Fusion F300S User Manual

F300S/F300SQ Ultraviolet Lamp SystemInstallation, Operation, and MaintenanceManual No. 509252 Rev R 3/04FUSION UV SYSTEMS, INC.910 Clopper RoadGaither

10 F300S/F300SQ Ultraviolet Lamp SystemP300M/P300MT Power Supply Parts List . . . . . . . . . . . . . . . . . . . 144P300MQ Quick Restart Option Par

100 F300S/F300SQ Ultraviolet Lamp System4. Remove the extrusions. While holding the extrusion inside the casting, remove the four screws securing the

Installation, Operation, and Maintenance Manual # 509252 Rev R 101Figure 39. I310M/I311M Irradiator Component Location (Scatter View)Direct View Phot

102 F300S/F300SQ Ultraviolet Lamp System6. Replace the photoresistor and UV filter lens assembly.7. Reinstall the housing.Figure 40. I310M-D/I311M-D I

Installation, Operation, and Maintenance Manual # 509252 Rev R 103Figure 41. Photoresistor Assembly for Direct View (I300M)Filament Transformer Remov

104 F300S/F300SQ Ultraviolet Lamp SystemMagnetron Removal/Replacement1. Remove the irradiator housing as described previously.2. Disconnect the filame

Installation, Operation, and Maintenance Manual # 509252 Rev R 105Air Pressure VerificationTo test air pressure inside the irradiator, remove one cov

106 F300S/F300SQ Ultraviolet Lamp System2. Pull the silicone tubing off the low pressure port of the switch.3. Disconnect the two electrical leads fro

Installation, Operation, and Maintenance Manual # 509252 Rev R 107Test Point VoltagesControl Card Removal/ReplacementThis unit must be disconnected a

108 F300S/F300SQ Ultraviolet Lamp SystemDiode TestAn ohmmeter can be used to check for a shorted or open capacitor. (Isolate the component before maki

Installation, Operation, and Maintenance Manual # 509252 Rev R 109Figure 44. P300M/P300MQ Component Identification

Installation, Operation, and Maintenance Manual # 509252 Rev R 11IntroductionThis manual is designed to be used, not set aside until problems occur.

110 F300S/F300SQ Ultraviolet Lamp SystemCapacitor TestCAUTION: An ohmmeter can be used to check for a shorted or open capacitor. (Isolate the componen

Installation, Operation, and Maintenance Manual # 509252 Rev R 1111. Disconnect all power, discharge the high voltage capacitors, and disconnect all

112 F300S/F300SQ Ultraviolet Lamp SystemNOTE: When colors are indicated, the first is the wire color and the second is the stripe color. P300MT Power

Installation, Operation, and Maintenance Manual # 509252 Rev R 113Test Point Voltages.Control Card Removal/ReplacementThis unit must be returned to F

114 F300S/F300SQ Ultraviolet Lamp System3. Remove all connectors.4. Remove three screws at the top of the card. Slide the card approximately an inch a

Installation, Operation, and Maintenance Manual # 509252 Rev R 115Capacitor TestThe ohmmeter should have a minimum 6V battery, and should be set on t

116 F300S/F300SQ Ultraviolet Lamp System2. With an ohmmeter set on the highest scale, measure the resistance between the two outside capacitor termina

Installation, Operation, and Maintenance Manual # 509252 Rev R 117NOTE: When colors are indicated, the first is the wire color and the second is the

118 F300S/F300SQ Ultraviolet Lamp SystemThe filters pull out easily. New filters should be tucked in at the edges. The white side belongs outside, so

Installation, Operation, and Maintenance Manual # 509252 Rev R 119Figure 48. Blower ComponentsBlower CoverGroundConnectionsCapacitor HousingJ11Ground

12 F300S/F300SQ Ultraviolet Lamp System• Appendix C, “Outline Drawings,” contains drawings that provide overview details for general reference for Fus

120 F300S/F300SQ Ultraviolet Lamp SystemFigure 49. J11 Connections8. Connect the replacement J11 connector to the chassis. The black and white leads f

Installation, Operation, and Maintenance Manual # 509252 Rev R 121Appendix A. SpecificationsThis appendix outlines the various characteristics of ma

Specifications122 F300S/F300SQ Ultraviolet Lamp SystemFront Panel ControlsSystem Power ON/OFF - 2 position switchLamp Control ON/STANDBY/OFF - 3 illum

Installation, Operation, and Maintenance Manual # 509252 Rev R 123IrradiatorsIrradiatorsTable 26 lists the various Fusion UV Systems Irradiator model

Specifications124 F300S/F300SQ Ultraviolet Lamp SystemExterior: Brushed aluminum.Mechanical (without Blower):Length: 260.4 mm (10.25")Height: 276

Installation, Operation, and Maintenance Manual # 509252 Rev R 125IrradiatorsSystem Agency ApprovalsTable 28 lists the quality standards and agency r

Specifications126 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 127Appendix B. Cables and ConnectorsThis appendix provides information on the interco

Cables and Connectors128 F300S/F300SQ Ultraviolet Lamp SystemSystem Connector Contact KitsEach kit includes pins and contacts for referenced connectio

Installation, Operation, and Maintenance Manual # 509252 Rev R 129Appendix C. Outline DrawingsThe drawings in this appendix provide overview details

Installation, Operation, and Maintenance Manual # 509252 Rev R 13DANGER: Danger indications identify conditions where death or permanent injury to pe

Outline Drawings130 F300S/F300SQ Ultraviolet Lamp SystemFigure 50. P300M/P300MQ Power Supply Dimensions and Clearances

Installation, Operation, and Maintenance Manual # 509252 Rev R 131Figure 51. P300MT Power Supply Dimensions and Clearances

Outline Drawings132 F300S/F300SQ Ultraviolet Lamp SystemFigure 52. I300M Irradiator Dimensions3. Air pressure measured at lamp inlet 695Pa (2.8"H

Installation, Operation, and Maintenance Manual # 509252 Rev R 133Figure 53. I300MB Irradiator DimensionsNotes:1. Dimensions in mm (in)2. Air pressur

Outline Drawings134 F300S/F300SQ Ultraviolet Lamp SystemFigure 54. I310M/I310M-D Irradiator Dimensions3. Air pressure measured at lamp inlet 695Pa (2.

Installation, Operation, and Maintenance Manual # 509252 Rev R 135Figure 55. I310MB/I310MB-D Irradiator DimensionsNotes:1. Dimensions in mm (in)2. Ai

Outline Drawings136 F300S/F300SQ Ultraviolet Lamp SystemFigure 56. I311M/I311M-D Irradiator DimensionsOptimum substratelocation for focusingUV to maxi

Installation, Operation, and Maintenance Manual # 509252 Rev R 137Figure 57. RF-1 RF Detector Dimensions

Outline Drawings138 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 139Appendix D. Lamp System Maintenance LogTable 31 gives an example of a Fusion UV Sy

14 F300S/F300SQ Ultraviolet Lamp SystemCAUTION: Ultraviolet RadiationThis icon identifies instances where damaging levels of ultraviolet radiation may

Lamp System Maintenance Log140 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 141Appendix E. Replacement PartsTable 32 lists the various accessory replacement part

Replacement Parts142 F300S/F300SQ Ultraviolet Lamp SystemI300M/I310M Irradiator Parts ListTable 33 lists the various replacement parts available for F

Installation, Operation, and Maintenance Manual # 509252 Rev R 143I300M/I310M Irradiator Parts ListKit, reflector assembly, I300M, R500 (includes mai

Replacement Parts144 F300S/F300SQ Ultraviolet Lamp SystemP300M/P300MT Power Supply Parts ListTable 34 lists the various replacement parts available fo

Installation, Operation, and Maintenance Manual # 509252 Rev R 145P300M/P300MT Power Supply Parts ListHV transformer, 230V, 50/60 Hz T101, T102 34137

Replacement Parts146 F300S/F300SQ Ultraviolet Lamp SystemP300MQ Quick Restart Option Parts ListTable 35 lists the various replacement parts available

Installation, Operation, and Maintenance Manual # 509252 Rev R 147K300 Blower Assembly Parts ListK300 Blower Assembly Parts List Table 36. K300 Blowe

Replacement Parts148 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 149Appendix F. Ignitor BulbNOTE: This appendix applies to lamps manufactured before J

Installation, Operation, and Maintenance Manual # 509252 Rev R 15System DescriptionThe Fusion Ultraviolet Lamp System has been designed specifically

Ignitor Bulb150 F300S/F300SQ Ultraviolet Lamp SystemIgnitor Bulb Removal/Replacement1. Replace the ignitor bulb only if the lamp does not start consis

Installation, Operation, and Maintenance Manual # 509252 Rev R 151Ignitor Bulb Removal/Replacement2. Remove the irradiator housing as described in Ch

Ignitor Bulb152 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 153Appendix G. SchematicsThe following schematics are located within the F300 folder

Schematics154 F300S/F300SQ Ultraviolet Lamp System

16 F300S/F300SQ Ultraviolet Lamp SystemFigure 1. F300S/F300SQ Lamp SystemThe F300S/F300SQ Fusion UV Lamp System (Figure 1) is modular, consisting of i

Installation, Operation, and Maintenance Manual # 509252 Rev R 17Electrical inputs to the lamp module are provided by a high voltage/control cable wi

18 F300S/F300SQ Ultraviolet Lamp SystemCoolingProper operation of the lamp requires adequate cooling of the magnetron and the bulb. (See Appendix C, p

Installation, Operation, and Maintenance Manual # 509252 Rev R 19The following table lists the various irradiator models manufactured by Fusion UV Sy

20 F300S/F300SQ Ultraviolet Lamp SystemMountingThe lamps can be mounted over a moving substrate or web, supported by the bottom rails. The lamps shoul

Installation, Operation, and Maintenance Manual # 509252 Rev R 21Figure 4. P300M Front PanelWarranty PolicyItems manufactured by Fusion UV Systems In

22 F300S/F300SQ Ultraviolet Lamp SystemNOTE: Any repairs or alterations, including the use of non-Fusion UV Systems (Fusion) parts, made by the user o

Installation, Operation, and Maintenance Manual # 509252 Rev R 23IrradiatorsIrradiators should be returned in their original packaging. If this is no

24 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 25Chapter 1. SafetyFusion UV Systems’ Ultraviolet (UV) Lamp Systems have been designe

26 F300S/F300SQ Ultraviolet Lamp SystemUltraviolet RadiationThere are no present U.S. government standards on worker exposure to ultraviolet light. Ho

Installation, Operation, and Maintenance Manual # 509252 Rev R 27Personnel Effects of Microwave RadiationOSHA (U.S. Department of Labor, Occupational

28 F300S/F300SQ Ultraviolet Lamp SystemOzoneThe Fusion UV Lamp System makes less ozone than a conventional arc lamp. For example, a pair of lamps runn

Installation, Operation, and Maintenance Manual # 509252 Rev R 29High VoltageInsulated electrical cables carry power at 3900 Volts from the power sup

F300S/F300SQ Ultraviolet Lamp SystemInstallation, Operation, and MaintenanceManual No. 509252 Rev R 3/04Applies to systems using P300M/P300MQ/P300MT p

30 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 31Chapter 2. Mechanical InstallationMechanical Installation ChecklistBefore operating

32 F300S/F300SQ Ultraviolet Lamp SystemPreliminary unpacking and inspection should be completed immediately on receipt of equipment to allow time for

Installation, Operation, and Maintenance Manual # 509252 Rev R 33Irradiator MountingThe irradiator mounting structure must also provide UV shielding

34 F300S/F300SQ Ultraviolet Lamp SystemLamps Mounted in Opposing ConfigurationFigure 6. Lamps in Opposing ConfigurationUV Light ShieldingAdequate ligh

Installation, Operation, and Maintenance Manual # 509252 Rev R 35The louvers which allow the flow of cooling air away from the irradiator must be of

36 F300S/F300SQ Ultraviolet Lamp SystemRemote BlowersAn optional remote blower package is available from Fusion UV Systems. The package includes an ai

Installation, Operation, and Maintenance Manual # 509252 Rev R 37Figure 8. Quartz Plates - Example Mounting DesignQuartz platemounting structureIrrad

38 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 39Chapter 3. Electrical SystemThis chapter discusses the electrical installation and

40 F300S/F300SQ Ultraviolet Lamp SystemInterconnect CablesThe F300S/F300SQ interconnect cables and connector contact kits are listed in Appendix B, “C

Installation, Operation, and Maintenance Manual # 509252 Rev R 411. Disassemble the strain relief housing by removing the retaining screws and unscre

42 F300S/F300SQ Ultraviolet Lamp SystemFigure 10. Location of Programming Switch S1 on PWBK1J9J10J8J6J5JP2J7J3J4J1J2J14J15J16J11K3K4K5K2TP1TP2DS1S1S2S

Installation, Operation, and Maintenance Manual # 509252 Rev R 43Figure 11. Table A: Programming Switch S1Single Unit Programming and ConnectionsThe

44 F300S/F300SQ Ultraviolet Lamp SystemFigure 12. F300/F300SQ Single-unit InstallationProgrammingSelect one unit as the Master. Set S1-1, 1-2, 1-3, an

Installation, Operation, and Maintenance Manual # 509252 Rev R 45Input/Output ConnectionsThe P300M/P300MQ/P300MT has three customer use interlock inp

46 F300S/F300SQ Ultraviolet Lamp SystemNOTE: A dry contact (such as a relay contact or a PLC containing a relay contact) with gold contact material s

Installation, Operation, and Maintenance Manual # 509252 Rev R 47NOTE: When using circuit currents for K1-K5 below 10mA, contact Fusion UV Systems Cu

48 F300S/F300SQ Ultraviolet Lamp SystemMultiple-Unit Programming and ConnectionsProgramming and connections for multiple-unit systems are summarized i

Installation, Operation, and Maintenance Manual # 509252 Rev R 49ProgrammingRefer to Figure 11 for programming switch S1 settings and set programming

Installation, Operation, and Maintenance Manual # 509252 Rev R 5Table Of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 F300S/F300SQ Ultraviolet Lamp SystemPower Source NOTE: If a line voltage greater than 230V and a frequency of 50 Hz is used, see the “F300S Relay C

Installation, Operation, and Maintenance Manual # 509252 Rev R 51North American Applications: 3x12 AWG UL listedInternational Applications: 3x2.5 mm2

52 F300S/F300SQ Ultraviolet Lamp SystemQRO Transformer Taps (FOR QRO only)When the Quick Restart Option is installed, the QRO transformers must be tap

Installation, Operation, and Maintenance Manual # 509252 Rev R 53F300S Relay Coil Resistor Assembly InstallationThe relay coil resistor assembly must

54 F300S/F300SQ Ultraviolet Lamp SystemFigure 15. K101 and K102 on P300M/P300MQTB1C101CB1ACB1BC102TB1DB1DB2T103L101T102 T101B101J101C103S1S2S3Top Vi

Installation, Operation, and Maintenance Manual # 509252 Rev R 55Chapter 4. OperationSystem Operation ControlsThe lamp system is operated from the c

56 F300S/F300SQ Ultraviolet Lamp System• Bulb producing insufficient output to activate the photocellFor proper initial ignition, the recommended “MIN

Installation, Operation, and Maintenance Manual # 509252 Rev R 573. Press the LAMP ON switch: the green LAMP ON indicator blinks, then stays lit.4. C

58 F300S/F300SQ Ultraviolet Lamp System4. The LAMP CONTROL switches on the Master may now be used to activate all units in the system at the same time

Installation, Operation, and Maintenance Manual # 509252 Rev R 59NOTE: Times indicated are approximate and will vary. The exact interval is determine

6 F300S/F300SQ Ultraviolet Lamp SystemTemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28High Voltage . .

60 F300S/F300SQ Ultraviolet Lamp System2. Turn the Master POWER switch ON and press the LAMP ON switch.3. The system will now operate from remote swit

Installation, Operation, and Maintenance Manual # 509252 Rev R 61The QRO consists of a high-voltage, low-current power supply section located in the

62 F300S/F300SQ Ultraviolet Lamp SystemFigure 16. Restart Time Versus QRO State Duration, D-bulbFigure 17. Restart Time Versus QRO State Duration, H-b

Installation, Operation, and Maintenance Manual # 509252 Rev R 63Figure 18. Restart Time Versus QRO State Duration, V-bulbElectrical Installation and

64 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 65Chapter 5. TroubleshootingBasic ChecksCheck that input power is connected properly.

66 F300S/F300SQ Ultraviolet Lamp SystemSafety Interlock TestsThe fault indicators, RF detector, and external interlocks should be tested at regular in

Installation, Operation, and Maintenance Manual # 509252 Rev R 67System FaultsThe bottom three LEDs indicate system faults. These faults always shut

68 F300S/F300SQ Ultraviolet Lamp SystemTable 18, “Troubleshooting/Fault Diagnosis,” on page 69 covers miscellaneous faults and malfunctions.NOTE: The

Installation, Operation, and Maintenance Manual # 509252 Rev R 69Table 18. Troubleshooting/Fault DiagnosisOperationSignal/Other SymptomsPossible Caus

Installation, Operation, and Maintenance Manual # 509252 Rev R 7Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 F300S/F300SQ Ultraviolet Lamp SystemLamp control at OFF, or from OFF to STANDBYEXT INTLK indicator lightsOpen control input. A jumper or an externa

Installation, Operation, and Maintenance Manual # 509252 Rev R 71Switch from OFF to STANDBYBLWR PRESSURE indicator lightsSingle-phase voltage missing

72 F300S/F300SQ Ultraviolet Lamp SystemSwitch from OFF to STANDBY or from STANDBY to ONPS TEMP indicator lightsPower supply fan inoperativeRepair or r

Installation, Operation, and Maintenance Manual # 509252 Rev R 73Switch from STANDBY to ONLAMP OUT indicator lights after 8 seconds;Lamp bulb does no

74 F300S/F300SQ Ultraviolet Lamp SystemSwitch from STANDBY to ON(continued)LAMP OUT indicator lights after 8 seconds;Lamp bulb does not light (continu

Installation, Operation, and Maintenance Manual # 509252 Rev R 75Switch from STANDBY to ON (continued)LAMP OUT indicator lights after 8 seconds; Lamp

76 F300S/F300SQ Ultraviolet Lamp SystemSwitch from STANDBY to ON(continued)PWR IMBAL indicator lightsPower Supply Usually, a diode or capacitor failur

Installation, Operation, and Maintenance Manual # 509252 Rev R 77Lamp Control at LAMP ONLAMP OUT indicator does not light, or UV lamp does not lightC

78 F300S/F300SQ Ultraviolet Lamp System

Installation, Operation, and Maintenance Manual # 509252 Rev R 79Chapter 6. MaintenanceThis chapter provides maintenance procedures for the I300M ir

8 F300S/F300SQ Ultraviolet Lamp SystemBulb, Screen, and Reflector Maintenance . . . . . . . . . . . . . . . . 79Cleaning Guidelines . . . . . . .

80 F300S/F300SQ Ultraviolet Lamp SystemIf cleaning reflectors while assembled in the irradiator, drying with compressed air is NOT recommended because

Installation, Operation, and Maintenance Manual # 509252 Rev R 811. Refer to Figure 19. Loosen the four M3 screen retaining screws three turns each.

82 F300S/F300SQ Ultraviolet Lamp SystemCAUTION: Do not apply bending force to the lamp bulb. Do not touch the bulb with bare fingers or allow it to co

Installation, Operation, and Maintenance Manual # 509252 Rev R 833. Referring to Figure 23, remove and discard the two end reflectors and the gaskets

84 F300S/F300SQ Ultraviolet Lamp System7. Align the reflector squarely over the opening. With gentle pressure and a rocking motion, slide the reflecto

Installation, Operation, and Maintenance Manual # 509252 Rev R 85CAUTION: Do not use the flathead screws to pull the reflector into place. Excessive

86 F300S/F300SQ Ultraviolet Lamp System11. Replace the screen assembly. After replacing the screen assembly, refer to Figure 26; hand-tighten the four

Installation, Operation, and Maintenance Manual # 509252 Rev R 87Figure 27. I300M/I301M Irradiator Component LocationDirect View Photoresistor Remova

88 F300S/F300SQ Ultraviolet Lamp System5. Remove and discard the PWB and inspect the UV filter lens for damage.6. Replace the photoresistor and UV fil

Installation, Operation, and Maintenance Manual # 509252 Rev R 895. Reconnect the filament transformer wires to the magnetron and tighten the termina

Installation, Operation, and Maintenance Manual # 509252 Rev R 9Control Card Removal/Replacement . . . . . . . . . . . . . . . 107Diode Test . . .

90 F300S/F300SQ Ultraviolet Lamp SystemAir Pressure VerificationTo test air pressure inside the irradiator, remove one cover plate screw and, using a

Installation, Operation, and Maintenance Manual # 509252 Rev R 91Air Pressure Switch Replacement1. Remove the irradiator cover.2. Pull the silicone t

92 F300S/F300SQ Ultraviolet Lamp SystemBulb CleaningHandle bulbs with a lint-free cloth or tissue taking care not to leave fingerprints.Baked-on mater

Installation, Operation, and Maintenance Manual # 509252 Rev R 93Screen Assembly Removal/Replacement1. Refer to Figure 31. Loosen the four M3 screen

94 F300S/F300SQ Ultraviolet Lamp SystemCAUTION: Do not apply bending force to lamp bulb. Do not touch the bulb with bare fingers or allow it to contac

Installation, Operation, and Maintenance Manual # 509252 Rev R 952. Remove the six flat head screws and lift the reflector out. Examine the cross-gui

96 F300S/F300SQ Ultraviolet Lamp SystemFigure 34. Gasket Installation (I330M/I311M)4. Insert both end reflectors, ensuring that they both seat fully a

Installation, Operation, and Maintenance Manual # 509252 Rev R 97Figure 35. Correct Reflector Alignment (I310M/I311M)7. Align the reflector squarely

98 F300S/F300SQ Ultraviolet Lamp SystemFigure 36. Reflector Screw Tightening Sequence (I310M/I311M)8. When the reflector is properly installed, the fa

Installation, Operation, and Maintenance Manual # 509252 Rev R 99Replacing the RF Gasket Assembly1. If you detect evidence of arcing on the back of t