The MPS610V Power Supply with Unicable is a crucial component of the Nordson CoolWave ultraviolet microwave-applied curing system, specifically designed for use with the CW610 lamphead. Its primary function is to provide the high voltage supply necessary for the lampheads and to incorporate a control circuit that interlocks the lampheads with the curing machine. This system is engineered for the accelerated curing of UV inks, adhesives, and coatings in various industrial applications.
Function Description:
The core principle of UV curing involves a chemical reaction in specialized inks and coatings when exposed to intense UV energy. The MPS610V power supply facilitates this by utilizing a microwave generator (magnetron) operating between 2400 and 2500 MHz. This magnetron excites a medium-pressure mercury bulb within the lamphead, causing it to emit ultraviolet light in the 220 to 470 nanometer range. A protective screen at the cavity opening allows UV light to pass through while containing microwave radiation.
Beyond UV light, the high-energy bulbs also radiate heat. To manage this, the system integrates a cooling system that dissipates excess heat, ensuring the bulbs and housings maintain acceptable operating temperatures. The unit is equipped with interlocks and safety faults that prevent unsafe operation and indicate any issues on the power supply's front panel. Light shielding is also required to meet safety criteria for stray UV light and heat.
The power supply is fully modular, with one unit required for each lamphead. It can operate as a standalone system or as part of a Master/Remote circuit. An RF detector monitors microwave energy levels, shutting down the system if levels exceed 5 mW/cm². In networked systems, the master power supply unit must connect to one RF detector, though it's recommended that every six units have one.
Important Technical Specifications:
- Dimensions: 753 mm (29.65 in.) length, 465.5 mm (18.33 in.) width, 256.3 mm (10.09 in.) height.
- Weight: 105 kg (230 lb).
- Voltage: 440/480 Vac, 3Ø, at 60 Hz; or 380/400 Vac, 3Ø, at 50 Hz.
- Current Draw (60 Hz):
- @ 440 Vac: L1: 13 Amps, L2: 21 Amps, L3: 13 Amps.
- @ 480 Vac: L1: 12 Amps, L2: 18 Amps, L3: 12 Amps.
- Current Draw (50 Hz):
- @ 380 Vac: L1: 16 Amps, L2: 25 Amps, L3: 16 Amps.
- @ 400 Vac: L1: 15 Amps, L2: 23 Amps, L3: 15 Amps.
- Ambient Temperature: 13-49 °C (55-120 °F).
- Lamphead Cooling: Requires approximately 350 CFM at 7 in. W.C. of cooling air per lamphead. Minimum vent/extraction air of 450 CFM at 2-in. W.C.
- RF Detector: Shuts down if microwave leakage exceeds 2 mW/cm².
- High Voltage: Operates at up to 5000 Vdc, utilizing high-voltage, self-discharging capacitors that require 120-130 seconds to discharge after power shut-off.
- Ozone Gas: Generated by short-wave UV light (200-220 nm). Recommended atmospheric levels should not exceed 0.1 PPM.
- Magnetron Current: Normal current is 850 mA ± 5% at 100% power.
Usage Features:
- Mounting: Can be mounted on any horizontal surface. Up to five units can be stacked, though accessibility for service is recommended. Requires at least six inches of ventilation clearance on all four sides.
- Cable Connections: Unicable connectors must be fully engaged and tightened to prevent damage. Each connector has an indicator to confirm proper mating.
- Control Board Dip Switches (SW1 & SW3): Configure remote analog input, fault handling (individual unit or all units), RF detector usage, front panel controls (enabled/disabled), front panel configuration (on/off), front panel display type (LEDs only or number display), and communication network (CAN or 485).
- Power Supply Address Switch (SW2): Sets the electronic address for networked systems (0 for master, unique values for remotes). Can be set from the front panel if Remote Configuration (REM CFG) is enabled.
- Remote Configuration: Allows configuration settings to be changed via the front panel display and select buttons, provided SW1-5 is in the Closed/On position.
- Startup Procedures: Supports both locally operated and remotely operated units, as well as single units and networked systems. Includes rapid startup (10-second magnetron filament warm-up, 8-second stabilization) and standard startup (10-second warm-up, 8-second stabilization).
- Power Setting: Adjustable in 5% increments via front panel buttons. Settings can be saved. In networked systems, each remote unit's power setting is proportional to the master unit's setting.
- Display Messages: Provides status updates (OFF, WARMUP, STDBY, LMPDLY, LAMPON, L COOL, C DELAY) and fault messages (F PRSW, F LOCK, F OTMP, F STOP, F CABL, F RF, F POWR, F LOUT, F NETW, F IBAL, F OVER, F FUSE, F MAG).
- Fault Resetting: In local mode, faults are cleared by pressing the Off button. In remote mode, opening and closing the off/reset contact resets faults.
Maintenance Features:
- Qualified Personnel: Installation, operation, and servicing must be performed by qualified personnel familiar with safety rules and regulations.
- Safety Precautions: Emphasizes following safety instructions, ensuring guards and interlocks are intact, locking out power before servicing, wearing personal protection (UV glasses), ensuring adequate ventilation, avoiding contact with hot surfaces, and never exposing body parts to UV light.
- Ozone Gas Management: Ozone should be removed via a sealed duct and discharged to atmosphere. Regular ozone checks (every three months) using an ozone meter are recommended.
- High Voltage Safety: Equipment operates at high voltages; in case of electrical faults, switch off immediately and contact a qualified electrician. Capacitors require 120-130 seconds to discharge.
- Control System Cleaning: Contactors and relays should be kept clean and free from dirt and dust, especially in dusty environments.
- High Voltage Connections: Connections should be checked regularly for cleanliness and absence of conducting material.
- Cabinet Cooling: The cabinet cooling fan should be checked weekly and kept clear of obstructions to prolong power supply life.
- Disposal: Equipment and materials must be disposed of according to local codes.
- Air Filter and Cooling Fan Cleaning: Filters on lampheads, remote blowers, and power supplies should be washed with soap and water weekly or as needed. Dirty filters can cause excessive heat and premature failure. Fan blades should be examined for contamination.
- Fuses: Four replaceable fuses are located on the main control board.
- Main Control Board Replacement: Involves removing the top cover, disconnecting connectors, unscrewing the board, configuring the new board with appropriate dip switch settings and address, securing the new board, reconnecting, and restoring power.
- Recommended Spare Parts: A list of recommended spare parts is provided, categorized by level of importance (Level 1 for critical day-to-day operation).
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