Fusion Light Therapy Device F300S User Manual
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F300S/F300SQ Ultraviolet  
Lamp System  
Installation, Operation, and Maintenance  
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.  
FUSION UV SYSTEMS, INC.  
910 Clopper Road  
Gaithersburg, MD 20878-1357 USA  
(301) 527-2660 • FAX (301) 527-2661  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Table Of Contents  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Indications of Note, Caution, Warning, and Danger . . . . . . . . . 12  
Icon Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
Reflector and Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
Lamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
P300M/P300MQ/P300MT . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
RF Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
System Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
Shipping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
Returned Material Authorization Number . . . . . . . . . . . . . . . . 22  
General Packing Instructions . . . . . . . . . . . . . . . . . . . . . . . . 22  
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
Magnetrons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
UV Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
Control Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
RF Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
Chapter 1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
Ultraviolet Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
Microwave Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
Personnel Effects of Microwave Radiation . . . . . . . . . . . . . . . . . . . 27  
Radio Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27  
Ozone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
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Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
UV Curable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
Chapter 2. Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
Mechanical Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 31  
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
Power Supply Unit(s) Placement . . . . . . . . . . . . . . . . . . . . . . . . . 32  
Irradiator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
Lamps Mounted in Opposing Configuration . . . . . . . . . . . . . . . . . . 34  
UV Light Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34  
RF Detector Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35  
Remote Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
Irradiator Exhaust Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
Quartz Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
Chapter 3. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
Electrical Installation/Setup Checklist . . . . . . . . . . . . . . . . . . . . . . 39  
Accessory Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
Connection and Program Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
Installing the External Interlocks Control . . . . . . . . . . . . . . . . 40  
User Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
Power Supply Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
Settings for Six-Position Switch S1 . . . . . . . . . . . . . . . . . . . . 41  
Single Unit Programming and Connections . . . . . . . . . . . . . . . . . . 43  
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44  
Irradiator Cable H340 Connections . . . . . . . . . . . . . . . . . . . . 44  
Input/Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
Remote Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
Output Ports (J105B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46  
Alternate Function for K5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
Multiple-Unit Programming and Connections . . . . . . . . . . . . . . . . . 48  
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49  
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49  
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Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
System Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Frequency Tapping of HV Capacitors . . . . . . . . . . . . . . . . . . . 51  
QRO HV Capacitors (For QRO only) . . . . . . . . . . . . . . . . . . . . 51  
High Voltage Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . 51  
QRO Transformer Taps (FOR QRO only) . . . . . . . . . . . . . . . . . 52  
F300S Relay Coil Resistor Assembly Installation . . . . . . . . . . . . . . 53  
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
Chapter 4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
System Operation Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Lamp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56  
Off/Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56  
Initial Startup Procedure, Single Unit . . . . . . . . . . . . . . . . . . . . . . 56  
Initial Startup Procedure, Multiple-Unit Systems . . . . . . . . . . . . . . 57  
Master/Slave Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57  
Operating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57  
Resetting the System After a Fault . . . . . . . . . . . . . . . . . . . . 58  
Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
Operation with Remote Controls . . . . . . . . . . . . . . . . . . . . . . 60  
Quick Restart Option (QRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60  
Electrical Installation and Setup . . . . . . . . . . . . . . . . . . . . . . 63  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Chapter 5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
Basic Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
Safety Interlock Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Unit Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Fault Diagnosis Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Failure Diagnosis Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . 68  
Chapter 6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
I300M Irradiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
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Bulb, Screen, and Reflector Maintenance . . . . . . . . . . . . . . . . 79  
Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
Bulb Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
Reflector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
Screen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80  
I300M Screen Assembly Removal/Replacement . . . . . . . . . . . 80  
Lamp Bulb Removal/Replacement . . . . . . . . . . . . . . . . . . . . 81  
Reflector Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 82  
I300M Irradiator Housing Removal/Replacement . . . . . . . . . . 86  
Direct View Photoresistor Removal/Replacement . . . . . . . . . . . 87  
Filament Transformer Removal/Replacement . . . . . . . . . . . . . 88  
Magnetron Removal/Replacement . . . . . . . . . . . . . . . . . . . . . 89  
Air Pressure Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90  
Air Pressure Switch Replacement . . . . . . . . . . . . . . . . . . 91  
I310M/I311M Irradiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91  
Bulb, Screen, and Reflector Maintenance . . . . . . . . . . . . . . . . 91  
Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 91  
Bulb Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92  
Reflector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92  
Screen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92  
Screen Assembly Removal/Replacement . . . . . . . . . . . . . . . . 93  
Lamp Bulb Removal/Replacement . . . . . . . . . . . . . . . . . . . . 93  
Reflector Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 94  
Replacing the RF Gasket Assembly . . . . . . . . . . . . . . . . . 99  
I310M/I311M Irradiator Housing Removal/Replacement . . . . . 100  
I310M/I311M Scatter View Photoresistor Removal/Replacement . .  
100  
Direct View Photoresistor Removal/Replacement . . . . . . . . . . 101  
Filament Transformer Removal/Replacement . . . . . . . . . . . . 103  
Magnetron Removal/Replacement . . . . . . . . . . . . . . . . . . . . 104  
Air Pressure Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 105  
Air Pressure Switch Replacement . . . . . . . . . . . . . . . . . 105  
P300M/P300MQ Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 106  
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106  
Test Point Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107  
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Control Card Removal/Replacement . . . . . . . . . . . . . . . 107  
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108  
Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110  
High Voltage Transformer Removal/Replacement . . . . . . 110  
P300MT Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112  
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112  
Test Point Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113  
Control Card Removal/Replacement . . . . . . . . . . . . . . . . . . . 113  
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114  
Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115  
High Voltage Transformer Removal/Replacement . . . . . . 116  
K300 Modular Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117  
Blower Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117  
Blower Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 118  
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 118  
Appendix A. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121  
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121  
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121  
Irradiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123  
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124  
RF Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124  
System Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . 125  
Appendix B. Cables and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 127  
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127  
System Connector Contact Kits . . . . . . . . . . . . . . . . . . . . . . 128  
Appendix C. Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129  
Appendix D. Lamp System Maintenance Log . . . . . . . . . . . . . . . . . . . . 139  
Appendix E. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141  
I300M/I310M Irradiator Parts List . . . . . . . . . . . . . . . . . . . . . . . 142  
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P300M/P300MT Power Supply Parts List . . . . . . . . . . . . . . . . . . . 144  
P300MQ Quick Restart Option Parts List . . . . . . . . . . . . . . . . . . . 146  
K300 Blower Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . 147  
Appendix F. Ignitor Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149  
Ignitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149  
Ignitor Bulb Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . 150  
Appendix G. Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153  
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Introduction  
This manual is designed to be used, not set aside until problems occur. The following  
list of chapters and appendixes describes where to find information in this manual.  
•
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.  
•
•
•
Chapter 1, “Safety,” contains important information! This chapter should be read  
by all persons who will operate or troubleshoot system equipment.  
Chapter 2, “Mechanical Installation,” gives unpacking instructions, and  
instructions for equipment placement, mounting, shielding and exhaust venting.  
Chapter 3, “Electrical System,” explains the power supply software setup,  
including single and multiple unit programming and connections. HV capacitor  
frequency tapping instructions are also provided.  
•
•
Chapter 4, “Operation,” describes steps for initial startup for both single and  
multiple unit systems, how to operate master/slave and remote systems, and how  
to reset the system after a fault. It also contains setup and operations instructions  
for the Quick Restart Option (QRO).  
Chapter 5, “Troubleshooting,” consists mainly of information in table form. There  
is a reference table for faults and indications, tables describing unit and system  
fault indications, and a fault diagnosis table. The fault diagnosis table provides  
faults, causes, and corrective actions.  
•
•
•
Chapter 6, “Maintenance,” covers routine maintenance and removal/replacement  
instructions for the irradiator, power supply and modular blower. There is a  
maintenance procedure page locator at the front of the chapter.  
Appendix A, “Specifications,” outlines the various characteristics of major  
components of the F300S/F300SQ Ultraviolet Lamp System. It also lists agency  
approvals and certificates for the relevant systems and components.  
Appendix B, “Cables and Connectors,” provides information on the interconnect  
cables and system connector contact kits used with the F300S/F300SQ Ultraviolet  
Lamp System.  
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•
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,” contains an example of a Fusion  
UV Systems form to use for tracking lamp system maintenance.  
Appendix E, “Replacement Parts,” lists the various accessory replacement parts  
available for Fusion UV Systems Irradiators.  
Appendix F, “Ignitor Bulb,” applies to lamps manufactured before July 1, 2002. It  
describes the operation of the ignitor bulb that provides ignition to the main bulb.  
Appendix G, “Schematics,” contains figures that illustrate the various wiring  
diagrams for Irradiator components.  
Document Conventions  
The products and components discussed in this document are designed and tested for  
safe operation; however, they use technologies and resources that have inherent risks.  
This section describes the conventions used throughout this manual when discussing  
such technologies, so that users can plan and act accordingly when installing,  
operating, or troubleshooting equipment.  
Indications of Note, Caution, Warning, and Danger  
Four categories of notice are indicated in this document; descriptions and examples of  
their formatting are provided next.  
NOTE: Notes serve to point out additional information about a subject or  
process that is important, but not hazard-related.  
CAUTION: Cautions generally indicate areas where a user should take  
special care to avoid minor or moderate injury. It may also indicate  
unsafe practices that could damage equipment or materials.  
WARNING: Warnings indicate actions that can cause recoverable physical  
harm; or destruction of equipment, data, or products.  
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DANGER: Danger indications identify conditions where death or  
permanent injury to personnel can occur if proper procedures and  
precautions are not followed.  
Icon Usage  
Several icons are used throughout the documentation to identify the types of hazardous  
resources or technologies used when working with a particular aspect of the system.  
Table 1, “Icons,” lists these and their definitions. Exercise extreme care by reading the  
material thoroughly and following all procedures when working with the various  
components.  
Table 1. Icons  
Icon  
Definition  
CAUTION:  
Exclamation Mark: This icon is used for other instances and  
items for which a standard symbol does not exist.  
CAUTION: Risk of Electric Shock  
This icon identifies instances where dangerous or lethal  
voltages might be present when working with various  
components of the irradiator or site power.  
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  
should never be turned on if the lamp housing and  
screen are not intact, or if the microwave leak detector  
and interlock are not functioning.  
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Table 1. Icons (continued)  
Definition  
Icon  
CAUTION: Ultraviolet Radiation  
This icon identifies instances where damaging levels of  
ultraviolet radiation may be present. Adequate shielding  
around the equipment and region must be provided, and  
personnel should be required to wear goggles with UV  
certified lenses. All personnel within ten feet of the lamp  
should wear gloves and long sleeves to protect their hands  
and arms, and ensure that their legs are covered.  
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. Please check with your LAN manufacturer  
for compatibility. Ensure that the equipment is properly  
maintained and shielded.  
CAUTION: Ozone  
High concentrations of ozone can cause discomfort, or at  
sufficiently high levels be dangerous. Although Fusion lamp  
systems make ozone at a level that could barely be detected  
by odor and at a factor of five below the level of 0.1 parts per  
million allowable for continuous exposure (American  
Conference of Governmental Hygienists), all Fusion UV Lamp  
Systems should be exhausted to the outdoors.  
CAUTION: Hot Temperature, Do Not Touch  
Surface temperatures of the lamp during normal  
o
operation may exceed 120 F. Metal components near  
the lamp will also be hot. Observe appropriate  
precautions to avoid burns.  
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Table 1. Icons (continued)  
Definition  
Icon  
Protective Conductor Terminal  
Earth (ground) Terminal  
Three Phase Alternating Current  
System Description  
The Fusion Ultraviolet Lamp System has been designed specifically for applications  
involving the industrial curing of inks and coatings and may be used effectively for a  
wide variety of applications.  
An ultraviolet (UV) lamp system for industrial curing must generate extremely intense  
radiation in the 200-400 nanometer region. Such radiation, when properly generated  
and focused, and used in conjunction with specially formulated 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. The patented Fusion UV Systems lamp has no electrodes,  
and consequently overcomes many of the basic limitations of conventional mercury  
arc lamps.  
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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. This is  
possible because the illumination of the lamp is a full 6". When two 6" lamps are  
placed end-to-end forming a 12" lamp, material being irradiated in the focal plane  
53.3mm (2.1") below the lamp bottom, and at the juncture between the two lamps,  
receives sufficient radiation from each 6" module to provide uniform curing over the  
entire region.  
Microwave energy from a single magnetron is directed into the cavity formed by an  
aluminum reflector and a screen over the bottom of the reflector. The lamp bulb is  
located inside this chamber. The screen keeps microwaves inside the chamber but  
allows UV light to pass through onto the material to be cured.  
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Electrical inputs to the lamp module are provided by a high voltage/control cable with  
a quick-connect fitting which supplies power for the magnetron, filament transformer  
and the interlock circuitry.  
System Components  
The basic F300S/F300SQ system consists of the following items:  
•
•
•
•
•
•
A P300M/P300MQ/P300MT power supply  
An HV Cable H340 (no modular blower)  
An HV Cable H341 (with modular blower)  
An I300 series irradiator  
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” and Appendix C, “Outline Drawings” for irradiator cooling  
requirements.)  
Mechanical mounting of the lamp modules over a substrate, conveyor, or other  
transport mechanism  
•
•
•
•
Light shield surrounding the lamps  
Exhaust system for the light shield  
Any desired interlock mechanisms (see Chapter 3 on page 39)  
Electrical wiring of the power supply into the plant electrical system  
Control  
The control system of the F300S/F300SQ provides precise control of high voltage and  
filament voltage supplies. The control board also monitors cooling air pressure,  
detection of RF, power levels, bulb ignition, and interlocks such as transformer  
thermal switches. If a problem arises, the control system turns off all high voltage  
power to the lamp and flashes a fault LED indicator on the power supply control panel.  
Inputs for customer ON/OFF control are available. Outputs allow detection of  
STANDBY or LAMP ON operation, or of interlock failures.  
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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. This airflow cools the bulb and exhausts through the RF screen.  
Irradiators  
The I300M irradiator family is the heart of the UV system. For example, the model  
I300M contains both the 15.2 cm (6") long electrodeless lamp bulb mounted in the  
elliptical reflector and the magnetron which energizes the bulb. The reflector is  
elliptical in cross-section and the lamp bulb is mounted at the focus of the ellipse,  
producing an intense strip of light at the other focus of the reflector (53 mm [2.1"]  
below the bottom rails of the lamp).  
M3 screen retaining  
screws (4) (2 per side)  
RF screen  
Cooling air holes  
Lamp bulb  
Cavity  
Reflector  
Figure 2. Reflector Assembly  
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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  
I301M  
Direct View  
Direct View  
Direct View  
Scatter View  
Scatter View  
Scatter View  
Direct View  
Direct View  
Direct View  
Standard  
Front Connect Plenum  
Top Connect Plenum  
Modular Blower  
Standard  
I300MB  
I310MP  
I311MP  
I310MB  
I310MP-D  
I311MP-D  
I310MB-D  
Standard  
I6  
I6  
I6  
I6  
I6  
I6  
Front Connect Plenum  
Top Connect Plenum  
Modular Blower  
Front Connect Plenum  
Top Connect Plenum  
Modular Blower  
Reflector and Cavity  
The top of the reflector contains two rectangular slots which admit microwave energy  
into the cavity. The slots are fed by one 1800 W, 2450 MHz magnetron located in the  
top half of the lamp enclosure and connected to the cavity by a waveguide launcher.  
Lamp Bulb  
The lamp bulb (Figure 3) is made of quartz and has a tapered shape which optimizes  
its UV, thermal, and microwave properties. The short quartz stubs at either end of the  
15.3 cm (6") bulb provide mechanical support for quick mounting into spring-loaded  
receptacles at the cavity ends. They are not electrodes and have no electrical function.  
Figure 3. Lamp Bulb  
Access to the cavity for changing the bulb or routine cleaning of the bulb and reflector  
is easily accomplished by removing the screws which secure the screen assembly to  
the bottom of the lamp. This procedure is explained in detail in Chapter 6,  
“Maintenance”. The fine mesh screen must be intact and firmly secured to the lamp if  
the system is to work properly and safely. The RF leakage interlock automatically  
shuts the system off if excess microwave energy passes through the screen.  
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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.  
Power Supply  
Each lamp system has its own power supply to house the high voltage circuits  
necessary to energize the magnetron, as well as all control and interlock electronics,  
and the built-in cooling fan.  
The power supply is fully modular. Up to six units may be interconnected and  
controlled from a single master unit. Any power supply may assume either Master or  
Slave status in a multi-unit installation.  
P300M/P300MQ/P300MT  
The power supply high voltage circuit consists of a dual half-wave voltage doubler  
circuit which supplies a regulated source of high voltage power (approximately  
3900V, 700 mA DC) to the magnetron in the irradiator. The capacitors and diodes  
provide regulation and rectification to the high voltage transformer outputs.  
RF Detector  
The system includes a detection device which shuts the system down if microwave  
energy in excess of permissible levels is in danger of being released into the work  
environment. This might be caused by a faulty RF screen or some other type of damage  
to the lamp, or by inadequate or damaged shielding.  
The power supply fault detection circuitry searches the system for a functioning RF  
detector by means of the System Interconnections Bus. A multi-unit installation must  
have at least one RF detector, which is usually connected to the master power supply.  
Additional detectors may be connected to slave units.  
During the startup sequence, each power supply will automatically perform a  
functional test on any installed RF detector (if switch S1-5 is set to “YES”). The  
operator may also verify detector operation by pushing a test button on the RF-1  
module for 4 seconds. Complete information appears in Chapter 5, “Troubleshooting”.  
System Interconnections  
All electrical connections to the power supply are made through connectors at the rear.  
Instructions for wiring are provided in Chapter 3, “Electrical System”. The power  
supply does not require any routine maintenance other than occasional cleaning of the  
interior with compressed air (depending on the environment).  
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Figure 4. P300M Front Panel  
Warranty Policy  
Items manufactured by Fusion UV Systems Incorporated are warranted (under normal  
and proper use) to be free from defects in material and workmanship. Fusion UV  
Systems will repair or replace, at its option, any defective parts when returned to  
Fusion by the purchaser, transportation paid. See the Terms & Conditions included  
with your sales order for the length of the warranty period.  
Equipment may not be returned, whether for warranty or other purposes, without prior  
authorization and issuance of a Returned Material Authorization Number by Fusion  
UV Systems. After inspection and acceptance, equipment returned for credit will be  
subject to a handling and restocking charge.  
Fusion UV Systems assumes no expense or liability for repairs made outside its plant  
without written consent nor for any labor costs which are so incurred. For equipment  
manufactured by others, Fusion UV Systems will pass along to the purchaser whatever  
warranty it receives and will not be responsible for any incurred expense outside of  
such warranty.  
If repair of equipment is required but return of such equipment to Fusion UV Systems  
is not feasible, then by mutual consent of Fusion and the purchaser, an authorized  
Fusion UV service representative will be sent to the purchaser’s plant to effect  
necessary repairs. 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.  
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NOTE: Any repairs or alterations, including the use of non-Fusion UV  
Systems (Fusion) parts, made by the user of this product without Fusion  
UV Systems’ prior written consent shall void all warranties provided by  
Fusion UV Systems and such warranties shall cease to be in effect. No  
allowance will be granted for such repairs or alterations. 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.  
Shipping Instructions  
Read the following sections carefully to ensure compliance with the requirements and  
recommendations for returning products or components, whether for credit,  
replacement, or repairs.  
Returned Material Authorization Number  
Equipment may not be returned, whether for warranty or other purposes, without prior  
authorization and issuance by Fusion UV Systems of a Returned Material  
Authorization Number. After inspection and acceptance, equipment returned for credit  
will be subject to a handling and restocking charge. Returned equipment must be  
shipped prepaid.  
General Packing Instructions  
If possible, original packaging materials should be reused for return shipment to  
Fusion UV Systems. If Fusion UV Systems’ packaging materials are not used,  
equivalent packaging, as outlined in the following sections, is to be used.  
Power Supply  
Secure the chassis to the cover by M5 x 12 mm screws. (There are three on each side  
of power supply for the P300M/P300MQ, two on each side of power supply for the  
P300MT.)  
2
Box:  
Gross Weight Limit: 70 kg (155 lbs.)  
Fills: Rigid high density styrofoam or cardboard fills as required to  
Bursting Test: 24 kg/cm (350 lbs./sq. in.)  
ensure power supply does not shift in box during shipment.  
CAUTION: Packaging materials should not push against connectors or  
controls.  
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Irradiators  
Irradiators should be returned in their original packaging. If this is not available, lamps  
must be double boxed, as follows:  
The lamp is to be placed in an inner box, using cardboard fills to assure a snug fit. The  
RF screen should be protected by taping a piece of cardboard over it. The inner box  
should then be placed in an outer box that provides about a two-inch clearance on all  
sides. High density styrofoam corner pads should be placed in the corners between the  
outer and inner boxes to isolate the lamp from impact.  
2
Box:  
Bursting test: 24 kg/cm (350 lbs./sq. in.)  
Gross Wt. Limit: 70 kg (155 lbs.)  
Magnetrons  
If available, use a special Fusion replacement magnetron shipping box. Otherwise,  
magnetrons must be double boxed as described next.  
Wrap magnetrons in three layers of plastic “bubble wrap” or equivalent. Place  
magnetrons in the box and add loose styrofoam fill. Place this inner box in an outer  
box and surround the inner box with loose styrofoam fill.  
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” or equivalent. Ship with loose  
styrofoam fill in the box.  
Control Cards  
The integrated circuits in control board assemblies are susceptible to damage from  
static electrical charges which may be transmitted by handling or packaging materials.  
To guard against static, place control cards in anti-static bags, if available. If not, wrap  
control cards in aluminum foil. Isolate the cards from impact with additional wrapping  
of “bubble wrap” or equivalent.  
RF Detectors  
RF Detectors should be wrapped in two layers of “bubble wrap” or equivalent and  
placed in a box with loose styrofoam fill.  
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Chapter 1. Safety  
Fusion UV Systems’ Ultraviolet (UV) Lamp Systems have been designed to operate  
safely. Many systems are in production in a wide variety of industrial environments  
without any problems of worker safety or health hazards. However, like most  
industrial equipment, this equipment can present worker safety problems if care is not  
taken to install, operate, and maintain it correctly.  
The following pages provide information concerning various aspects of worker safety  
with regard to this equipment. Because some features of the system may be new to  
personnel using the equipment, an attempt has been made to provide a fairly extensive  
background on these issues as well as references, where feasible, to further information  
or U.S. Government Standards.  
IMPORTANT: All personnel using the equipment  
must become familiar with this safety information.  
Care in installation and operation, coupled with adequate worker training, should  
ensure that no unusual safety problems arise.  
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Ultraviolet Radiation  
Ultraviolet radiation which is emitted during normal operation of the  
Fusion Ultraviolet Lamp System can be dangerous to the eyes and  
skin of personnel. Adequate shielding around the system and the  
region to be irradiated must be provided. If unsafe levels of light are  
allowed to escape during operation, then all personnel in the vicinity  
of the lamps should be required to wear goggles with UV certified  
lenses. Protection is needed for indirect as well as direct eye  
exposure; UV certified lenses are recommended. Discomfort from  
excessive eye exposure to ultraviolet light typically occurs about six  
hours after exposure. Personnel who experience eye pain after  
possible exposure to direct rays from the UV lamp should see a  
doctor. Furthermore, in the event that adequate shielding is not  
possible, all personnel within ten feet of the lamp should wear gloves  
and long-sleeved shirts to protect hands and arms.  
There are no present U.S. government standards on worker exposure to ultraviolet  
light. However, there is a NIOSH document, “Criteria for a Recommended  
Standard...Occupational Exposure to Ultraviolet Radiation” (No. HSM 73-11009),  
and several useful publications are available from the Bureau of Radiological Health  
of the Food and Drug Administration.  
Microwave Radiation  
The Fusion UV Lamp System is powered by high energy RF  
microwave power. This form of energy is identical to that used in  
home microwave ovens and, as in the case of ovens, can be  
dangerous if misused or inadequately shielded. In the Fusion UV  
lamp, the shielding is adequate only as long as the lamp and the  
screen on the bottom of the lamp are intact. Any rip or large hole in  
the screen may lead to microwave radiation leakage in dangerous  
amounts. The power to the lamp is interlocked to shut off if there is  
excessive microwave radiation leakage. The lamp system should  
never be turned on if the lamp housing and screen are not intact, or if  
the microwave leak detector and interlock are not functioning.  
Fusion UV equipment is interlocked to shut down if microwave leakage in excess of 5  
2
mW/cm (milliwatts per square centimeter) is detected.  
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Personnel Effects of Microwave Radiation  
OSHA (U.S. Department of Labor, Occupational Safety, and Health Administration -  
Standard 29CFR 1910.97) and ANSI (American National Standards Institute -  
Standard C95.1-1999) are the only major national organizations with voluntary  
guidelines for safe limits of occupational microwave radiation exposure.  
The ANSI recommendation is the more stringent of the two guidelines. Conservatively  
expressed, it states that a worker should not be exposed to microwave radiation levels  
2
in excess of 8 mW/cm on a continuous basis at 2.45 GHz. It allows for short-term  
exposure to much higher levels by stating that over a six-minute period the average  
power density to which a worker is exposed to microwave radiation should not exceed  
2
8 mW/cm .  
Microwave radiation is considered a non-ionizing electromagnetic radiation, which is  
not known to produce genetic damage. The primary effect of this energy is to simply  
2
raise the temperature of a body which absorbs it. For example, 5 mW/cm will raise 1  
o
cc of water 0.07 C in one minute. If the average worker were exposed to this energy  
level continuously, he would absorb about 30 watts over his whole body. At rest, the  
body dissipates about 100 watts. Therefore, this additional heat load is considered safe,  
although we do not recommend continuous exposure to levels anywhere near 5  
2
mW/cm .  
Fusion UV Systems equipment normally produces low level leakage well below  
2
8mW/cm in the work environment. If a microwave survey meter is used, one should  
2
read levels well below 1 mW/cm where personnel are likely to be continuously  
exposed. When a lamp is started, leakage levels may increase by a factor of two or  
three for the few seconds it takes to start and couple energy to the bulb. This is  
2
considered safe due to the requirement to average under 8 mW/cm over a six-minute  
period.  
Radio Interference  
Fusion UV lamps are classified as non-consumer industrial, scientific  
and medical equipment, as defined in Federal Communication  
Commission (FCC) Rules and Regulations Volume 47, Part 18. As  
required by these rules, Fusion UV Systems verifies that their systems  
are capable of compliance with applicable technical standards  
governing radiated emissions when the equipment is properly  
maintained and is installed in an appropriate light shield.  
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.  
Please check with your LAN manufacturer for compatibility.  
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Ozone  
Ozone is a gaseous form of oxygen which is formed by ultraviolet light. It  
has a characteristic pungent odor to which most people are quite sensitive  
(people can typically detect concentrations of several parts per hundred  
million). 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. This was a level that  
could barely be detected by odor and a factor of five below the level of 0.1 parts per  
million allowable for continuous exposure (American Conference of Governmental  
Hygienists).  
All Fusion UV Lamp Systems should be exhausted to the outdoors.  
Temperature  
Surface temperatures of the lamp during normal operation may  
o
exceed 120 F. Metal components near the lamp will also be hot.  
Before attempting service procedures on the lamp, allow the unit  
to operate in STANDBY so that the blower continues to run. The  
bulb will cool completely in less than one minute. If the blower  
is not allowed to run, the bulb will retain heat for several  
minutes. Observe appropriate precautions to avoid burns.  
Handle the bulb with cotton or surgical gloves or a lint-free towel at all times, as  
fingerprints can be etched into the quartz.  
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High Voltage  
Insulated electrical cables carry power at 3900 Volts from the power supply to the  
lamp. These voltages can be dangerous, so some precautions should be taken in both  
the location and protection of these lines. High voltages are exposed within the power  
supply chassis, which should never be operated without its cover.  
DANGER: Never touch the power supply/lamp cable  
connections while the system is ON or in STANDBY. A faulty  
magnetron may cause 7000 Volts DC to appear on connector  
pins and may cause serious injury.  
Do not touch power supply/irradiator harness plug P10 near the  
contacts, and do not lay P10 down on any conductive material.  
Never troubleshoot the power supply without first disconnecting  
all external power and discharging the high voltage capacitors  
with an insulated screwdriver.  
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.  
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Chapter 2. Mechanical Installation  
Mechanical Installation Checklist  
Before operating the ultraviolet lamp system for the first time, be sure the following  
procedures have been completed.  
Table 3. Mechanical Installation Checklist  
Item  
Chapter  
Chapter 1, “Safety”  
† Review safety procedures  
† Light shields in place  
“UV Light Shielding” on page 34  
† RF detector positioned correctly  
“RF Detector Mounting” on page 35  
† Fan connection for exhaust of light shield “Remote Blowers” on page 36  
† RF screen and lamp bulb inspected Introduction, page 11  
This chapter describes the physical installation of the F300S/F300SQ Fusion UV  
Lamp System. Directions regarding mounting and shielding of the system are  
somewhat general because they will vary depending upon the details of each  
individual installation.  
Unpacking and Inspection  
This Fusion UV lamp system has been thoroughly tested inspected, and packed prior  
to shipment. 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.  
CAUTION: Irradiators are particularly vulnerable to dust, dirt, metal  
chips, and RF screen damage. They are shipped with a protective  
covering over the screen. The covering should not be removed until just  
prior to installation.  
When unpacking, identify and compare each item with the packing list enclosed.  
Remember to examine each component for damage. Appendix E, “Replacement Parts”  
details the items included with the system which will be required to complete the  
installation.  
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Preliminary unpacking and inspection should be completed immediately on receipt of  
equipment to allow time for repair or replacement if necessary prior to installing the  
equipment.  
The P300M/P300MQ power supplies are shipped with six large Phillips head screws  
holding the cover to the chassis. There are three screws located on each side. The  
P300MT power supply is shipped with four large Phillips head screws holding the  
cover to the chassis. There are two screws located on each side of the P300MT.  
The four or six cover screws  
must be in place before  
operation to maintain continuity  
of the power supply enclosure  
ground circuit.  
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.  
Power Supply Unit(s) Placement  
The mechanical installation of a power supply unit is almost entirely at the user’s  
convenience. It can be placed on a sturdy shelf or in a cabinet provided that  
approximately 30 cm (12 inches) of space is left behind the power supply for cooling  
air to escape, and so that the cable harnesses can be run to the other components. See  
Appendix C, page 129 for restricted space clearance minimums.  
The P300M/P300MQ power supplies can function in any position, although standard  
horizontal mounting is recommended. Mounting the power supply so that the control  
panel is facing upward is not recommended because this allows dirt and dust to settle  
into the unit. In this position, the horizontal surface that is provided by the inlet finger  
guard also can be easily blocked by papers, notebooks, or other flat materials that will  
cause thermal overload and system shutdown.  
Power supplies are stackable up to three (3) units high. However, a power supply can  
weigh up to 40.3 kg (88.6 lbs.), so units should not be stacked to, or installed at, a  
height that makes access of chassis removal difficult.  
32  
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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. (Irradiator  
dimensions are shown in Appendix C, “Outline Drawings” and detailed in the  
Appendix A, “Specifications”.  
The easiest and most common mounting position is with the irradiator vertical and the  
screen at the bottom 53 mm (2.1 in.) above the substrate. Simply rest the module on a  
pair of angle irons oriented in the same direction as the lamp bulb. One common  
mounting scheme is shown in Figure 5.  
Vertical mounting requires that no part of the support can push against the irradiator  
screen, causing it to tear. Provisions may be made for raising or lowering the support  
structure with respect to the substrate to be irradiated. This allows the user to optimize  
the curing by working in focus or somewhat out of focus.  
Figure 5. Vertical Mounting Design for Irradiators  
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Lamps Mounted in Opposing Configuration  
IMPORTANT: If two lamps are to be mounted  
opposing each other (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. Long sleeved clothing is  
required to protect the skin from the effects of UV light.  
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The louvers which allow the flow of cooling air away from the irradiator must be of a  
light shielding design.  
(For more information on safety considerations, see Chapter 1, “Safety.”)  
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.  
However, to protect the antenna from heat and UV light, it should be placed outside  
the light shield. It may “look” into the light shield through an existing opening, or one  
made for this purpose. The tip of the sensing cone should be at least two inches from  
the opening of the light shield.  
The presence of metal surfaces near the detector may cause false readings; allow a  
maximum open area around the device.  
The connection of the cable from the RF detector to the power supply is explained in  
Chapter 3, “Electrical System”.  
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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,  
3
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" H O). See Chapter 6,  
2
“Maintenance” for information on the measurement procedure.  
Irradiator Exhaust Venting  
3
Fusion UV Systems recommends that 3.6 m /min (130 cfm) of air be exhausted from  
each irradiator. The air flow must be vented below the irradiator to prevent back  
pressure buildup, which would reduce the flow of cooling air. An exhaust fan is  
recommended to draw hot air and ozone away from the UV lamp and discharges them  
to the outside. The fan must remove at least 30% more air than is supplied to the  
irradiator inlets so a negative pressure will exist under the lamps. The makeup air  
enters through the UV shielding louvers or any other vents in the light shielding  
enclosure.  
2
Light shielding louvers are recommended. At least 142 cm (22 sq. in.) of louvered  
area is recommended for each irradiator to allow free flow of make-up air. If the  
exhaust air is not vented outside the building care should be taken to prevent it from  
recirculating into the inlet of the blower(s).  
Quartz Plates  
To protect the material being cured, quartz plates may be mounted below the UV lamp  
to block the air carrying heat away from the bulb. A typical mounting design is shown  
in Figure 8 on page 37. Details of the mounting structure depend upon the position and  
location of the irradiator and UV shielding.  
Clearance C prevents the substrate from striking and breaking the quartz plate but  
varies with the application. Distance D should be at least one inch and as large as  
practical to provide maximum area for the escape of cooling air (see Figure 8 on page  
37).  
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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  
cooling  
air flow  
Substrate  
to be cured  
Removal access  
for cleaning  
Quartz plate  
mounting structure  
Figure 8. Quartz Plates - Example Mounting Design  
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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. Electrical Installation and Setup Checklist  
Item  
Chapter  
† AC input voltage matches equipment label and  
Chapter 3, “Electrical System”  
connected correctly  
† Power supply HV capacitors tapped for AC line  
frequency  
Chapter 3, “Electrical System”,  
page 51  
† Power supply HV transformers correctly tapped for AC  
input voltage  
Chapter 3, “Electrical System”,  
page 51  
† Programming correct for each unit  
† Interconnection cables secure  
† RF cable secure  
Chapter 3, “Electrical System”,  
page 43, page 44  
Chapter 3, “Electrical System”,  
page 44, page 49  
Chapter 3, “Electrical System”,  
page 45, page 49  
† User inputs (EXTERNAL INTERLOCK, SYSTEM  
BLOWER) connected if wanted  
Chapter 3, “Electrical System”,  
page 40  
† Remote inputs (RESET, LAMP ON) connected if  
wanted  
Chapter 3, “Electrical System”,  
page 45  
† User outputs (FILAMENT ON, HV ON, FUTURE USE,  
LAMP ON, and PRESS ENABLE) connected if wanted  
Chapter 3, “Electrical System”,  
page 46  
† Review normal operating procedures  
Chapter 4., Operation, on page 55  
Accessory Parts List  
The Accessory Parts List is located in Appendix E, “Replacement Parts,” and should  
be reviewed when setting up your system.  
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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. A blank log form is  
included in Appendix D, “Lamp System Maintenance Log” of this manual.  
Installing the External Interlocks Control  
An input has been made available for use as an external interlock control. When  
activated, this circuit will cause the system to shut down. (See Chapter 5,  
“Troubleshooting” for details.)  
User Connections  
Pin removal and crimping tools are required to complete the optional user input/output  
connections to P105A and P106. Make these connections as described next.  
J105A  
J106  
J103  
INTERLOCKS  
J105B  
BUS INPUT  
J107  
RELAYS  
(K1-K5)  
BUS OUTPUT  
HIGH VOLTAGE CABLE  
J104  
IRRADIATOR  
BLOWER CABLE  
J101  
DISCONNECT POWER  
BEFORE SERVICING  
Figure 9. P300M/P300MQ Power Supply Rear Panel  
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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 5, Table 6, and Table 7 in this chapter.  
3. With a crimping tool, attach wires from user devices to new pins (supplied with  
system) and insert the pins in the proper locations.  
4. Reassemble the strain relief housing.  
Power Supply Programming  
P300M/P300MQ/P300MT power supplies may be interconnected to form a complete  
system of up to six lamps. Through use of the System Interconnections Bus control  
functions, the entire system may be operated by the lamp control switch of one master  
power supply, or by a switch on an external control panel.  
See Figure 10 on page 42 for the location of programming switch S1. To access S1,  
remove the six screws on the side of the power supply cover. For programming switch  
S1 settings, see the table illustration in Figure 11 on page 43.  
Settings for Six-Position Switch S1  
Positions 1, 2, and 3 of S1 (see Figure 10) must be set to determine whether a power  
supply is a master or a slave.  
Position 4 determines whether a unit fault will turn off all power supplies or only the  
unit where the fault occurs.  
Position 5 indicates to the system bus whether a power supply (either the master or a  
slave) has an RF Detector connected to it. (There must be at least one RF Detector  
connected to a system.)  
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J1  
J14  
J2  
J4  
J3  
F2  
F1  
J9  
S3  
TP2  
OFF/RST MASTER  
ON MASTER  
HI / LO MASTER  
UNIT TO SYS  
RF MASTER  
QRO  
J15  
J16  
S1  
TP1  
DS1  
ASSY P/N 32755X  
J10  
K1  
K2  
JP2  
J11  
K3  
S2  
K4  
K5  
J8  
J5  
J7  
J6  
F3q0008  
Figure 10. Location of Programming Switch S1 on PWB  
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Switch Position  
1, 2, and 3  
POS4  
POS5  
POS6  
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 12.  
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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 11.  
Irradiator Cable H340 Connections  
Non-blower version cable H340 connects to J103 and J104 on the power supply; and  
to J10 on the irradiator. All connectors are labeled, and keyed so they cannot be  
inadvertently interchanged.  
Blower version cable H341 connects to J103 and J104 on the power supply, and to J10  
and J11 on the irradiator. All connectors are labeled, and keyed so they cannot be  
inadvertently interchanged.  
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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. The system blower and external interlock inputs in the P105A connector  
must be jumpered if these inputs are not used.  
NOTE: All external switches must have gold contacts or be designed for use  
with logic-level signals to ensure reliable operation.  
Table 5. J105A Inputs (Customer Use Interlocks)  
Fault  
Condition  
Contact  
Ratings  
Interlock  
Pins  
Application Comments  
RFDetector 1,2,3,4 RF trip or  
12mA @12 VDC Single lamp: One detector per system  
Multiple lamps: RF Master must have  
RF detector.  
(Master)  
no detector  
present  
RFDetector 3,4  
(Slave)  
OPEN  
CIRCUIT  
12mA @12 VDC Single lamp: N/A  
Multiple lamps: Typically jumpered. User  
should remove jumper to install  
additional RF detectors and set S1-5 to  
ON (Yes)  
SYS Blower 11,12  
OPEN  
CIRCUIT  
12mA @12 VDC Typically jumpered. User may remove  
jumper to install N.O. pressure switch.  
Multiple switches should be wired in  
series.  
External  
Interlock  
9,10  
OPEN  
CIRCUIT  
12mA @12 VDC Typically jumpered. User may remove  
jumper to install N.O. interlock switch.  
Multiple switches should be wired in  
series.  
Remote Inputs  
One switch is required for remote operation of an F300S/F300SQ (to control the  
STANDBY/LAMP ON functions). Connections are made through the P106 connector.  
Single or Master/Slave systems may be operated remotely.  
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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.  
In a multi-lamp system, connections are made to the Master power supply.  
If there is a requirement for clearing faults remotely, a Remote Reset switch must  
be used.  
Table 6. J106 Inputs (Remote Operation)  
Active  
Condition  
Contact  
Ratings  
Signal  
Pins  
Application Comments  
REMOTE  
LAMP ON  
4,5  
Closed circuit  
12mA @12 VDC Set switch S1-2 of Master  
to NO. Leave S1-1 and  
S1-5 set to YES.  
REMOTE  
RESET  
1,2  
8
Closed circuit  
N/A  
12mA @12 VDC Set switch S1-1 of Master  
to NO.  
CABLE  
SHIELD  
N/A  
Keep cable length to a  
minimum.  
Output Ports (J105B)  
There are five relay outputs available on the P300M/P300MQ/P300MT through  
J105B. These outputs may be used to synchronize customer equipment with the  
system. In a multi-lamp system, connections are made to the Master power supply.  
Table 7. J105B Outputs (Customer Interface)  
Asserted  
State  
J105B  
Filament ON (K1) 3, 4  
Circuit Ratings  
Comments  
Closed  
1 A @120 VAC  
(10mA minimum)  
K1 contacts close when filament  
voltage is applied (STANDBY).  
HV ON (K2)  
QRO  
5, 6  
7, 8  
Closed  
Closed  
1 A @120 VAC  
(10mA minimum)  
K2 contacts close when high  
voltage is applied to lamp.  
1 A @120 VAC  
(10mA minimum)  
K3 contacts close when QRO is  
active.  
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Table 7. J105B Outputs (Customer Interface) (continued)  
Asserted  
State  
J105B  
Circuit Ratings  
Comments  
LAMP ON (K4)  
9, 10  
Closed  
1 A @120 VAC  
(10mA minimum)  
K4 contacts close when photocell  
is satisfied. Note: If using K4 for  
press control, wait 6-8 seconds  
for lamp output to stabilize.  
PRESS ENABLE  
(K5)  
11, 12  
Closed  
1 A @120 VAC  
(10mA minimum)  
K5 contacts remain closed when  
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. The STANDBY-READY function is asserted (K5 closed) when the  
power supply completes the transition from the STANDBY-WAIT (flashing yellow)  
to the STANDBY-READY state (steady yellow). K5 remains closed for the LAMP  
ON state (flashing or steady green), the QRO state (alternate flashing of yellow and  
green), and the return to the STANDBY-READY state (steady yellow). K5 opens  
during the OFF/RESET state and the STANDBY-WAIT state (flashing yellow) from  
either the LAMP ON state or from the OFF/RESET state.  
Table 8. Alternate Function for K5  
J105B  
Asserted State  
Circuit Ratings  
Comments  
STANDBY 11, 12  
READY  
(K5 alt.)  
Closed  
1 A @120 VAC  
(10mA minimum)  
K5 contacts close once  
STANDBY-READY state is  
achieved, and for any higher  
state.  
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Multiple-Unit Programming and Connections  
Programming and connections for multiple-unit systems are summarized in Figure 13.  
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” of this manual.  
RF DETECTOR  
EXT. INTERLOCK (JUMPERED)  
SYSTEM BLOWER (JUMPERED)  
RF DETECTOR (JUMPERED)  
EXT. INTERLOCK (JUMPERED)  
SYSTEM BLOWER (JUMPERED)  
RF DETECTOR (JUMPERED)  
EXT. INTERLOCK (JUMPERED)  
SYSTEM BLOWER (JUMPERED)  
F3q0011  
Figure 13. F300S/F300SQ Multiple Unit Programming & Connections  
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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. To shut down all units in case of a single-unit fault, set S1-4 on all units to YES  
(For a detailed explanation of unit faults, see Chapter 4, “Operation.”)  
Connections  
The following procedure describes how to connect multiple power supplies  
(master/slave) within a system.  
1. For proper operation, including fault detection, connect each power supply to the  
next using the H760 interconnect cables supplied with the system. Cables run  
from J107 of one unit to J106 of the next.  
2. Install input/output plugs P105A (with jumpers - provided with system) in  
J105A of slave units.  
3. The Master power supply must have an RF Detector connected to J105A;  
additional RF detectors may be plugged into J105A of the Slave power supplies  
by replacing the jumpered plug with the RF detector cable connector.  
4. Make interlock connections to the Master using the P105A plug on RF detector  
cable harness as indicated in “Input/Output Connections” on page 45 in this  
chapter.  
NOTES: When installing additional RF detectors on slave power supplies, be  
sure to set S1-5 to YES on those power supplies.  
If additional RF detectors are used, an RF fault in a slave will automatically be  
interpreted as a system fault; this will shut down the entire system.  
Additional interlocks such as RF, Remote Blower, and External Interlock may  
be connected to a SLAVE unit through P105A. Remove any factory-installed  
jumpers.  
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Power Source  
CAUTION: Measure the main single-phase voltage  
of your plant facilities to ensure that it conforms to  
the factory-wired operating voltage specified on the  
equipment label (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. Each power supply requires a  
separate, fused single-phase circuit with a line  
disconnect.  
NOTE: If a line voltage greater than 230V and a frequency of 50 Hz is used, see  
the “F300S Relay Coil Resistor Assembly Installation” on page 53 at the end of  
this chapter.  
System Power Connections  
F3q0004  
Figure 14. Power Supply Front Panel  
Listed current ratings indicate current demands during normal full-power operation.  
Your customer-supplied wiring and circuit breaker or fuses should be sized to allow  
for heavier current draw at startup. Current ratings are the same for 50 Hz or 60 Hz  
systems. The recommended power cord to wire to P101 is:  
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North American Applications: 3x12 AWG  
UL listed  
2
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 in Chapter 4, “Operation,” for the leg currents for each  
power supply/voltage combination.  
Frequency Tapping of HV Capacitors  
If it becomes necessary to configure the system for a line frequency other than that  
delivered, the following steps should be followed:  
1. Turn the unit POWER switch OFF and unplug the power cord.  
2. Remove the power supply cover (six screws).  
3. Locate the HV capacitors C101 and C102 (refer to Figure 15 on page 54).  
4. Discharge the capacitor by shorting the capacitor terminals with an insulated  
screwdriver.  
5. Locate the jumper connected to the T terminal of each capacitor.  
6. Disconnect the opposite end of this jumper from the capacitor terminal to which  
it is connected, and reconnect it to the appropriate terminal for the desired line  
frequency (50 for 50 Hz, 60 for 60 Hz).  
QRO HV Capacitors (For QRO only)  
When the Quick Restart Option is installed, one element of the retrofit is the  
replacement of the HV capacitors. These HV capacitors are a different value than the  
standard HV capacitors, but the frequency tapping procedure is exactly the same.  
High Voltage Transformer Taps  
Standard high voltage transformers have labeled taps. Power supplies are shipped with  
transformers tapped according to customer power specifications. If a unit is relocated  
or a transformer must be replaced, connections should be installed as shown in the  
following table.  
Table 9. High Voltage Transformer Taps  
HV Plate  
Power  
Transformer  
Primary Tap  
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Table 9. High Voltage Transformer Taps (continued)  
HV Plate  
Power  
Transformer  
200  
200  
208  
50 Hz  
220  
220, 240  
240  
200  
200  
208  
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. QRO Transformer Taps (Optional)  
QRO Transformer  
Power  
Primary and  
Primary Front Tap  
Secondary Rear Taps  
200  
200V  
208  
50 Hz  
60 Hz  
50 Hz  
60 Hz  
220  
240  
200  
208  
220  
240  
240V  
200V  
240V  
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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. There are two coil resistor assemblies available in a  
retrofit kit (See Appendix E, “Replacement Parts”). One assembly is placed in series  
with each of the coils of K101 and K102 in the power supply. These resistors should  
also be used when it becomes necessary to configure the system for a line voltage and  
frequency of greater than 230 VAC at 50 Hz (nominal voltage.)  
Installation Instructions  
1. Turn off the power and disconnect power from the power supply.  
2. Remove the six cover screws and cover from the P300M/P300MQ power  
supply. (Remove the four cover screws and cover from the P300MT power  
supply.)  
3. Locate relays K101 and K102. K101 is closer to the rear of the power supply  
and K102 is closer to the front (refer to Figure 15 on page 54).  
4. On K102, locate tab 0. A black wire with a pink-insulated terminal will be  
connected to it.  
5. Disconnect the black wire and press the pink-insulated female terminal of one  
resistor assembly onto K102 relay tab 0.  
6. Connect the black wire with the red-insulated terminal to the red male terminal  
of the resistor assembly. The leads of the resistor assembly should be bent to  
form a U shape to make this connection easier.  
7. On K101, locate tab 1. Two black wires with pink-insulated terminals will be  
connected to it.  
8. Disconnect the black wire with the fully insulated right-angle terminal and leave  
the double terminal with the pink insulation connected. Press the female terminal  
of the remaining resistor assembly onto the exposed tab of the double terminal.  
9. Connect the right-angle terminal to the male terminal of the resistor assembly.  
The leads of the resistor assembly should be bent to form a Z shape to make this  
connection easier.  
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CB1A  
CB1B  
L101  
C101  
C102  
T102  
T103  
Front  
Rear  
T101  
DB2  
DB1  
TB1  
K102  
K101  
Top View  
S1  
S2  
S3  
T
B1  
Front  
Rear  
K103  
K101  
K102  
Side View  
Figure 15. K101 and K102 on P300M/P300MQ  
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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.  
Lamp Control  
At STANDBY, power (115 VAC) is applied to the magnetron filaments without  
energizing the bulb. All interlocks and controls will continue to operate in STANDBY.  
An external blower can be triggered through a connection to output relay K1.  
Pressing the LAMP ON button energizes the lamp to its full power level after a  
STANDBY delay and an additional “full power” delay. If after 8 seconds in the ON  
position the bulb has not successfully ignited, the lamp will shut down. Check the LED  
display on the power supply; it will indicate the probable source of the problem.  
A “LAMP OUT” is a result of many different causes. The following are some reasons  
that may be a source of this fault condition:  
•
•
•
•
•
Successive short cycles  
Operation at improper air pressure  
Operation at continuous reduced power level with improper air pressure  
Improper initial ignition of the system  
Poor distribution of the fill material inside the bulb as a result of shipping and  
handling  
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•
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” fault can occur when the bulb does not  
reach sufficient output to activate the sensing photocell. This will particularly occur at  
initial startup of the system, after successive “short cycles” (LAMP ON times below  
10 seconds), or at the initial startup of a new bulb. In these instances, the bulb fill  
material has not completely vaporized. With repeated attempts to start the system, the  
problem may become worse, and can reduce the life of the electrical components.  
Refer to Chapter 5, “Troubleshooting” for other possible causes of a LAMP OUT  
condition.  
Power  
With the POWER switch in the OFF position, neither the control card nor the high  
voltage circuitry are energized. With the switch in the ON position, the power supply  
cooling fans and the control card are energized, and the LAMP Control switches are  
enabled.  
Off/Reset Control  
When a fault occurs, the fault must be corrected and the unit(s) reset by pressing the  
LAMP OFF/RESET switch before operation can be resumed.  
1. If a UNIT fault occurs, correct and reset the individual unit.  
2. If a SYSTEM fault occurs, reset the Master unit.  
3. If a slave has an RF detector connected, reset the Master when the Slave  
indicates a fault.  
4. If a system is operated by a remote ON/STANDBY switch, reset the MASTER  
power supply when a system fault occurs.  
5. If a system uses a remote LAMP OFF/RESET switch, that switch may be used  
instead of the front panel switch to reset a fault.  
Initial Startup Procedure, Single Unit  
1. Turn POWER switch to ON position and press the LAMP OFF/RESET switch:  
The red LAMP OFF indicator is lit.  
2. Press the STANDBY switch: the yellow STANDBY indicator blinks, then stays  
lit.  
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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  
11.  
Table 11. P300M/P300MQ/P300MT Current Requirements  
Line Currents (A)  
System Line  
Voltage  
Single Phase  
with K300M  
Modular Blower Modular Blower  
without K300M  
200  
15  
14.5  
13.5  
13  
208  
220  
230  
240  
14  
14  
13.5  
13.5  
13  
12  
5. Check RF detector and customer use interlocks as described in Chapter 5,  
“Troubleshooting.”  
Initial Startup Procedure, Multiple-Unit Systems  
1. Turn POWER switches of all units to ON.  
2. Press the LAMP OFF/RESET switch of the Master.  
3. Press the LAMP ON switch of all slaves.  
4. Press LAMP ON switch of the Master.  
NOTE: Front panel controls take precedence over remote or master commands.  
Master/Slave Operation  
One master power supply can control up to five slave units. Review Chapter 2,  
“Mechanical Installation” to understand the interconnections and programming  
needed.  
Operating the System  
1. Turn POWER switches of all units to ON.  
2. Press the LAMP OFF/RESET switch of the Master.  
3. Press the LAMP ON switch of all slaves.  
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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.  
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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.  
In a Master/Slave system, the Slave units must be switched to STANDBY or ON  
before Master power supply is switched from OFF to STANDBY.  
Table 12. Routine Operation  
Power  
Switch  
Lamp  
Control  
Lamp Control  
Flasher  
Time  
0 sec  
Operation  
Lamp Off  
Red  
Control card energized  
1-2 sec  
Yellow flash  
Power supply FAN ON;  
Modular Blower ON  
Standby  
10 sec  
Steady yellow  
Interlocks and fault detection  
circuits function. Ready to  
start.  
0 sec  
Lamp On  
from  
Standby  
Green flash  
Start HV transformers  
UV bulb ignites  
ON  
2-8 sec  
8-10 sec  
0 sec  
Steady green  
UV bulb at full power  
Slow flash yellow  
From LAMP  
OFF to  
LAMP ON  
10 sec  
12-18 sec  
18-20 sec  
0 sec  
Fast flash green  
UV bulb ignites  
Full power  
Steady green  
Yellow flash  
Steady yellow  
From LAMP  
ON to  
STANDBY  
UV bulb extinguished  
Ready to restart  
18 sec  
Remote Operation  
The F300S/F300SQ can be operated remotely with a STANDBY/LAMP ON switch  
connected to the Master. Refer to Chapter 3, “Electrical System” for instructions on  
connecting remote switches.  
The following procedure describes how to operate a lamp remotely:  
1. Turn all remote switches OFF (open contacts).  
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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  
Switch Open  
Standby  
Default to lowest state  
Switch Closed  
Lamp ON  
Lamp ON  
Lamp ON  
LAMP OFF/RESET  
Lamp RESET  
LAMP OFF/RESET  
Operation with Remote Controls  
Table 14. Operation with Remote Controls  
Remote  
Panel Controls on Master  
Switches  
Lamp ON  
Power  
Lamp Control  
Lamp Status  
Off/Reset  
ON  
S
S
S
Off/Reset  
LAMP OFF/RESET  
LAMP OFF/RESET  
ON  
Remote RESET LAMP OFF/RESET  
Switch CLOSED (overrides remote Lamp  
ON switch)  
ON  
OPEN  
STANDBY  
ON  
STANDBY  
CLOSED  
ON  
OPEN  
CLOSED  
Lamp ON  
KEY:  
S- Switch position does not matter.  
Quick Restart Option (QRO)  
The Quick Restart Option (QRO) provides the ability to restart the lamp at any time,  
even immediately after the lamp has been switched to Standby mode. Thus, the  
mandatory 18-second restart cycle time associated with routine operation has been  
eliminated. The QRO may be installed at the time of the P300MQ power supply  
construction or may be retrofitted into P300M power supplies in the field by trained  
personnel.  
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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%). This feature is intended for use in processes that require  
occasional periods of decreased UV output, or in the event of a short duration process  
interruption.  
CAUTION: The QRO is not intended for use  
as a shutter, or in processes that require rapid  
On-Off cycles. This kind of use may be  
detrimental to bulb life span.  
The actual restart time of the bulb will depend upon the elapsed time from when the  
lamp was switched from the Lamp On state to the Standby state. Representative data  
for the restart time from the QRO state to the Lamp On state (70%, 80%, and 90% UV  
output) is shown versus QRO state duration in Figure 16, Figure 17, and Figure 18.  
The QRO state, when enabled, will automatically occur when the power supply is  
switched from the Lamp On state to the Standby state. The QRO state is indicated by  
the alternate flashing of the green Lamp On and yellow Standby buttons on the front  
of the power supply. The QRO state will last for a maximum of 40 seconds, after which  
it will revert to the Standby state and the yellow button only will remain on.  
WARNING: While the lamp’s light output is low  
during the QRO state, both eye and skin protection  
should be worn in the event of possible direct or  
indirect exposure. Refer to Chapter 1, “Safety” for  
detailed information regarding ultraviolet radiation  
safety.  
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Figure 16. Restart Time Versus QRO State Duration, D-bulb  
Figure 17. Restart Time Versus QRO State Duration, H-bulb  
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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. See Chapter 3, “Electrical System” for further programming details.  
Operation  
The QRO state, when enabled by programming switch S1-6 on the control card, will  
be active during every transition from the Lamp On state to the Standby state, whether  
the lamp is operated remotely or from the front panel. The Lamp On state may be  
reentered by pressing the LAMP ON front panel switch or by remotely switching to  
Lamp On. If no other action is taken, the Standby state will become active after a QRO  
state duration of 40 seconds. The Reset state may be entered at any time by pressing  
the RESET front panel switch or by remotely switching to Reset.  
In a multiple-unit configuration, mixing QRO and non-QRO units is unlikely.  
However, if power supplies with and without the QRO are mixed, units with the QRO  
will operate as described in the preceding paragraph, and the units without the QRO  
will operate as described previously for a standard P300M power supply. The Initial  
Startup Procedure, Master/Slave Operation, and Remote Operation of power supplies  
with the QRO are the same as for standard non-QRO units.  
See Appendix E, “Replacement Parts” for the QRO parts list.  
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Chapter 5. Troubleshooting  
DANGER: High Voltage -- Use extreme caution at all times when  
troubleshooting the power supply. Line voltages are present even  
when the lamp control switch is set to STANDBY.  
Do not measure any voltages not specified in the troubleshooting  
procedures: dangerously high voltages exist in the power supply.  
Do not touch power supply/irradiator cable connectors while the  
system is on. High voltages are present in the connector.  
Do not touch any power supply components or wiring while the unit  
is operating.  
To troubleshoot the power supply, first turn off and disconnect all  
power to the unit. All high voltage capacitors have an internal  
discharge resistor which should discharge to a safe level in five  
seconds. Physically shorting the capacitor terminals with an  
insulated screwdriver blade is advised as an additional safety  
measure.  
DANGER: Ultraviolet Radiation -- Do not  
test the irradiator without using adequate  
ultraviolet light shielding and never look  
directly at the UV lamp. Severe ultraviolet  
burning of the skin and eyes can result  
without proper safeguards.  
Basic Checks  
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.  
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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.  
2. Turn all POWER control switches to ON. (No UV light is being produced by the  
bulb.) Press the STANDBY switches of all units.  
3. Operate the external interlock switch(es), by opening light shields, etc. The  
system should shut down and produce an LED signal. Reset unit by pressing the  
LAMP OFF/RESET switch on the master units.  
4. To actuate self-test of the RF detector, depress the test button on the detector and  
hold it down for 4 seconds. The system should shut down and produce an RF  
Interlock LED signal. Reset as before.  
Fault Indicators  
When an interlock switch is opened or improper equipment operation is detected, a  
fault signal is generated. Power is removed from the irradiator and blower of one or all  
units, depending on the type of fault and the programming selected by the user. The  
type of fault (Unit or System) is indicated on the front panel of the unit detecting the  
fault.  
Unit Faults  
Unit faults are those detected within an individual module. The Lamp Control switch  
and the top five light-emitting diodes on the front panel indicate the unit faults (see  
Figure 14 on page 50).  
Table 15. Unit Faults  
Indicator  
Description  
(HV Cable)  
If the LAMP OFF/RESET switch is lit when the POWER switch is  
ON, but the unit will not go to STANDBY when the switch is  
pressed, the high voltage cable is not connected or faulty.  
LAMP OUT  
After ON switch pressed: the photocell was not satisfied within 8  
seconds of initial startup time, or the light output fell low enough  
to unsatisfy the photocell at any time after startup. After  
STANDBY switch: Shorted Photocell detected.  
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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. To prevent magnetron  
damage, single-phase power should be disconnected (see PWR  
ERROR fault).  
PS TEMP  
The power supply is overheating.  
BLWR PRESSURE  
Cooling air pressure within the irradiator is insufficient.  
System Faults  
The bottom three LEDs indicate system faults. These faults always shut down ALL  
units in the system, causing all LAMP CONTROL switches to flash.  
System interlock switches and the RF detector may be connected to any unit, but are  
normally connected to the master. System faults will then be detected and displayed at  
the master power supply.  
Table 16. System Faults  
Indicator  
Description  
SYS BLWR  
EXT INTLK  
RF INTLK  
Insufficient cooling air pressure in an external supply or exhaust  
blower causes pressure switch to open.  
Open external interlock switch on a plenum cover, for example,  
connected at customer option.  
Excessive RF at the RF detector, or loss of power to detector.  
Fault Diagnosis Tables  
To determine the likely cause of failure in an F300S/F300SQ unit, note the operating  
sequence when the failure occurs. Also, record which fault indicator LED lights. The  
indicator may light immediately when the unit is switched from one condition to  
another (for example, from STANDBY to ON); or the signal may be displayed until  
after a programmed internal delay has elapsed.  
There is a troubleshooting table for each fault indicator, showing secondary symptoms  
to help localize the problem. The possible causes are listed, followed by testing and  
repair instructions.  
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Table 18, “Troubleshooting/Fault Diagnosis,” on page 69 covers miscellaneous faults  
and malfunctions.  
NOTE: The control card may be responsible for any of the fault conditions  
described following. 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. Table 18, “Troubleshooting/Fault Diagnosis,” on  
page 69 is organized around these signals and observable clues. Use the following  
table to locate the fault indicated.  
Notice that the failure of some signals to light is also an indication of a fault.  
Table 17. Fault Diagnosis Cross Reference  
Signal  
Page  
Arcing sound  
EXT INTLK  
LAMP OUT  
81  
74  
74, 75, 77, 78, 79, 81  
LAMP OUT light is off  
BLWR PRESSURE  
PS TEMP  
77, 78, 79  
75  
76  
PWR IMBAL  
75, 80  
76, 80  
73  
PWR ERROR  
LAMP OFF/RESET light is off  
RF INTLK  
73, 75, 80  
75  
STANDBY switch does not light  
SYS BLWR  
76  
Failure with no signal  
73, 75  
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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. Press  
STANDBY LAMP CONTROL button. If  
fuse does not blow, proceed to (B). If the  
fuse blows, the problem is in the internal  
wiring or control card.  
POWER switch  
from OFF to ON OFF/RESET  
button does  
LAMP  
not light at  
Control card  
Replace control card.  
power up  
Irradiator cable  
B. Turn OFF. Reconnect P104. Press  
STANDBY. If the fuse does not blow,  
proceed to (C). If the fuse blows, the  
problem is in the connectors or cable.  
RF detector  
C. Turn OFF. Reconnect P20 at the RF  
detector. Press STANDBY. If fuse does not  
blow, proceed to (D). If the fuse blows, the  
problem is in the RF detectors or cable.  
Filament  
transformer  
D. Turn OFF. Reconnect P10 to the  
irradiator. Press STANDBY. If the fuse  
blows, the problem is in the filament  
transformer or connections.  
Master turns  
slaves ON but  
not OFF  
Programming error  
Cable connection  
Close S1-1 (YES) on master.  
RF INTLK  
Connect cable H760 to slave.  
indicator lights  
on slave with  
slave OFF,  
master ON  
RF INTLK  
Programming error  
Close S1-5 (YES) on master.  
indicator lights  
on all units  
System shuts  
down; no fault  
indicators light  
Momentary loss of  
AC  
Turn off all units and then turn each unit  
on. A momentary loss of power to one or  
more units may be interpreted as a system  
fault.  
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Table 18. Troubleshooting/Fault Diagnosis (continued)  
Signal/  
Operation  
Other  
Possible Cause  
Corrective Action  
Symptoms  
Open control input.  
A jumper or an external circuit between  
J105A-9 and J105A-10 must be closed by  
a jumper or an external switch.  
Lamp control at  
OFF, or from  
OFF to  
EXT INTLK  
indicator lights  
Poor connection  
Disconnect all power. Reseat control board  
assembly connections. Try again.  
STANDBY  
Control card  
Replace the control card.  
Switch from  
OFF to  
STANDBY or  
from LAMP ON  
to STANDBY  
LAMP OUT  
indicator lights  
Shorted photocell  
Press LAMP OFF switch. Attach voltmeter  
probes to Photocell Voltage Test Points.  
Press the STANDBY switch. Measure the  
photocell voltage between Photocell  
Voltage Test Points while in STANDBY.  
The voltage level indicated should be  
greater than +9.3 VDC. If the voltage level  
indicated is less than this value, the  
photocell is defective. Replace the  
photocell assembly.  
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Table 18. Troubleshooting/Fault Diagnosis (continued)  
Signal/  
Operation  
Other  
Possible Cause  
Corrective Action  
Symptoms  
BLWR  
PRESSURE  
indicator lights  
Single-phase  
voltage missing  
phase  
See “Basic Checks” on page 65.  
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  
modular blower.  
Pressure switch  
faulty  
Replace the pressure switch.  
Air handling design  
Check for adequate air handling  
requirements.  
Switch from  
OFF to  
STANDBY  
STANDBY  
switch does  
not light  
HV cable  
disconnected  
Connect HV cable.  
No fault  
indicators light.  
Faulty HV cable  
Control card  
Inspect cable, check for continuity.  
Replace control card.  
LAMP OUT  
and/or PWR  
IMBAL  
indicators light  
immediately  
Card connectors not Check control card. All connectors must be  
secure  
properly secured.  
Control card  
Replace control card.  
RF INTLK  
indicator lights  
or flashes  
alternately with  
the lamp  
No RF detector  
connected  
Connect RF detector. A system must have  
at least one RF detector connected.  
Programming error:  
1. All units have  
S1-5 open.  
2. Unit(s) with S1-5  
open and no jumper  
between J105A-3  
and J105A-4.  
1. Close S1-5 on unit with RF detector  
connected.  
control  
switches  
2. Install jumper.  
RF cable shorted or  
open  
Check cable for continuity.  
RF detector faulty  
Control card  
Replace RF detector.  
Replace control card.  
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Table 18. Troubleshooting/Fault Diagnosis (continued)  
Signal/  
Operation  
Other  
Possible Cause  
Corrective Action  
Symptoms  
Switch from  
OFF to  
PS TEMP  
indicator lights  
Power supply fan  
inoperative  
Repair or replace fan.  
STANDBY or  
from STANDBY  
to ON  
Power supply too  
hot or in poor  
location  
Move to cooler location.  
Temperature switch  
faulty or not  
connected.  
With power off, check the T101 and T102  
thermal switches, which should be closed,  
with an ohmmeter or DVM. Check that the  
thermal switch interconnections are  
secure.  
Card connectors not Reseat connectors.  
secure  
Control card  
Replace control card.  
SYS BLWR  
indicator lights  
Blower power;  
pressure  
If SYS BLWR input for external blower in  
J105A is in use, check external blower  
power and pressure in the same manner  
as remote blower.  
Jumper in J105A  
If SYS BLWR input not in use, check  
jumper is in place in connector J105A.  
Control card  
K101  
Replace control card.  
Lamp Control at  
STANDBY  
PWR ERROR  
indicator lights  
Check for presence of magnetron current.  
If within specifications, then examine  
relays for stuck armature or contacts  
welded shut. Check operation of relay with  
single-phase power only connected.  
Control card  
Replace control card.  
CAUTION: Disconnect single-phase power at main circuit breaker immediately.  
Magnetron may be severely damaged by application of high voltage when lamp  
control is in OFF or STANDBY.  
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Table 18. Troubleshooting/Fault Diagnosis (continued)  
Signal/  
Operation  
Other  
Possible Cause  
Corrective Action  
Symptoms  
High Voltage Cable  
Lamp Bulb  
Check cable connections at J103, J104,  
J10, and J11.  
Measure the Photoresistor output at the  
photocell test points and magnetron  
current test points on the front panel while  
switching to LAMP ON.  
If the photocell voltage does not drop when  
the magnetron current voltage changes,  
replace the bulb.  
If the photocell voltage drops, remove and  
inspect the bulb for normal mercury  
condensation. If normal mercury  
condensation is not observed, (if all the  
pellets are at one end, or at the center of  
the bulb), if possible, test the bulb in a  
separate unit. If the bulb starts, check your  
process (air handling, duty cycle, etc.). If  
the bulb does not start, replace the bulb.  
Switch from  
STANDBY to  
ON  
LAMP OUT  
indicator lights  
after 8  
seconds;  
Lamp bulb  
does not light  
New bulb  
During its first start, a new lamp bulb may  
take up to 8 seconds after ignition before  
reaching full intensity if the mercury (Hg) fill  
has accumulated at one end or at the  
center of the tube.  
High Voltage cable  
Control  
Check cable connections at J103, J104,  
J10, and J11.  
Listen for the sound of K101, the high  
voltage contactor, inside the power supply.  
It should be heard closing with an audible  
click when switched ON (after a three  
second wait in STANDBY). If not detected:  
Disconnect single-phase power. Reseat  
control board assembly connectors P8 and  
P9. Observe K1 and K102 when switching  
to STANDBY. Reconnect the single-phase  
power and observe K2 and K101 when  
switching to ON.  
K1, K2 Relays  
Control card  
Replace K1 and K2 on the control board  
assembly.  
Replace control card.  
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Table 18. Troubleshooting/Fault Diagnosis (continued)  
Signal/  
Operation  
Other  
Possible Cause  
Corrective Action  
Symptoms  
Switch from  
STANDBY to  
ON  
LAMP OUT  
indicator lights  
after 8  
Diodes, capacitors  
If the readings are not different, a power  
supply fault is indicated. Disconnect all  
power and inspect for wiring damage. Test  
diodes and capacitors according to the  
procedures in Chapter 6, “Maintenance”.  
seconds;  
(continued)  
Lamp bulb  
does not light  
(continued)  
Irradiator  
Disconnect all power. Remove the  
irradiator cover (see Chapter 6,  
“Maintenance”). Inspect for obvious  
damage to wiring. Inspect the reflector for  
pitting near the large slots, which is  
evidence of arcing.  
Magnetron  
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.  
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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  
specification  
NOTE: If the magnetron needs to be  
replaced prematurely, check that the  
single-phase voltage is within specification  
(see “Basic Checks” on page 65).  
LAMP OUT  
indicator lights  
after 8  
seconds;  
Lamp Bulb  
does not light  
(continued)  
Weak magnetron  
Photoresistor  
If photoresistor reading does not fall to  
below 9.3 VDC in 8 seconds, a weak  
magnetron is commonly indicated.  
Switch from  
STANDBY to  
ON (continued)  
LAMP OUT  
indicator lights  
after 8  
seconds;  
UV bulb  
Measure photoresistor output at Photocell  
Voltage Test Points while switching to ON  
(see schematic) +12 VDC at STANDBY,  
2-5.5 VDC at ON. If voltages are incorrect,  
remove the irradiator cover and replace the  
photoresistor as described in Chapter 6,  
“Maintenance”.  
reaches full  
intensity  
Weak magnetron  
Connections  
If photoresistor reading does not fall to  
below 9.3 VDC in 8 seconds, a weak  
magnetron is commonly indicated.  
Disconnect all power. Remove the power  
supply cover. Reseat the control card  
connectors P6 and P10. Restart.  
Control card  
Replace the control card.  
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Table 18. Troubleshooting/Fault Diagnosis (continued)  
Signal/  
Operation  
Other  
Possible Cause  
Corrective Action  
Symptoms  
PWR IMBAL  
indicator lights  
Power Supply  
Usually, a diode or capacitor failure will  
reduce magnetron current by one-half.  
Test the diodes and capacitors according  
to Chapter 6, “Maintenance”. The voltage  
to the primary coils ONLY of the high  
voltage transformers should also be  
checked.  
Filament  
Transformer  
Check the filament transformer and  
connections.  
Control Card  
Replace the control card if no power  
supply, magnetron, or other malfunctions  
are found.  
Switch from  
STANDBY to  
ON  
Failing (Moding)  
Magnetron  
Check magnetron current at front panel  
test points. If it is not within specifications,  
replace magnetron.  
(continued)  
PWR ERROR  
indicator lights  
Filament  
transformer  
Check filament transformer and  
connections.  
Magnetron  
Check for presence of magnetron current.  
If it is zero, disconnect all power, and  
replace magnetron. If magnetron current is  
low or half, check diode block and HV  
capacitors.  
Control Card  
Replace the control card.  
Replace the lamp bulb.  
Replace the RF screen.  
RF INTLK  
indicator lights  
Lamp bulb faulty  
RF Screen  
damaged  
RF - arcs forming  
RF Detector faulty  
Position  
Inspect reflector for pitting; replace if  
necessary.  
See “RF Detector” on page 20 to test RF  
detectors.  
Reposition the detector farther from the  
screen and/or the light shield opening.  
WARNING: The RF detector should at all times be closer to the screen or light shield  
opening than personnel working nearby. It should be aimed so that it intercepts RF  
radiation from the irradiators.  
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Table 18. Troubleshooting/Fault Diagnosis (continued)  
Signal/  
Operation  
Other  
Possible Cause  
Corrective Action  
Symptoms  
Lamp Control at  
LAMP ON  
LAMP OUT  
indicator does  
not light, or UV  
lamp does not  
light  
Control card  
Replace control card.  
Arcing sound  
from irradiator,  
a grinding  
noise  
Damaged Reflector  
Disconnect all power. Inspect reflector for  
pitting near large slots. Replace reflector if  
necessary.  
Wiring or connector  
Magnetron  
Remove irradiator cover and inspect wiring  
for damage.  
Replace the magnetron; see Chapter 6,  
“Maintenance”.  
System not  
responding in  
accordance  
with  
Incorrect  
See Chapter 3, “Electrical System”.  
MASTER/SLAVE  
arrangement or  
cable hook up  
programming  
switch SW1  
settings  
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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. Clean as needed.  
Instructions for removing and replacing these components appear later in this chapter.  
Guidelines for cleaning these components follow.  
If the reflector or bulb surfaces show signs of dirt, oil, or vaporized materials, they  
should be removed and cleaned with a good industrial cleaner, using a lint-free cloth  
or tissue. The cleaner should contain no waxes, silicones, dyes or perfumes. Simple  
Green® and Windex® are recommended. Wipe away any residues, using the cloth or  
tissue with pure water. Alcohol, isopropyl, or methanol may be used for final removal  
of residues, except when alcohol is not allowed as a solvent.  
If deposits on the screen, bulb, and reflector are consistently found at 500-hour  
inspections, the blower filters should be changed more frequently, or a more efficient  
filter should be used. These deposits can cause premature failures when particles burn  
into the quartz lamp or result in dulling of the reflectors.  
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. Harsh abrasives and steel wool should NEVER be used on bulbs.  
Reflector Cleaning  
If the reflector surface is dull or discolored, it should be cleaned. Abrasives should  
never be used on reflectors.  
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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. Take care not to damage the gaskets or the fine  
screen wires.  
I300M 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.  
M3 screen retaining  
screws (4) (2 per side)  
RF screen  
Cooling air holes  
Lamp bulb  
Cavity  
Reflector  
Figure 19. Reflector Assembly (I300M)  
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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. To replace existing screen or install a new one, place the screen assembly in  
position.  
3. Apply pressure to the frame only and press firmly into place. Install the four  
screws alternately, working from side to side. Tighten each to a snug position;  
finally tighten to 0.9 N-m (8 inch-lbs.) using a torque-controlled screwdriver.  
Figure 20. RF Screen Screw Tightening Sequence  
Lamp Bulb Removal/Replacement  
WARNING: During operation, the lamb bulb  
and adjacent metal surfaces become very hot.  
Operate the blower for about one minute to  
cool hot surfaces.  
1. Remove the screen as described in “I300M Screen Assembly  
Removal/Replacement” on page 80.  
2. Next, see Figure 21 on page 82. Using clean cotton gloves or lint free tissue, grasp  
the lamp bulb at one end between the thumb and fingers and apply firm pressure  
axially toward the opposite end. When the tip of the bulb has cleared its retaining  
hole and is free to move past or along the end reflector, gently slide it up and out.  
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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” on page  
79).  
Retaining hole  
Figure 21. Removing or Replacing the Bulb  
4. To replace a lamp bulb in the reflector, hold it near the middle and insert the tip  
of the bulb into the retaining hole of one end reflector. Apply pressure in the  
direction of the length of the bulb, moving it toward the end that is inserted. This  
will allow the free end to clear the end reflector. Gently slide the end of the bulb  
down to the retaining hole and allow it to pop into position.  
Reflector Removal/Replacement  
Replace the reflector only if it becomes dull and its surface cannot be cleaned  
successfully, or if severe arcing is apparent (dark or burned spots).  
1. Remove the screen assembly and the bulb.  
2. Remove the six flat head screws and lift the reflector out.  
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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.  
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 22). Working  
toward the other end of the groove, press the gasket strip down firmly with the  
thumbnail so that it rests at the bottom of the groove.  
Profile of properly installed gaskets  
Figure 22. Gasket Installation  
6. Examine the cross-guide gaskets for evidence of arcing. Replace if there is any  
evidence of wear or arcing (dark or burned spots). Also if there is evidence of  
arcing on the back side of the reflector caused by the cross-guide gaskets (behind  
the reflector), then replace them.  
Install the two pre-cut RF gaskets (short ones) into the grooves for the  
extrusions. Insert one end flush with one edge of the mounting surfaces.  
Working toward the other end of the groove, press the gasket strip down firmly  
with a thumbnail so that it rests at the bottom of the groove.  
IMPORTANT: The dichroic reflector and the R350  
reflector do not have plastic protective covers on  
the reflector surface. The dichroic reflector has a  
dark purple reflective coating. Do not attempt to  
remove the purple reflective coating.  
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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 23). Start the six flat head screws in the  
reflector but do not tighten. Tighten the six screws in the sequence 1-6 as shown  
in Figure 24 to a snug position; finally tighten to 3.4 N-m (30 inch-lbs.) using a  
torque controlled screwdriver. Repeat tightening the screws as illustrated and at  
the specified torque.  
Figure 23. Reflector Removal or Replacement (I300M)  
Figure 24. Reflector Screw Tightening Sequence  
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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.  
Figure 25. Correct Reflector Alignment (I300M)  
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 25.  
9. Clean the reflector to remove fingerprints.  
10. Clean and insert the lamp bulb according to “Cleaning Guidelines” on page 79.  
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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. RF Screen Screw Tightening Sequence (I300M)  
NOTE: After installing the reflector in the irradiator, the reflector mounting  
screws should be retightened (using a torque controlled screwdriver to 3.4 N-m  
(30 inch-lbs.)) after a minimum of 10 minutes of operation.  
I300M Irradiator Housing Removal/Replacement  
The I300M irradiator enclosure is removed as described in the following procedure.  
1. Disconnect the cables from J10 and J11.  
2. Place the irradiator (screen down) on a clean, level surface.  
3. Remove two M3 flat head screws from each side of the irradiator housing.  
4. Remove four M5 truss head screws that secure the housing to the casting.  
5. Remove two M5 truss head screws that secure the perforated panel to the front  
of the irradiator housing.  
6. Disconnect the pressure switch tubing from the perforated panel and remove the  
panel.  
7. Unthread the large plastic nut that secures the J10 connector to the housing and  
push the connector into the housing.  
8. Lift the housing straight up to remove.  
9. Reverse these steps to reassemble.  
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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. Unplug the photoresistor 3-circuit connector (P30) from the photoresistor PWB.  
3. Remove the two M4 screws securing the photoresistor mounting block to the  
casting and remove the photoresistor assembly.  
4. Remove the single screw holding the photoresistor PWB to the mounting block.  
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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. Photoresistor Assembly for Direct View (I300M)  
Filament Transformer Removal/Replacement  
1. Remove the irradiator housing.  
2. Cut the cable ties and slide the PVC tubing off the magnetron connections.  
3. Remove the filament terminal screws. Disconnect the leads at the primary  
terminals. Remove the two anchor screws holding the transformer to the side  
rail, and remove the transformer.  
4. Replace the transformer by reversing the process.  
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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” on page 86.  
Magnetron Removal/Replacement  
1. Remove the irradiator housing as described previously.  
2. Disconnect 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. Remove the four screws fastening the magnetron to the casting. Lift the  
magnetron off the waveguide assembly and place it upside down in a clear area  
on a wooden bench, at least five inches from any magnetic materials (such as  
iron or steel).  
5. Install the replacement magnetron and fasten it to the casting using the  
associated hardware.  
6. Refer to Figure 29; hand tighten the magnetron fasteners in sequence as shown  
until snug. Then, tighten the fasteners ¼ turn in sequence. Finally, tighten the  
fasteners in sequence to 3.4 N-m (30 inch-lbs) using a torque-controlled driver.  
Figure 29. Magnetron Fastener Tightening Sequence (I300M)  
7. Install the filament transformer bracket and air plenum.  
8. 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.  
9. Install the irradiator housing as described in “I300M Irradiator Housing  
Removal/Replacement” on page 86.  
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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  
2
(ambient) air.  
For the I300MB irradiator (modular blower), pressure should be 447 - 822 Pa (1.8 to  
3.3” H O).  
2
HV Connector (J11)  
Cover Plate  
Cover  
Screws  
Figure 30. Air Pressure Test Points (I300M) - I300 MB Similar  
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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.  
5. Insert the high pressure port (longer) of the new switch through the hole in the  
plenum wall and secure the switch with a new length of silicone tubing (supplied  
with the switch.)  
6. Reconnect the electrical leads.  
7. Reconnect the low pressure tube to the low pressure port (shorter) on the switch.  
8. Reinstall the irradiator cover.  
I310M/I311M Irradiator  
NOTE: The I310M/I311M model is different from the standard I300M  
irradiator in its internal construction, specifically in the reflector assembly and  
the RF gaskets used.  
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. Clean as needed.  
Instructions for removing and replacing these components appear later in this chapter.  
Guidelines for cleaning these components follow.  
If the reflector or bulb surfaces show signs of dirt, oil or vaporized materials, they  
should be removed and cleaned with a good industrial cleaner, using a lint-free cloth  
or tissue. The cleaner should contain no waxes, silicones, dyes or perfumes. Simple  
Green® and Windex® are recommended. Wipe away any residues, using the cloth or  
tissue with pure water. Alcohol, isopropyl, or methanol may be used for final removal  
of residues, except when alcohol is not allowed as a solvent.  
If deposits on the screen, bulb, and reflector are consistently found at 500-hour  
inspections, the blower filters should be changed more frequently, or a more efficient  
filter should be used. These deposits can cause premature failures when particles burn  
into the quartz lamp or cause dulling of the reflectors.  
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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. Harsh abrasives and steel wool should never be used on bulbs.  
Reflector Cleaning  
If the reflector surface is dull or discolored, it should be cleaned. Abrasives should  
never be used on reflectors.  
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 cleaners discussed earlier, soaking if necessary,  
brushing lightly, and rinsing well. Take care not to damage the gaskets or the fine  
screen wires.  
M3 screen retaining  
screws (4) (2 per side)  
RF screen  
Cooling air holes  
Lamp bulb  
Cavity  
Reflector  
Figure 31. Reflector Assembly (I310M/I311M)  
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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. Repeat, this time removing screws. Grasp the screen frame by both ends,  
taking care not to twist or bend the screen itself, and remove the screen assembly.  
2. To replace an existing screen or install a new one, place the screen assembly in  
position.  
3. Apply pressure to the frame only and press firmly into place. Install the four  
screws alternately, working from side to side. Tighten each to a snug position;  
finally tighten to 0.9 N-m (8 inch lbs.) using a torque-controlled screwdriver (see  
Figure 37).  
Lamp Bulb Removal/Replacement  
WARNING: During operation the lamb bulb and  
adjacent metal surfaces become very hot. Operate  
the blower for about one minute to cool hot  
surfaces.  
1. Remove the screen as described in “Screen Assembly Removal/Replacement”  
on page 93.  
2. Refer to Figure 32 on page 94. Using clean cotton gloves or lint free tissue, grasp  
the lamp bulb at one end between the thumb and fingers and apply firm pressure  
axially toward the opposite end. When the tip of the bulb has cleared its retaining  
hole and is free to move past or along the end reflector, gently slide it up and out.  
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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. Removing or Replacing the Bulb (I310M/I311M)  
3. Clean any deposits from the surface of the bulb (see “Cleaning Guidelines” on  
page 91).  
4. To replace a lamp bulb in the reflector, hold it near the middle and insert the tip  
of the bulb into the retaining hole of one end reflector. Apply pressure in the  
direction of the length of the bulb, moving it toward the end that is inserted. This  
will allow the free end to clear the end reflector. Gently slide the end of the bulb  
down to the retaining hole and allow it to rest in position.  
Reflector Removal/Replacement  
Replace the reflector only if it becomes dull and its surface cannot be cleaned  
successfully or if severe arcing is apparent.  
1. Remove the screen assembly and the bulb.  
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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 99.  
3. Refer to Figure 33 on page 95, and remove and discard the two end reflectors and  
the gaskets underneath. If evidence of arcing is present (dark or burned spots),  
clean the gasket grooves with emery cloth to remove all oxide.  
Figure 33. Reflector Removal or Replacement (I330M/I311M)  
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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). Working  
toward the other end of the groove, press the gasket strip down firmly with the  
thumbnail so that it rests at the bottom of the groove.  
6. If you detect evidence of arcing on the back side of the reflector caused by the  
RF gasket assemblies behind the reflector, then replace the two RF gasket  
assemblies. Replace as described in “Replacing the RF Gasket Assembly” on  
page 99.  
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.  
IMPORTANT: The dichroic reflector and the R350 reflector do not have a  
plastic protective cover on the reflector surface. The dichroic reflector has  
a dark purple reflective coating. Do not attempt to remove the purple  
reflective coating.  
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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 33). Start the six flat head screws in the  
reflector but do not tighten. Tighten the six screws in the sequence 1-6 as shown  
in Figure 36 to a snug position; finally tighten to 3.4 N-m (30 inch-lbs.) using a  
torque-controlled screwdriver. Repeat tightening the screws according to the  
illustrated sequence, and at the specified torque.  
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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 35.  
9. Clean the reflector to remove fingerprints.  
10. Clean and insert the lamp bulb as instructed earlier in this chapter.  
11. Replace the screen assembly. Hand-tighten the four M3 screws in sequence as  
shown in Figure 37 until snug. Tighten the fasteners 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.  
NOTE: After installing the reflector in the irradiator, the reflector mounting  
screws should be retightened (using a torque-controlled screwdriver to 3.4 N-m  
(30 inch-lbs) after a minimum of 10 minutes of operation.  
Figure 37. RF Screen Screw Tightening Sequence (I310M/I311M)  
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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  
RF SCREEN (Bottom of Irradiator)  
Figure 38. Gasket Installation with Cross-guide (Short) Gaskets  
(I310M/I311M)  
2. Remove the housing (see “I310M/I311M Irradiator Housing  
Removal/Replacement” on page 100).  
IMPORTANT: The extrusion and the RF gasket assembly are one  
assembly, and should not be separated from each other. To replace the RF  
gasket requires removal of the old extrusion as well as the old RF gasket.  
3. Access the casting by placing the lamp on its side and gently sliding the casting  
out of the housing until the eight extrusion screws are accessible. (There are four  
screws on each side).  
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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. Install the replacement  
extrusions using the same mounting screws. The extrusions should be positioned  
flush to the casting and as far from the face of the lamp as the mounting screws  
allow. Tighten the screws to 2.5 N-m (22 inch-lbs.) using a torque-limiting  
screwdriver.  
I310M/I311M Irradiator Housing Removal/Replacement  
The irradiator enclosure is removed as follows:  
1. Disconnect the cables from J10 and J11.  
2. Place the irradiator (screen down) on a clean, level surface.  
3. Remove two M3 flat head screws from each side of irradiator housing.  
4. Remove four M5 truss head screws that secure the housing to the casting.  
5. Remove two M5 truss head screws that secure the perforated panel to the front  
of the irradiator housing.  
6. Disconnect the pressure switch tubing from the perforated panel and remove the  
panel.  
7. Unthread the large plastic nut that secures the J10 connector to the housing, and  
push the connector into the housing.  
8. Lift the housing straight up to view the interior components of the irradiator, as  
shown in Figure 39 on page 101.  
9. Reverse these steps to reassemble.  
I310M/I311M Scatter View Photoresistor Removal/Replacement  
Figure 39 on page 101 shows the I310M/I311M Irradiator component locations.  
1. Remove the irradiator housing.  
2. Unsolder the photoresistor lead wires (blue wire next to the diode and a  
blue/white wire at the top terminal.)  
3. Remove the two M5x10 mm photoresistor fastening screws and remove the  
photoresistor assembly.  
4. Reverse these steps to replace the photoresistor assembly.  
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Air intake plenum  
Air pressure switch  
Magnetron  
Filament  
transformer  
bracket  
Photo resistor  
scatter view  
assembly  
Filament transformer  
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. Unplug the photoresistor 3-circuit connector (P30) from the photoresistor PWB.  
3. Remove the two M4 screws securing the photoresistor mounting block to the  
casting and remove the photoresistor assembly.  
4. Remove the single screw holding the photoresistor PWB to the mounting block.  
5. Remove and discard the PWB and inspect the UV filter lens for damage.  
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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)  
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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. Disconnect the leads at the primary  
terminals. Remove the two anchor screws holding the transformer to the side  
rail, and remove the transformer.  
3. Replace the transformer by reversing the process.  
4. 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.  
5. Install the irradiator housing as described in Chapter 6, page 100.  
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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. Remove the four screws fastening the magnetron to the casting. Lift the  
magnetron off the waveguide assembly and place it upside down in a clear area  
on a wooden bench, at least five inches from any magnetic materials (iron, steel,  
etc.).  
5. Install the replacement magnetron and fasten to the casting using the associated  
hardware.  
6. Refer to Figure 42. Hand tighten the magnetron fasteners in sequence as shown,  
until snug. Then, tighten the fasteners ¼ turn in sequence. Finally, tighten the  
fasteners in sequence to 3.4 N-m (30 inch-lbs) using a torque-limiting  
screwdriver.  
Figure 42. Magnetron Fastener Tightening Sequence  
7. Install the filament transformer bracket and air plenum.  
8. 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.  
9. Install the irradiator housing as previously described.  
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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”  
H O) with respect to outside (ambient) air.  
2
For the I310MB irradiator (modular blower), pressure should be 447 - 822 Pa (1.8 to  
3.3” H O).  
2
HV Connector (J11)  
Cover Plate  
Cover  
Screws  
Figure 43. Air Pressure Test Points  
Air Pressure Switch Replacement  
1. Remove the irradiator cover.  
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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. Insert the high pressure port (longer) of the new switch through the hole in the  
plenum wall and secure the switch with a new length of silicone tubing (supplied  
with the switch.)  
6. Reconnect the electrical leads.  
7. Reconnect the low pressure tube to the low pressure port (shorter) on the switch.  
8. Reinstall the irradiator cover.  
P300M/P300MQ Power Supply  
The only routine maintenance required on the power supply is periodic cleaning. The  
service interval will vary depending on the environment in which the unit is operated.  
Safety Procedures  
Before servicing the power supply, first turn off and disconnect all power to the unit.  
WARNING: Exercise extreme caution; the chassis weighs up to  
40.3 kg (88.6 lbs.)  
All high voltage capacitors have internal discharge resistors  
which should discharge to a safe level in 5 seconds. Physically  
shorting the capacitor terminals with an insulated screwdriver  
blade is advised as a second level of safety.  
CAUTION: The integrated circuits on the control board  
assembly can be damaged by relatively small charges of static  
electricity. Static charges transmitted by fingertip (for example,  
those generated by walking across a carpet) may be sufficient  
to cause damage. Always touch a grounded metal surface  
before removing or examining the control card.  
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Test Point Voltages  
WARNING: Before taking magnetron current  
readings, turn the unit off. Check resistance  
between “MAG CURRENT” test points.  
Reading should be approximately 40K Ohms.  
If this value is not correct, do not attempt  
current reading. Damage could result to the  
meter or personnel injury could result. Contact  
Fusion UV Systems Customer Service if 40K  
Ohms reading is not obtained.  
After checking resistance, be sure to switch  
the meter to correct setting for DC voltage  
reading.  
Table 19. Operating Voltages  
Status  
Test Points  
Application  
Standby  
P300M/ P300MQ 12 VDC  
P300M/P300MQ  
Lamp On  
Photoresistor Test (TP101 and TP102)  
0-6 VDC  
Magnetron Current Test MAG A - COM  
(TP105 and TP106)  
0
0.650-0.750 VDC  
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.  
2. Remove all connectors. 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.  
3. To install a replacement card, reverse this procedure. Note the location of  
connectors in Figure 44 on page 109 and reinstall as shown.  
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Diode Test  
An ohmmeter can be used to check for a shorted or open capacitor. (Isolate the  
component before making continuity tests.)  
WARNING: Disconnect all power sources  
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.  
1. With an insulated screwdriver, short the capacitor terminals to each other to  
assure discharge of capacitor voltage.  
2. Disconnect the wiring from the terminals of the rectifier assembly.  
3. Set the ohmmeter to highest resistance setting and measure resistance between  
the AC terminals and both the - (minus) terminal and the GND terminal.  
4. Measure the resistance between diode terminals with meter leads reversed.  
Readings should be 50,000 ohms or less one way and infinite with leads  
reversed.  
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Figure 44. P300M/P300MQ Component Identification  
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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.  
1. Remove all power, discharge the capacitor, and disconnect all leads from the  
capacitor terminals.  
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. If the ohmmeter indicates continuity between the capacitor terminals at all times  
(shorted capacitor), or if no meter deflection occurs at all (open capacitor), the  
capacitor should be replaced.  
4. A resistance check between each capacitor terminal and chassis ground should  
indicate infinite resistance (regardless of meter lead polarity).  
High Voltage Transformer Removal/Replacement  
CAUTION: To maintain proper polarity, transformers must be installed  
with terminals in correct locations. Wiring must be reconnected correctly  
to the terminals from which it was removed.  
WARNING: Disconnect all power sources before  
servicing high voltage components.  
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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. Refer to Table 20, “Transformer Terminal Orientation,” on  
page 112 that follows.  
CAUTION: Transformers must be securely mounted to the chassis to  
provide adequate transformer grounding.  
CB1A  
CB1B  
L101  
C101  
C102  
T102  
T103  
Front  
Rear  
T101  
DB2  
DB1  
TB1  
K102  
K101  
Top View  
S1  
S2  
S3  
T
B1  
Front  
Rear  
K103  
K101  
K102  
Side View  
Figure 45. P300M/P300MQ HV Wiring  
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Table 20. Transformer Terminal Orientation  
XFMR  
T101  
T102  
COM  
Tap  
P300M/  
Black/White  
Black/White  
Red/White  
Red/White  
P300MQ  
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.  
NOTE: The P300MT cannot be retrofitted for the Quick Restart Option (QRO).  
Routine Maintenance  
The only maintenance required on the power supply is periodic cleaning. The service  
interval will vary depending on the environment in which the unit is operated.  
Safety Procedures  
Before servicing the power supply, first turn off and disconnect all power to the unit.  
WARNING: Exercise extreme caution; the chassis weighs up to  
40.3 kg (88.6 lbs.)  
All high voltage capacitors have internal discharge resistors  
which should discharge to a safe level in 5 seconds. Physically  
shorting the capacitor terminals with an insulated screwdriver  
blade is advised as a second level of safety.  
CAUTION: The integrated circuits on the control board  
assembly can be damaged by relatively small charges of static  
electricity. Static charges transmitted by fingertip (for example,  
those generated by walking across a carpet) may be sufficient  
to cause damage. Always touch a grounded metal surface  
before removing or examining the control card.  
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Test Point Voltages.  
WARNING: Before taking magnetron current  
readings, turn the unit off. Check resistance  
between “MAG CURRENT” test points.  
Reading should be approximately 40K Ohms.  
If this value is not correct, do not attempt  
current reading. Damage could result to the  
meter or personnel injury could result. Contact  
Fusion UV Systems Customer Service if 40K  
Ohms reading is not obtained.  
After checking resistance, be sure to switch  
the meter to correct setting for DC voltage  
reading.  
Table 21. Operating Voltages  
Status  
Test Points  
Standby  
Lamp On  
0-6 VDC  
0.650-0.750 VDC  
Photoresistor Test (TP101 and TP102)  
12 VDC  
0
Magnetron Current Test MAG A - COM  
(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.  
WARNING: Disconnect all power sources  
before servicing high voltage components.  
1. Remove the six screws from the power supply cover.  
2. Remove the cover.  
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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. To install a replacement card, reverse this procedure. Note the location of the  
connectors in Figure 46 on page 115 and reinstall as shown.  
Diode Test  
An ohmmeter can be used to check for a shorted or open capacitor. (Isolate the  
component before making continuity tests.)  
WARNING: Disconnect all power sources  
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.  
1. With an insulated screwdriver, short the capacitor terminals to each other to  
assure discharge of capacitor voltage.  
2. Disconnect the wiring from the terminals of the rectifier assembly.  
3. Set the ohmmeter to highest resistance setting and measure resistance between  
the AC terminals and both the - (minus) terminal and the GND terminal.  
4. Measure the resistance between diode terminals with meter leads reversed.  
Readings should be 50,000 ohms or less one way and infinite with leads  
reversed.  
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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.  
CB1  
Top  
Side  
Figure 46. P300MT Component Identification  
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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. If the ohmmeter indicates continuity between the capacitor terminals at all times  
(shorted capacitor), or if no meter deflection occurs at all (open capacitor), the  
capacitor should be replaced.  
4. A resistance check between each capacitor terminal and chassis ground should  
indicate infinite resistance (regardless of meter lead polarity).  
High Voltage Transformer Removal/Replacement  
CAUTION: To maintain proper polarity, transformers must be installed  
with terminals in correct locations. Wiring must be reconnected correctly  
to the terminals from which it was removed.  
WARNING: Disconnect all power sources  
before servicing high voltage components.  
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. Refer to Table 22, “Transformer Terminal Orientation,” on  
page 116.  
CAUTION: Transformers must be securely mounted to the chassis to  
provide adequate transformer grounding.  
Table 22. Transformer Terminal Orientation  
XFMR  
COM  
TAP  
P300MT  
T101  
T102  
Black/White  
Black/White  
Red/White  
Red/White  
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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.  
Blower Air Filters  
The blower air filter is disposable and should be replaced when dirty. This interval may  
vary from daily to monthly depending upon the environment.  
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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.  
Blower Cover Removal  
Remove the six M5 truss head screws and lift off the blower cover. With this cover  
removed, the blower components are exposed and accessible.  
Motor Replacement  
WARNING: Turn off all power to the unit before  
servicing.  
1. Remove the blower cover. Remove the screws holding connector J11 to the  
blower chassis. Cut the leads to the blower and disconnect the ground wires from  
the ground screw (see Figure 48 on page 119).  
2. Remove wires from capacitor C200.  
3. Remove the blower housing cover plate.  
4. Loosen the motor support clamps. Remove the motor and wheel through the  
housing.  
5. Carefully measure and record the length of the shaft projection beyond the  
bearing hub.  
6. To remove the wheel from the motor, loosen the wheel set screw and remove the  
wheel.  
7. To replace these items, reverse the process, being careful to reinstall the wheel  
so that it is at the same point on the shaft.  
118  
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Blower Cover  
Blower Wheel  
Motor (B10)  
F3e0017  
Capacitor Housing  
Ground  
Screw  
Ground  
Strap  
Ground  
Connections  
J11  
Figure 48. Blower Components  
Installation, Operation, and Maintenance Manual # 509252 Rev R  
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1
2
3
4
Figure 49. J11 Connections  
Table 23. J11 Connections  
J11-1  
J11-2  
J11-3  
Green/Yellow  
Black  
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 49.  
9. Connect the ring terminals on the green/yellow wire from J11 and the  
green/yellow wire from the blower to the ground screw.  
10. Connect the push-on terminals to capacitor C200.  
11. Reinstall the blower housing cover plate and the blower cover.  
120  
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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  
Relative Humidity  
0-45°C  
30-95%  
Power Supply  
The following table provides the F300S and F300SQ system power supply  
specifications.  
Table 25. F300S and F300SQ System Power Supply Specifications  
Mechanical  
PM300M/P300MQ  
P300MT  
Length  
Height  
Width  
584 mm (23”)  
213 mm (8.4”)  
353 mm (13.9”)  
400 mm (15.75”)  
179.5mm (7.07”)  
353 mm (13.9”)  
Weight  
30.9 kg (68 lbs.)  
Weight w/QRO 40.3 kg (88.6 lbs.)  
Stacking  
Finish  
3 units maximum  
Stone gray textured polyurethane enamel  
Utilities  
1 Phase  
Power  
50/60Hz  
200/208/240 VAC +10%  
Control Power  
+12VDC, +5VDC  
supplied by transformer  
and rectifiers on the  
PWB  
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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  
Underpressure  
System  
System Blower  
Underpressure  
External Interlock  
Tripped  
RF Interlock Tripped  
High Voltage  
Rear Panel Connectors  
Power Supply Cooling  
Irradiator/Cooling  
System Interconnections  
RF Detector/Interlocks  
3
Air Flow 2.83 m /min  
(100 cfm)  
122  
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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  
Remote cooling (Note 1) 2.8 m /min  
3
F300S/  
F300SQ  
P300M/P300MQ/  
P300MT  
I300M/I310M/I310M-D/  
I311M/I311M-D  
(100 cfm) at 695 Pa (2.8 H O) inlet  
2
pressure  
I300MB/I310MB  
K300M Modular Blower  
3
NOTE: All air flow specifications assume standard air density of 1.20 kg/m  
3
(0.075 lbs/ft ). Remote blower specification must be corrected for air density  
variations at customer site.  
Cooling:  
I300M/I310M/I310M-D/I311N/I311M-D: Requires a remote pressure blower.  
I300MB/I310MB/I310MB-D:  
K300M modular blower mounts on top of  
the irradiator and is powered by the  
P300M/P300MQ power supply.  
Table 27. Power Inputs from P300M/P300MQ/P300MT  
Magnetron Power:  
695 mA+45mA @ 3900 VDC  
115 VAC  
Filament Voltage:  
STANDBY  
100% Power  
85 VAC  
Blower Voltage  
2.0 A @ 200-240 VAC  
Reflector:  
Polished and brightened aluminum elliptical reflector with protective  
aluminum oxide coating. Focus is 53.3 mm (2.1 inches) below  
irradiator base rails.  
The standard reflector has R500 coating. Optional reflectors have  
R350 or Dichroic (cold) coatings.  
Interlocks:  
Weight:  
Photoresistor assembly  
Air pressure switch  
12.0 kg (26.5 lbs) with modular blower.  
7.3 kg (16.0 lbs) without modular blower  
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123  
   
Specifications  
Exterior:  
Brushed aluminum.  
Mechanical (without Blower):  
Length:  
Height:  
Width:  
260.4 mm (10.25")  
276.9 mm (10.9")  
167.6 mm (6.6")  
Mechanical (with Blower):  
Length:  
Height:  
Width:  
260.4 mm (10.25")  
505.5 mm (19.9")  
167.6 mm (6.6")  
Blower  
Mechanical:  
Length  
Height  
Width  
260.4 mm (10.25")  
228.6 mm (9.00")  
167.6 mm (6.6")  
RF Detector  
Mechanical (without Bracket):  
Length:  
Height:  
Width:  
60 mm (2.35")  
75 mm (2.94")  
75 mm (2.94")  
Mechanical (with Bracket):  
Length:  
Height:  
Width:  
108 mm (4.28")  
137 mm (5.4")  
75 mm (2.94")  
124  
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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  
EN60204-1, UL 775, CSA C22.2  
Electrical Safety (ETL/ITS)  
Emissions (CE)  
Group 2, Class A  
EN 55011 (CISPR-11)  
Immunity (CE)  
EN61000-4-2 (IEC 801-2 (ESD)  
EN50140 (IEC 801-3) (RF Susceptibility)  
EN61000-4-4 (IEC 801-4) (Fast Transient)  
EN61000-4-5 (IEC 801-5) (Surge)  
ENV50141 (IEC 801-6) (Conducted RF)  
IEC 1000-4-11 (Voltage Dips, Interruptions, and Variations)  
Installation, Operation, and Maintenance Manual # 509252 Rev R  
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Specifications  
126  
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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 29.  
Table 29. Interconnect Cables  
From  
To  
Cable Type  
Length (M)  
Part Number  
2
328521  
328522  
328523  
328524  
328525  
328526  
328527  
328528  
328529  
328531  
328532  
328551  
328552  
328553  
328554  
328555  
328556  
328557  
328558  
328559  
328561  
328562  
4
6
8
11  
14  
17  
21  
26  
31  
5
Power Supply  
Irradiator without  
Blower  
H340 HV/Irradiator Cable  
2
4
6
8
11  
14  
17  
21  
26  
31  
5
Power Supply  
Irradiator (with  
K300M Blower)  
H341 HV/ Irradiator Cable  
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127  
       
Cables and Connectors  
Table 29. Interconnect Cables (continued)  
From  
To  
Cable Type  
Length (M)  
Part Number  
2
329281  
329282  
329283  
329284  
329285  
329286  
329287  
329288  
329289  
329291  
329292  
329293  
091231  
4
6
8
11  
14  
17  
21  
26  
31  
1.5  
5
Power Supply  
RF-1  
H790 RF Cable  
Power Supply  
Power Supply  
H760 (F300S/F300SQ  
0.65  
System) Interconnect Cable  
System Connector Contact Kits  
Each kit includes pins and contacts for referenced connections. See Table 32 on page  
141 for the proper contact extraction tool.  
Table 30. System Connector Contact Kits  
Quantity  
Connector  
Description  
Part Number  
per System  
P105B  
P106  
Kit, contacts  
Kit, contacts  
1
1
204041  
204042  
128  
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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  
Figure 51, P300MT power supply dimensions and clearances  
Figure 52, I300M Irradiator dimensions  
Figure 53, I300MB Irradiator dimensions  
Figure 54, I310M/I310M-D Irradiator dimensions  
Figure 55, I310MB/I310MB-D Irradiator dimensions  
Figure 56, I311M/I311M-D Irradiator dimensions  
Figure 57, RF-1 RF Detector dimensions  
Installation, Operation, and Maintenance Manual # 509252 Rev R  
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Outline Drawings  
Figure 50. P300M/P300MQ Power Supply Dimensions and Clearances  
130  
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Figure 51. P300MT Power Supply Dimensions and Clearances  
Installation, Operation, and Maintenance Manual # 509252 Rev R  
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Outline Drawings  
Notes:  
1. Dimensions in mm (in)  
2. Standard density 1.2 kg/m3(0.075 lb/ft3)  
3. Air pressure measured at lamp inlet 695Pa (2.8"H2O) at 2.8m3/min (100 cfm)  
4. Air pressure measured at vent holes 447-596Pa (1.8-2.4"H2O)  
Figure 52. I300M Irradiator Dimensions  
132  
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Notes:  
1. Dimensions in mm (in)  
2. Air pressure at vent holes 447- 822 Pa (1.8 - 3.3"H2O)  
Figure 53. I300MB Irradiator Dimensions  
Installation, Operation, and Maintenance Manual # 509252 Rev R  
133  
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Outline Drawings  
Notes:  
1. Dimensions in mm (in)  
2. Standard density 1.2 kg/m3(0.075 lb/ft3)  
3. Air pressure measured at lamp inlet 695Pa (2.8"H2O) at 2.8m3/min (100 cfm)  
4. Air pressure measured at vent holes 447-596Pa (1.8-2.4"H2O)  
Figure 54. I310M/I310M-D Irradiator Dimensions  
134  
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Notes:  
1. Dimensions in mm (in)  
2. Air pressure at vent holes 447- 822 Pa (1.8 - 3.3"H2O)  
Figure 55. I310MB/I310MB-D Irradiator Dimensions  
Installation, Operation, and Maintenance Manual # 509252 Rev R  
135  
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Outline Drawings  
Optimum substrate  
location for focusing  
UV to maximum  
peak irradiance  
Notes:  
1. Dimensions in mm (in)  
2. Standard density 1.2 kg/m3(0.075 lb/ft3)  
3. Air pressure measured at lamp inlet 695Pa (2.8"H2O) at 2.8m3/min (100 cfm)  
4. Air pressure measured at vent holes 447-596Pa (1.8-2.4"H2O)  
Figure 56. I311M/I311M-D Irradiator Dimensions  
136  
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Figure 57. RF-1 RF Detector Dimensions  
Installation, Operation, and Maintenance Manual # 509252 Rev R  
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Outline Drawings  
138  
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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.  
910 Clopper Road  
Irradiator Serial Number _________  
Bulb Serial Number at start of log _________  
Gaithersburg, MD 20878-1357 USA  
(301) 527-2660  
Removal/Installation Data  
Repair Data  
Location Position  
Date  
Hours of  
Operation  
By  
Repairs Made  
(record all items  
replaced)  
Replacement  
Serial  
Number  
By  
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139  
     
Lamp System Maintenance Log  
140  
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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  
Ref  
P/N  
Modular  
Blower  
Remote  
Cooling  
Cable, irradiator w/K300M modular blower, 4M  
Cable, irradiator w/o K300M modular blower, 4M  
Cable, RF detector (RF-1), 4M  
H341  
H340  
H790  
H760  
328552  
328522  
329282  
091231  
1
—
—
1
1
Cable, system interconnections  
Only provided in  
multiple lamp systems  
(one per slave)  
Clip, retaining, power cord  
—
501031  
091241  
1
Connector assembly, RF (for slaves)  
P105A  
Only provided in  
multiple lamp systems  
(one per slave)  
Connector, 16 CKT, plug (user outputs)  
Connector, 14 CKT (remote controls)  
Fuse, 4.0A, 250V; for PWB  
P105B  
P106  
F1, F2  
P101  
P101  
—
025791  
025794  
296397  
511591  
511592  
204041  
204042  
527321  
1
1
2
1
1
1
1
1
Kit, AC input plug with clip  
Kit, AC input plug with clip and resistor assemblies  
Kit, contacts (for P105B)  
Kit, contacts (for P106)  
—
Kit, I6 extrusion retrofit (for converting I300M  
irradiator to I310M irradiator only)  
—
Kit, power supply connector - F300S  
Kit, PWB, P300M spare  
—
—
322947  
508241  
1
1
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Replacement Parts  
Table 32. Accessory Parts List (continued)  
Quantity  
F300S/F300SQ  
Description  
Ref  
P/N  
Modular  
Blower  
Remote  
Cooling  
Kit, RF detector  
RF-1  
—
079961  
528641  
043041  
1
1
1
Kit, retrofit, relay coil resistor assemblies  
Tool, contact removal  
—
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  
Bulb, UV, (standard) BF9H2  
Designator  
Part Number  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
558432  
558434  
558437  
558442  
558444  
558447  
570202  
570204  
570212  
570214  
029831  
079246  
090426  
090423  
254101  
078612  
Bulb, UV, (optional) BF9D  
Bulb, UV, (optional) BF9V  
Bulb kit, 6” BF9H2 (1 bulb)  
Bulb kit, 6” BF9D (1 bulb)  
Bulb kit, 6” BF9V (1 bulb)  
Bulb kit, 6” BF9H2 (2 bulbs)  
Bulb kit, 6” BF9D (2 bulbs)  
Bulb kit, 6” BF9H2 (3 bulbs)  
Bulb kit, 6” BF9D (3 bulbs)  
End reflector, R500 (1 pc.)  
End reflector, R350 (1 pc.)  
Harness, for I30xM and I31xM-D series Irradiators (J10)  
Harness, for I31xM series Irradiators (J10)  
Hex nut, plastic, HV connector J10  
Kit, magnetron, for all I3xxM series Irradiators  
142  
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I300M/I310M Irradiator Parts List  
Table 33. I300M/I310M Irradiator Parts List (continued)  
Reference  
Designator  
Description  
Part Number  
Kit, reflector assembly, I300M, R500 (includes main reflector,  
2 end reflectors and gaskets  
—
—
—
—
—
292161  
Kit, reflector assembly, I300M, R350 (includes main reflector,  
2 end reflectors and gaskets)  
292162  
292163  
292164  
528795  
Kit, reflector assembly, I300M, dichroic (cold/R500)) (includes  
dichroic main reflector, 2 R500 end reflectors and gaskets)  
Kit, reflector assembly, I300M, dichroic (cold/cold) (includes  
main reflector, 2 end reflectors and gaskets)  
Kit, reflector assembly, I310M, R500 (includes main reflector,  
2 end reflectors and gaskets) (for I31xM and I31xM-D series  
irradiator only)  
Kit, reflector assembly, I310M, R350 (includes main reflector,  
2 end reflectors and gaskets) (for I31xM and I31xM-D series  
irradiator only)  
—
—
—
528796  
528797  
528798  
Kit, reflector assembly, I310M, dichroic (cold/R500) (includes  
main reflector, 2 end reflectors and gaskets) (for I31xM and  
I31xM-D series irradiator only)  
Kit, reflector assembly, I310M, dichroic (cold/cold) (includes  
main reflector, 2 end reflectors and gaskets) (for I31xM and  
I31xM-D series irradiator only)  
RF gasket (end reflector), 2 per lamp  
Kit, RF gasket  
—
—
002521  
032932  
514371  
019712  
292551  
036504  
007971  
550582  
Kit, RF gasket (for I31xM and I31xM-D series Irradiator only)  
Kit, screen assembly replacement  
Kit, switch, air pressure  
—
—
S201  
T201A  
—
Kit, transformer, filament, 50/60 Hz  
Photoresistor assembly (for I31xM series Irradiators)  
Photoresistor assembly (for I31xM and I31xM-D series  
Irradiators)  
—
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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  
Designator  
Part Number  
Capacitor, Oil filled 0.85/0.43 MFD (50/60 Hz)  
C101,C102  
CB1  
274951  
327611  
204041  
Circuit Breaker, P300M, Power Switch, 2P, 20A  
Contact Kit, SKT, 20-24GA, Set of 50  
J105A, J106,  
J107  
(Use Extraction Tool 043031, Crimp Tool 037373)  
Contact Kit, SKT, 20-40GA, Set of 50  
J105B  
204042  
201673  
(Use Extraction Tool 043031, Crimp Tool 037373)  
Contact Kit, SKT, 16-18GA, Set of 50  
—
(Use Extraction Tool 043031, Crimp Tool 037373)  
Control Board assembly, P300M/P300MQ  
Fan, 230, 50/60 Hz  
—
327554  
029225  
327571  
B101  
Harness assembly, P300M, User I/O  
J105A, J105B,  
P5, P11  
Harness assembly, P300M, Master/Slave  
J106, J107,  
P3, P4  
340761  
Harness assembly, P300M, PWB PWR, I/F  
Harness assembly, P300M, AC Distribution  
Harness assembly, P300M, HV I/O, Blower  
P9, P15  
508041  
508051  
340792  
J101, CB1  
J103, J104,  
P6, P10, P19  
Harness assembly, P300MT only, User I/O  
J105A, J105B,  
P5, P11  
529351  
529341  
Harness assembly, P300MT only, Master/Slave  
J106, J107,  
P3, P4  
Harness assembly, P300MT only, PWB PWR, I/F  
Harness assembly, P300MT only, AC Distribution  
Harness assembly, P300MT only, HV I/O, Blower  
P9, P15  
529311  
529321  
529331  
J101, CB1  
J103, J104,  
P6, P10, P19  
Harness assembly, P300MT only  
K101  
J104  
DB1  
529531  
254101  
327622  
Hex Nut, Plastic, HV Connector (for J103)  
HV Rectifier Bridge, 12KV, 700mA  
144  
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P300M/P300MT Power Supply Parts List  
Table 34. P300M and P300MT Replacement Parts (continued)  
Reference  
Designator  
Description  
HV transformer, 230V, 50/60 Hz  
Part Number  
T101, T102  
341371  
340701  
340704  
340702  
340703  
340706  
340707  
529552  
529551  
330483  
330481  
530481  
327581  
327591  
327592  
327593  
340705  
340731  
340727  
340712  
340711  
340722  
340723  
HV wire assembly, 8", White  
—
HV wire assembly, 3.5", Black  
—
HV wire assembly, 3.5" White  
—
HV wire assembly, 8" Black  
—
HV wire assembly, 9.6", White  
—
HV wire assembly, 9.6", Black  
—
HV wire assembly, 6", Black, P300MT only  
HV wire assembly, 7", White, P300MT only  
HV wire assembly, 8", Black Flag, P300MT only  
HV wire assembly, 8", White Flag, P300MT only  
Kit, F300S to F300SQ Conversion P300M only  
Relay, 20A; 240V Coil  
—
—
—
—
—
K101, K102  
Switch assembly - LAMP CONTROL, LAMP OFF/RESET, Red  
Switch assembly - LAMP CONTROL, STANDBY, Yellow  
Switch assembly - LAMP CONTROL, LAMP ON, Green  
Wire assembly, P300M, DB1 GND  
S3  
S2  
S1  
—
—
—
—
—
—
—
Wire assembly, P300M, HV MAG I TPS  
Wire assembly, P300M, K101/K102-TB1  
Wire assembly, P300M, K101-K102, Black  
Wire assembly, P300M, K101-K102, Red  
Wire assembly, P300M, T101-T102  
Wire assembly, P300M, T102-TB1  
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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  
Designator  
Part Number  
Bracket, Mtg, 1.75 oval  
For C103  
222291  
509111  
509121  
500591  
326631  
502031  
508101  
500101  
340703  
340701  
340727  
508482  
508483  
508481  
340728  
340732  
Inductor, QRO  
L101  
Capacitor, HV, Oil-filled, dual, 0.81/0.36 mF  
Capacitor, Oil-filled,dual,0.2 mF  
C101, C102  
C103  
—
Clip, HV wire  
Rectifier Bridge, QRO,7A,12kV  
DB2  
K103  
T103  
—
Solid State Relay assembly, P300MQ  
Transformer, HV Plate, QRO  
Wire assembly, P300M, HV, Black, 9.6 in  
Wire assembly, P300M, HV, White, 9.6 in  
Wire assembly, P300M, K101/K102, TB1  
Wire assembly, P300MQ, HV, Black,16.8 in  
Wire assembly, P300MQ, HV, Black, 9.6 in, F/I  
Wire assembly, P300MQ, HV,White,13.2 in F/I  
Wire assembly, P300MQ, TB1-T103  
Wire assembly, P300MQ, K103 Control  
—
—
—
—
—
—
—
146  
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K300 Blower Assembly Parts List  
K300 Blower Assembly Parts List  
Table 36. K300 Blower Assembly Parts List  
Reference  
Designator  
Description  
Part Number  
Capacitor, Fld. Fill, 4.0 MFD  
C200  
J11  
—
041981  
025802  
201673  
201675  
200231  
500211  
066398  
032473  
205661  
029284  
Connector, 4 CKT (Use Contact Kit 201675)  
Contact Kit, SKT, 16-18GA (set of 50)  
Contact Kit, pin, 16-18GA (set of 50)  
Cover, Blower  
—
—
Ground Strap, K300 Cover, copper  
Filters, Modular Blower (set of 20)  
Inlet Ring, Blower  
—
—
—
Kit, motor replacement, including terminals and J11 connector  
Wheel, Blower  
B10  
—
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Replacement Parts  
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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. The instant the magnetron is energized, the probe intercepts enough  
energy to ionize the ignitor bulb, creating a small amount of UV radiation which  
reliably causes ignition in the main bulb. When the main bulb is at full power, the  
energy level in the ignitor is reduced, prolonging the life of the bulb.  
TEFLON  
TUBING  
13 GA. ID  
CLIP  
BULB-PREVIOUS  
CONSTRUCTION  
CHOKE  
BULB  
CASTING  
TEFLON  
TUBING  
18 GA. ID  
Figure 58. Ignitor Bulb  
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149  
       
Ignitor Bulb  
Table 37. Routine Operations Associated with Ignitor Bulb  
(Refer to Table 12 on page 59 for other operational information.)  
Power  
Switch  
Lamp Control  
Flasher  
Time  
0 sec  
Lamp Control  
Operation  
Lamp on  
Green flash  
Start HV transformers  
Ignitor bulb lights  
2-4 sec  
UV bulb ignites; ignitor  
bulb turns off  
UV bulb at full power  
On  
8 sec  
0 sec  
Steady green  
From lamp off  
to lamp on  
Slow flash yellow  
10 sec  
Fast flash green  
Ignitor bulb lights  
12-18 sec  
UV bulb ignites; ignitor  
bulb turns off  
18-20 sec  
Steady green  
UV bulb at full power  
Table 38. Troubleshooting and Fault Diagnosis  
(Refer to Table 18 on page 69 for other operational information.)  
Possible  
Cause  
Operation  
Signal/Other Symptoms  
Corrective Action  
Switch from  
Standby to On or UV output is weak, or  
UV bulb does not light  
LAMP OUT indicator lights, Ignitor bulb  
The lead from the base of the  
ignitor bulb should be inserted  
up to its outer sleeve into the  
waveguide launcher  
position  
Ignitor bulb  
Replace ignitor bulb  
Replace ignitor bulb  
RF INTLK indicator lights  
Ignitor bulb  
faulty  
Ignitor Bulb Removal/Replacement  
1. Replace the ignitor bulb only if the lamp does not start consistently and all other  
indications are normal.  
150  
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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).  
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Ignitor Bulb  
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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.  
•
•
•
F300S System Wiring Diagram*  
P300MQ Chassis Schematic*  
PWB P300M Control w/QRO Schematic*  
* These documents pertain to systems with and without Quick Restart Option.  
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153  
   
Schematics  
154  
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