have minimum ratings of 16A, 300V, 0-60 °C. Refer to Table 11 on page 57 Chapter 4, “Operation,” for the leg currents for each power supply/voltage combination.
Page 52: Qro Transformer Taps (For Qro Only)
Table 9. High Voltage Transformer Taps (continued) HV Plate Power Transformer 50 Hz 220, 240 60 Hz 220, 240 QRO Transformer Taps (FOR QRO only) When the Quick Restart Option is installed, the QRO transformers must be tapped according to the frequency and voltage specifications of the customer. Should these specifications change, or if a transformer is replaced, the transformer should be tapped as follows: Table 10.
Page 53: F300S Relay Coil Resistor Assembly Installation
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 supply is 230-240 VAC at 50 Hz (nominal voltage). These resistor assemblies prevent the premature failure of the relay coils in high line voltage environments.
Page 54: Top View
CB1A L101 CB1B C102 C101 T103 Front Rear T102 T101 K102 K101 Top View Front Rear K103 K101 K102 Side View Figure 15. K101 and K102 on P300M/P300MQ F300S/F300SQ Ultraviolet Lamp System...
Page 55: Chapter 4. Operation
Chapter 4. Operation WARNING: Before operating the system, the operator must become familiar with the operating safety information presented in Chapter 1, “Safety”. 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.
Page 56: Power
• Bulb producing insufficient output to activate the photocell For proper initial ignition, the recommended “MINIMUM LAMP ON” time required for this system is “ten (10) seconds” at normal air pressure (3.5 inches w.c.) and full power operation (100% power level). As previously mentioned, a “LAMP OUT”...
Page 57: Initial Startup Procedure, Multiple-Unit Systems
3. Press the LAMP ON switch: the green LAMP ON indicator blinks, then stays lit. 4. Check the line currents. The line currents should conform to the values in Table Table 11. P300M/P300MQ/P300MT Current Requirements Line Currents (A) System Line Voltage with K300M without K300M...
Page 58: Resetting The System After A Fault
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 flashers of slaves will follow LAMP CONTROL on Master. Resetting the System After a Fault If a fault occurs in the system, press the LAMP OFF/RESET switch on the Master, or cycle the remote LAMP OFF/RESET switch, then press the Master LAMP ON switch to reset the system.
Page 59: Remote Operation
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 system.
Page 60: Operation With Remote Controls
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. Table 13. Remote Switch Functions Lamp Status Equivalent Panel Remote Switch Control...
Page 61 The QRO consists of a high-voltage, low-current power supply section located in the P300MQ power supply that allows the magnetron in the irradiator to maintain an ignited bulb at a very low input power level (approximately 10%) and a very low UV output level (less than 1%).
Page 62 Figure 16. Restart Time Versus QRO State Duration, D-bulb Figure 17. Restart Time Versus QRO State Duration, H-bulb F300S/F300SQ Ultraviolet Lamp System...
Page 63: Electrical Installation And Setup
Figure 18. Restart Time Versus QRO State Duration, V-bulb Electrical Installation and Setup For a power supply with the QRO components installed and properly connected, the QRO can be enabled by setting the control card DIP switch S1-6 (marked QRO) to the YES position.
Page 64 F300S/F300SQ Ultraviolet Lamp System...
Page 65: Chapter 5. Troubleshooting
Check that input power is connected properly. Actual line voltage must be within 10% of the voltage rating shown on the equipment label. Labels are located on the rear of the power supply. If the input voltage does not match, contact Fusion UV Systems. Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 66: Safety Interlock Tests
Safety Interlock Tests The fault indicators, RF detector, and external interlocks should be tested at regular intervals to assure safe operation of the UV system. 1. With the power supply chassis inserted into the cover and single-phase power applied, depress the IND TEST button on each power supply. All LED indicators should light.
Page 67: System Faults
Table 15. Unit Faults (continued) Indicator Description PWR ERROR Improper operation of magnetron: either no magnetron anode current 2-4 seconds after high voltage is applied, or the presence of high voltage when the Lamp system is in OFF or STANDBY. CAUTION: If a PWR ERROR fault is indicated, press the LAMP OFF/RESET switch immediately.
Page 68: Failure Diagnosis Cross-Reference
If the fault cannot be determined after investigating all possible causes listed, check the control card for damage or improperly secured connectors. Return malfunctioning control cards to Fusion UV Systems. Failure Diagnosis Cross-Reference The F300S/F300SQ system is designed to signal the operator when a failure occurs in one unit or a multiple unit system.
Page 69 Table 18. Troubleshooting/Fault Diagnosis Signal/ Operation Other Possible Cause Corrective Action Symptoms Fuses F1 and F2 Check fuse and replace if blown. Power supply wiring If fuse immediately blows again, replace fuses. Then: A. Disconnect P104 on back of power supply, P10 from the irradiator, and P20 at the RF detector.
Page 70 Table 18. Troubleshooting/Fault Diagnosis (continued) Signal/ Operation Other Possible Cause Corrective Action Symptoms Open control input. A jumper or an external circuit between Lamp control at EXT INTLK J105A-9 and J105A-10 must be closed by OFF, or from indicator lights a jumper or an external switch.
Page 71 Table 18. Troubleshooting/Fault Diagnosis (continued) Signal/ Operation Other Possible Cause Corrective Action Symptoms BLWR Single-phase “Basic Checks” on page PRESSURE voltage missing indicator lights phase Air pressure Measure air pressure inside irradiator following the procedure described in Chapter 6, “Maintenance”. IF PRESSURE IS LOW: Dirty air filters Replace dirty air filter on remote or...
Page 72 Table 18. Troubleshooting/Fault Diagnosis (continued) Signal/ Operation Other Possible Cause Corrective Action Symptoms Switch from PS TEMP Power supply fan Repair or replace fan. OFF to indicator lights inoperative STANDBY or Power supply too Move to cooler location. from STANDBY hot or in poor to ON location...
Page 73 Table 18. Troubleshooting/Fault Diagnosis (continued) Signal/ Operation Other Possible Cause Corrective Action Symptoms High Voltage Cable Check cable connections at J103, J104, J10, and J11. Lamp Bulb Measure the Photoresistor output at the photocell test points and magnetron current test points on the front panel while switching to LAMP ON.
Page 74 If no power supply fault can be found, disconnect all power. Replace magnetron (see Chapter 6, “Maintenance”). WARNING: If no magnetron test voltage is measured at the magnetron test points, remove power from the unit immediately. Consult Fusion UV Systems Technical Services. F300S/F300SQ Ultraviolet Lamp System...
Page 75 Table 18. Troubleshooting/Fault Diagnosis (continued) Signal/ Operation Other Possible Cause Corrective Action Symptoms Dirty surface Inspect lamp bulb and reflector. Clean or replace as necessary. Try to start again. Line voltages out of NOTE: If the magnetron needs to be LAMP OUT specification replaced prematurely, check that the...
Page 76 Table 18. Troubleshooting/Fault Diagnosis (continued) Signal/ Operation Other Possible Cause Corrective Action Symptoms PWR IMBAL Power Supply Usually, a diode or capacitor failure will indicator lights reduce magnetron current by one-half. Test the diodes and capacitors according Chapter 6, “Maintenance”. The voltage to the primary coils ONLY of the high voltage transformers should also be checked.
Page 77 Table 18. Troubleshooting/Fault Diagnosis (continued) Signal/ Operation Other Possible Cause Corrective Action Symptoms Lamp Control at LAMP OUT Control card Replace control card. LAMP ON indicator does not light, or UV lamp does not light Arcing sound Damaged Reflector Disconnect all power. Inspect reflector for from irradiator, pitting near large slots.
Page 78 F300S/F300SQ Ultraviolet Lamp System...
Page 79: Chapter 6. Maintenance
Chapter 6. Maintenance This chapter provides maintenance procedures for the I300M irradiator, the I310M/311M Irradiator, the P300MT power supply, and the K300 modular blower. I300M Irradiator Bulb, Screen, and Reflector Maintenance Cleaning Guidelines At least every 500 hours of operation, the irradiator should be removed from the light shield, and the screen, lamp bulb, and reflector inspected carefully.
Page 80: Screen Cleaning
If cleaning reflectors while assembled in the irradiator, drying with compressed air is NOT recommended because particles or residues can be driven into spaces between components and into optical sensing elements. Screen Cleaning Screens may be cleaned with the same cleaners cited previously, soaking if necessary, brushing lightly and rinsing well.
Page 81: Lamp Bulb Removal/Replacement
1. Refer to Figure 19. Loosen the four M3 screen retaining screws three turns each. Repeat, this time removing screws. Grasp the screen frame by both ends, taking care not to twist or bend the screen itself, and remove screen assembly. 2.
Page 82: Reflector Removal/Replacement
CAUTION: Do not apply bending 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 failure. 3. Clean any deposits from the surface of the bulb (see “Cleaning Guidelines”...
Page 83 3. Referring to Figure 23, remove and discard the two end reflectors and the gaskets underneath. If evidence of arcing is present, 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 replacement end reflectors must be installed before installing the new bulb and reflectors and the new RF Gasket.
Page 84 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 final motion, grasp the sides of the reflector and gently force them together a small amount, then settle the reflector down over the mounting surfaces (Figure...
Page 85 CAUTION: Do not use the flathead screws to pull the reflector into place. Excessive pull on these screws will deform the reflector face at its bend radius or loosen its rivets. This would result in a failure of the screen assembly to seat properly and subsequent damage to the screen gaskets.
Page 86: I300M Irradiator Housing Removal/Replacement
11. Replace the screen assembly. After replacing the screen assembly, refer to Figure 26; hand-tighten 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 specified. Figure 26.
Page 87: Direct View Photoresistor Removal/Replacement
Air intake plenum Air pressure switch Magnetron Filament transformer bracket Filament transformer Photo resistor direct view assembly Die casting RF screen Figure 27. I300M/I301M Irradiator Component Location Direct View Photoresistor Removal/Replacement 1. Remove the housing as described in the previous section. 2.
Page 88: Filament Transformer Removal/Replacement
5. Remove and discard the PWB and inspect the UV filter lens for damage. 6. Replace the photoresistor and UV filter lens assembly. 7. Reinstall the housing. Photoresistor PWB Photoresistor mating connector Photoresistor UV filter lens Photoresistor mounting block Photoresistor block mounting holes Figure 28.
Page 89: Magnetron Removal/Replacement
5. Reconnect the filament transformer wires to the magnetron and tighten the terminal screws to 0.9 N-m (8 inch-lbs) using a torque-limiting screwdriver. Reposition the tubing over the terminal screws and install cable ties. 6. Install the irradiator housing as described in “I300M Irradiator Housing Removal/Replacement”...
Page 90: Air Pressure Verification
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 (Figure 30 on page 90). For the I300M, the pressure should be 447-596 Pa (1.8-2.4” H O) with respect to outside (ambient) air.
Page 91: Air Pressure Switch Replacement
Air Pressure Switch Replacement 1. Remove the irradiator cover. 2. Pull the silicone tubing off the low pressure port of the switch. 3. Disconnect the two electrical leads from the switch. 4. Reach inside the air distribution plenum and remove the short length of silicone tubing which secures the pressure switch to the plenum wall.
Page 92: Bulb Cleaning
Bulb Cleaning Handle bulbs with a lint-free cloth or tissue taking care not to leave fingerprints. Baked-on material can be removed from bulbs with a mild abrasive cleaner such as Soft Scrub®, followed by a thorough rinse with water. If alcohol is allowed, do a final wipe with alcohol.
Page 93: Screen Assembly Removal/Replacement
Screen Assembly Removal/Replacement CAUTION: In handling the irradiator or screen assembly, try to avoid all direct contact with the screen, as it punctures easily. Do not apply pressure to the screen. 1. Refer to Figure 31. Loosen the four M3 screen retaining screws, using three turns each.
Page 94: Reflector Removal/Replacement
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 failure. Retaining hole Figure 32.
Page 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 there is any sign of either. Replace as described in “Replacing the RF Gasket Assembly” on page 3. Refer to Figure 33 on page 95, and remove and discard the two end reflectors and the gaskets underneath.
Page 96 Profile of properly installed gaskets Figure 34. Gasket Installation (I330M/I311M) 4. Insert both end reflectors, ensuring that they both seat fully and evenly. The replacement end reflectors must be installed before the new RF Gasket. 5. Install the two pre-cut (long) RF gaskets into the grooves for the end reflectors. Insert one end flush with the top of the mounting surfaces (Figure 34).
Page 97 Figure 35. Correct Reflector Alignment (I310M/I311M) 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 final motion, grasp the sides of the reflector and gently force them together a small amount, then settle the reflector down over the mounting surfaces (Figure...
Page 98 Figure 36. Reflector Screw Tightening Sequence (I310M/I311M) 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 9. Clean the reflector to remove fingerprints. 10.
Page 99: Replacing The Rf Gasket Assembly
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. Cross-guide (short) Gasket Mesh...
Page 100: I310M/I311M Irradiator Housing Removal/Replacement
4. Remove the extrusions. While holding the 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 extrusions) with the mesh facing outward toward the RF screen (at the bottom of the irradiator) along with the two cross-guide (short) gaskets behind each assembly.
Page 101: Direct View Photoresistor Removal/Replacement
Air intake plenum Air pressure switch Magnetron Filament transformer bracket Photo resistor Filament transformer scatter view assembly Die casting RF screen Figure 39. I310M/I311M Irradiator Component Location (Scatter View) Direct View Photoresistor Removal/Replacement 1. Remove the housing as described in the previous section. 2.
Page 102 6. Replace the photoresistor and UV filter lens assembly. 7. Reinstall the housing. Air intake plenum Air pressure switch Magnetron Filament transformer bracket Filament transformer Photo resistor direct view assembly Die casting RF screen Figure 40. I310M-D/I311M-D Irradiator Component Location (Direct View) F300S/F300SQ Ultraviolet Lamp System...
Page 103: Filament Transformer Removal/Replacement
Photoresistor PWB Photoresistor mating connector Photoresistor UV filter lens Photoresistor mounting block Photoresistor block mounting holes Figure 41. Photoresistor Assembly for Direct View (I300M) Filament Transformer Removal/Replacement 1. Remove irradiator housing. 2. Cut the cable ties and slide the PVC tubing off the magnetron connections. Remove the filament terminal screws.
Page 104: Magnetron Removal/Replacement
Magnetron Removal/Replacement 1. Remove the irradiator housing as described previously. 2. Disconnect the filament transformer wires from magnetron by removing the cable ties and sliding back the tubing. Remove the terminal screws. 3. Remove the filament transformer bracket and air plenum. 4.
Page 105: Air Pressure Verification
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 I310M-D/I311M-D, the pressure should be 447-596 Pa (1.8-2.4” O) with respect to outside (ambient) air.
Page 106: P300M/P300Mq Power Supply
2. Pull the silicone tubing off the low pressure port of the switch. 3. Disconnect the two electrical leads from the switch. 4. Reach inside the air distribution plenum and remove the short length of silicone tubing which secures the pressure switch to the plenum wall. 5.
Page 107: Test Point Voltages
(TP105 and TP106) Control Card Removal/Replacement This unit must be disconnected and returned to Fusion UV Systems for repair or direct replacement. The control card cannot be repaired in the field. 1. Remove the six screws from the power supply cover. Remove the cover.
Page 108: Diode Test
Diode Test An ohmmeter can be used to check for a shorted or open capacitor. (Isolate the component before making continuity tests.) Disconnect all power sources WARNING: before servicing high voltage components. Ohmmeters having less than a 6V battery can give erroneous indications of high resistance in both directions when testing these high voltage diodes.
Page 109 Figure 44. P300M/P300MQ Component Identification Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 110: Capacitor Test
Capacitor Test CAUTION: An ohmmeter can be used to check for a shorted or open capacitor. (Isolate the component before performing continuity tests.) WARNING: Disconnect all power sources before servicing high voltage components. The ohmmeter should have a minimum 6V battery, and should be set on the high resistance scale.
Page 111 1. Disconnect all power, discharge the high voltage capacitors, and disconnect all leads from the transformer terminals. 2. Unbolt the transformer from the power supply chassis. 3. To replace the transformer, reverse the steps, being certain that terminals are in the correct locations.
Page 112: P300Mt Power Supply
Table 20. Transformer Terminal Orientation XFMR P300M/ T101 Black/White Red/White P300MQ T102 Black/White Red/White NOTE: When colors are indicated, the first is the wire color and the second is the stripe color. P300MT Power Supply The P300MT power supply is electrically identical to the standard P300M power supply except that the chassis is 7 inches (184 mm) shorter than the standard P300M.
Page 113: Test Point Voltages
Magnetron Current Test MAG A - COM 0.650-0.750 VDC (TP105 and TP106) Control Card Removal/Replacement This unit must be returned to Fusion UV Systems for repair or direct replacement. The control card cannot be repaired in the field. Disconnect all power sources WARNING: before servicing high voltage components.
Page 114: Diode Test
3. Remove all connectors. WARNING: Exercise extreme caution; the chassis weighs up to 40.3 kg (88.6 lbs.) 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.
Page 115: Capacitor Test
Capacitor Test An ohmmeter can be used to check for a shorted or open capacitor. (Isolate the component before making continuity tests.) The ohmmeter should have a minimum 6V battery, and should be set on the high resistance scale. 1. Remove all power, discharge the capacitor, and disconnect all leads from the capacitor terminals.
Page 116: High Voltage Transformer Removal/Replacement
2. With an ohmmeter set on the highest scale, measure the resistance between the two outside capacitor terminals and the center terminal. The meter needle should momentarily deflect upward to indicate continuity, and should then return to infinity. Reversing the meter leads should give the same indication. 3.
Page 117: K300 Modular Blower
NOTE: When colors are indicated, the first is the wire color and the second is the stripe color. Rear Top View Figure 47. P300 MT HV Wiring K300 Modular Blower Routine Maintenance The following sections discuss maintenance for the various parts of your blower system.
Page 118: Blower Cover Removal
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 blower without a properly installed air filter. Unfiltered cooling air can reduce lamp bulb and reflector life.
Page 119 Blower Cover Blower Wheel Motor (B10) F3e0017 Capacitor Housing Ground Screw Ground Ground Strap Connections Figure 48. Blower Components Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 120 Figure 49. J11 Connections Table 23. J11 Connections J11-1 Green/Yellow J11-2 Black J11-3 White 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 the back of J11 as indicated in Figure 9.
Page 121: Appendix A. Specifications
Appendix A. Specifications This appendix outlines the various characteristics of major components of F300S and F300SQ systems. System Table 24. System Operating Requirements Ambient Operating Temperature 0-45°C Relative Humidity 30-95% Power Supply The following table provides the F300S and F300SQ system power supply specifications.
Page 122 Specifications Table 25. F300S and F300SQ System Power Supply Specifications (continued) Front Panel Controls System Power ON/OFF - 2 position switch Lamp Control ON/STANDBY/OFF - 3 illuminated pushbutton switches Interlocks Unit HV Cable Disconnect Lamp Out Power Imbalance Power Error Power Supply Overtemperature Lamp Cooling Air...
Page 123: Irradiators
Irradiators Irradiators Table 26 lists the various Fusion UV Systems Irradiator models and cooling method. Table 26. Irradiator Models and Details System Power Supply Irradiator Designation Cooling Method F300S/ P300M/P300MQ/ I300M/I310M/I310M-D/ Remote cooling (Note 1) 2.8 m /min F300SQ P300MT I311M/I311M-D (100 cfm) at 695 Pa (2.8 H...
Page 124: Blower
Specifications Exterior: Brushed aluminum. Mechanical (without 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 mm (10.25") Height 228.6 mm (9.00") Width...
Page 125: System Agency Approvals
Irradiators System Agency Approvals Table 28 lists the quality standards and agency regulatory guidelines against which the Fusion UV Systems products described in this document have been certified/validated. Table 28. System Agency Approvals Quality Measured Standard Electrical Safety (ETL/ITS) EN60204-1, UL 775, CSA C22.2...
Page 126 Specifications F300S/F300SQ Ultraviolet Lamp System...
Page 127: Appendix B. Cables And Connectors
Appendix B. Cables and Connectors This appendix provides information on the interconnect cables and system connector contact kits used with the F300S/F300SQ Ultraviolet Lamp System. Interconnect Cables Fusion UV Systems irradiators use the interconnect cables described in Table Table 29. Interconnect Cables From...
Page 128: System Connector Contact Kits
Cables and Connectors Table 29. Interconnect Cables (continued) From Cable Type Length (M) Part Number 329281 329282 329283 329284 329285 329286 Power Supply RF-1 H790 RF Cable 329287 329288 329289 329291 329292 329293 Power Supply Power Supply H760 (F300S/F300SQ 0.65 091231 System) Interconnect Cable System Connector Contact Kits...
Page 129: Appendix C. Outline Drawings
Appendix C. Outline Drawings The drawings in this appendix provide overview details for general reference for Fusion UV Systems products. These drawings are not to be used in designing an installation; contact Fusion directly for current specifications. • Figure 50, P300M/P300MQ power supply dimensions and clearances •...
Page 130 Outline Drawings Figure 50. P300M/P300MQ Power Supply Dimensions and Clearances F300S/F300SQ Ultraviolet Lamp System...
Page 131 Figure 51. P300MT Power Supply Dimensions and Clearances Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 132 Outline Drawings Notes: 1. Dimensions in mm (in) 2. Standard density 1.2 kg/m (0.075 lb/ft ) 3. Air pressure measured at lamp inlet 695Pa (2.8"H O) at 2.8m /min (100 cfm) 4. Air pressure measured at vent holes 447-596Pa (1.8-2.4"H O) Figure 52.
Page 133 Notes: 1. Dimensions in mm (in) 2. Air pressure at vent holes 447- 822 Pa (1.8 - 3.3"H O) Figure 53. I300MB Irradiator Dimensions Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 134 Outline Drawings Notes: 1. Dimensions in mm (in) 2. Standard density 1.2 kg/m (0.075 lb/ft ) 3. Air pressure measured at lamp inlet 695Pa (2.8"H O) at 2.8m /min (100 cfm) 4. Air pressure measured at vent holes 447-596Pa (1.8-2.4"H O) Figure 54.
Page 135 Notes: 1. Dimensions in mm (in) 2. Air pressure at vent holes 447- 822 Pa (1.8 - 3.3"H O) Figure 55. I310MB/I310MB-D Irradiator Dimensions Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 136 Outline Drawings Optimum substrate location for focusing UV to maximum peak irradiance Notes: 1. Dimensions in mm (in) 2. Standard density 1.2 kg/m (0.075 lb/ft ) 3. Air pressure measured at lamp inlet 695Pa (2.8"H O) at 2.8m /min (100 cfm) 4.
Page 137 Figure 57. RF-1 RF Detector Dimensions Installation, Operation, and Maintenance Manual # 509252 Rev R...
Page 138 Outline Drawings F300S/F300SQ Ultraviolet Lamp System...
Page 139: Appendix D. Lamp System Maintenance Log
Appendix D. Lamp System Maintenance Log Table 31 gives an example of a Fusion UV Systems form to use for tracking lamp system maintenance. Table 31. Lamp System Maintenance Log Lamp System Log FUSION UV SYSTEMS, INC. Irradiator Serial Number _________...
Page 140 Lamp System Maintenance Log F300S/F300SQ Ultraviolet Lamp System...
Page 141: Appendix E. Replacement Parts
Appendix E. Replacement Parts Table 32 lists the various accessory replacement parts available for Fusion UV Systems F300S/F300SQ Lamp Systems. Table 32. Accessory Parts List Quantity F300S/F300SQ Description Modular Remote Blower Cooling Cable, irradiator w/K300M modular blower, 4M H341 328552 —...
Page 142: I300M/I310M Irradiator Parts List
— 528641 Tool, contact removal — 043041 I300M/I310M Irradiator Parts List Table 33 lists the various replacement parts available for Fusion UV Systems I300M and I310M Irradiators. Table 33. I300M/I310M Irradiator Parts List Reference Description Designator Part Number Bulb, UV, (standard) BF9H2 —...
Page 143 I300M/I310M Irradiator Parts List Table 33. I300M/I310M Irradiator Parts List (continued) Reference Description Designator Part Number Kit, reflector assembly, I300M, R500 (includes main reflector, — 292161 2 end reflectors and gaskets Kit, reflector assembly, I300M, R350 (includes main reflector, — 292162 2 end reflectors and gaskets) Kit, reflector assembly, I300M, dichroic (cold/R500)) (includes...
Page 144: P300M/P300Mt Power Supply Parts List
Replacement Parts P300M/P300MT Power Supply Parts List Table 34 lists the various replacement parts available for Fusion UV Systems P300M and P300MT power supplies. Table 34. P300M and P300MT Replacement Parts Reference Description Part Number Designator Capacitor, Oil filled 0.85/0.43 MFD (50/60 Hz)
Page 145 P300M/P300MT Power Supply Parts List Table 34. P300M and P300MT Replacement Parts (continued) Reference Description Part Number Designator HV transformer, 230V, 50/60 Hz T101, T102 341371 HV wire assembly, 8", White — 340701 HV wire assembly, 3.5", Black — 340704 HV wire assembly, 3.5"...
Page 146: P300Mq Quick Restart Option Parts List
Replacement Parts 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. P300MQ Quick Restart Option Parts List Reference Description Part Number Designator Bracket, Mtg, 1.75 oval...
Page 147: K300 Blower Assembly Parts List
K300 Blower Assembly Parts List K300 Blower Assembly Parts List Table 36. K300 Blower Assembly Parts List Reference Description Part Number Designator Capacitor, Fld. Fill, 4.0 MFD C200 041981 Connector, 4 CKT (Use Contact Kit 201675) 025802 Contact Kit, SKT, 16-18GA (set of 50) —...
Page 148 Replacement Parts F300S/F300SQ Ultraviolet Lamp System...
Page 149: Appendix F. Ignitor Bulb
Appendix F. Ignitor Bulb NOTE: This appendix applies to lamps manufactured before July 1, 2002. Ignitor The ignitor bulb is designed to provide positive instant ignition of the main bulb. As shown in Figure 58, the ignitor is a UV bulb with a probe which projects into the waveguide.
Page 150: Ignitor Bulb Removal/Replacement
Ignitor Bulb Table 37. Routine Operations Associated with Ignitor Bulb (Refer to Table 12 on page 59 for other operational information.) Power Lamp Control Time Lamp Control Operation Switch Flasher 0 sec Lamp on Green flash Start HV transformers 2-4 sec Ignitor bulb lights UV bulb ignites;...
Page 151 Ignitor Bulb Removal/Replacement 2. Remove the irradiator housing as described in Chapter 6, “Maintenance”. 3. Pull the defective bulb out and push the new bulb into the mounting clip. make sure the stem of the bulb fits into the waveguide so that the outer Teflon sleeve on the antenna wire is against the casting (see Figure 58).
Page 152 Ignitor Bulb F300S/F300SQ Ultraviolet Lamp System...
Page 153: Appendix G. Schematics
Appendix G. Schematics The following schematics are located within the F300 folder on your product documentation CD in a subfolder or directory entitled “Schematics”. These files are in PDF format. They illustrate various wiring diagrams and other schematics forF300S/F300SQ lamp systems. •...
Page 154 Schematics F300S/F300SQ Ultraviolet Lamp System...

This manual is also suitable for:

F300s

Fusion F300SQ Installation, Operation And Maintenance Manual

Chapter 1. Safety

Chapter 2. Mechanical Installation

Chapter 3. Electrical System

Chapter 4. Operation

Chapter 5. Troubleshooting

Chapter 6. Maintenance

Appendix A. Specifications

Appendix B. Cables and Connectors

Appendix C. Outline Drawings

Appendix D. Lamp System Maintenance Log

Appendix E. Replacement Parts

Appendix F. Ignitor Bulb

Appendix G. Schematics

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