O N EQUIPMENT Operation Manual Run Mode Set Mode 100% 100% 50% 10% Lamp Fault Lamp Strength Fault Point Select 1 2 3 4 5 6 7 8 Power On Set to 100% Light Intensity Monitor Item No. 891494 Loctite Light Intensity Monitor Part Number 891494
1.1 Emphasized Sections 1 Please Observe the Following WARNING! Refers to safety regulations and requires measures to protect the operator and others from injury or danger to life. Caution! Emphasizes what must be done or avoided so that the unit or other property is not damaged. Notice: Gives recommendations for better handling of the unit during operation or adjustment, as well as for service activities. 1.2 Items Supplied 1 Intensity Monitor, part # 891494 1 Shielded power cord, part # 985470 1 Users manual, part # 8900813 1 Sensor cable, part # 8900811 1 Shutter signal cable, (for use with shuttered curing systems only), part # 8900812 1.3 For Your Safety For safe and successful operation of the unit, read these instructions completely. If the instructions are not observed, the manufacturer can assume no responsibility. Be sure to retain this manual for future reference. WARNING! Never remove the cover of the unit without first switching the power off and unplugging the power cord. WARNING! Damage to the power cord or the housing can result in contact with live electrical parts. Check the power cord and housing before each use. If the power cord or unit is damaged, do not operate. The unit must only be repaired by a Henkel authorized service technician. Caution! Avoid touching or scratching the lens of the photo-sensor. 1.4 Field of Application, (Intended Usage) The Loctite 891494 Light Intensity Monitoring System is designed to operate with all Loctite light curing systems. Notice: The monitor requires installation of a Loctite light sensor kit 891493, (sold as a separate item), in the curing unit.
2 Description 2.1 Theory of Operation The 891494 Light Intensity Monitoring System continuously monitors the intensity of the curing lamps used in Loctite light curing systems. The light sensor, installed in close proximity to the curing lamp, produces an electrical current proportional to the incident light that originates from the curing lamp. That signal is received by the monitoring unit by means of a cable and a nine pin D-sub connector located on the rear panel of the monitor. When a new lamp is installed, the monitoring system is manually set to 100%. The yellow LED will light to confirm that the system is adjusted to 100%. The lamp intensity is indicated in ten percent increments by an LED bar graph located on the front panel. When the Light Intensity Monitor is used with a shuttered curing system such as a Loctite wand system, the shutter is controlled from the monitoring system either manually, (using the footswitch port on the rear panel of the monitor), or by a control device such as a PLC, (pins 1 and 9 of the I/O to PLC port). The monitor provides a signal to the PLC or other control device to indicate that the lamp intensity has fallen below a preset limit. That point of minimum allowable intensity is selected using the eight dip switches located on the front panel next to the LED display. The switches correspond to increments from 80 to 10 percent, (20 to 90 percent loss of intensity). As long as the intensity is greater than the preset fault point, the fault relay in the monitoring system is energized and the contacts remain closed. The contacts are connected to pins 3 and 4 of the nine pin D-sub output connector labeled I/O to PLC. When the intensity falls below the preset minimum, the red LED on the front panel will flash and the closed relay contacts will open, indicating a fault condition. Also, if the curing unit is outfitted with a shutter, it will be disabled. The shutter disable feature can be overridden by setting the slide switch in the monitor. 3 Technical/Physical Data Input voltage: 100-240 VAC; 50/60 Hz Main fuse located in the input module: 1A/250V Housing dimensions: 5 ½ x 6 x 6 inches, (height x width x depth) Weight: 4 lbs
4 Installation 4.1 Connections - Connect one end of the sensor cable, (female on both ends), to the male nine pin D-sub input labeled Light Sensor Input on the rear panel of the monitor system. Connect the other end to the cable to the connector labeled Light Sensor Output on the curing unit. The sensor signal is transmitted across pins 3 and 4. Pin 5 is connected to case ground. - Pins 1 and 9 are used for shutter control in Loctite shuttered systems. Connect one end of the shutter connection cable, (male on both ends), to the 9 pin D-sub connector located on the curing system. Connect the opposite end to the connector on the rear panel of the monitor labeled, Shutter Output. - If the monitor is connected to a PLC, install a cable, (not included), from the output connector of the monitoring system labeled I/O to PLC to the PLC input. Closure across pins 1 and 9 controls the wand system shutter. Pins 3 and 4 are the fault relay output, (open indicates an intensity fault condition). - Connect the power cord to the power entry module on the rear panel and plug into power source. I/O to PLC - Connects shutter signal, (pins 1 and 9), and fault signal, (pins 3 and 4), from monitor to PLC. Shutter Output - Connects shutter signal from curing system to monitor, (pins 1 and 9). Note: Pins 1 and 9 of the Shutter Output port are connected in parallel with pins 1 and 9 of the I/O to PLC port. Foot Pedal Connects to a remote footswitch or other manual shutter control. Pins 1 and 9 are in parallel with pins 1 and 9 of the I/O to PLC and Shutter Output ports. Light Sensor Input Input for the light sensor located in the curing unit. Pins 3 and 4 are the anode and cathode, respectively, and pin 5 is shield to case ground. 5 Operating the System 5.1 Powering up - After making the connections described in section 4, switch on the power to the curing system and the monitoring system. Notice: Avoid turning the monitor on without the having the photosensor connected. 5.2 Setting the System to 100% Notice: The procedure described in this section must be repeated each time and only when a new lamp is installed. The Set to100% adjustment must not be changed again
until a new lamp is installed. It is recommended that the absolute intensity be measured at the time of this procedure using a Loctite radiometer. - Allow the curing lamp to reach its maximum output. The warm-up period is specified in the curing unit s manual. If the warm-up time is not known, allow a minimum of ten minutes. - Set the toggle switch on the front panel to Set Mode, (all segments of the LED bar graph will light). - If the yellow LED located above the adjustment is lit, turn the Set to 100% adjustment clockwise until the LED turns off. Then slowly turn the adjustment counter-clockwise, stopping when the LED turns on. The yellow LED confirms that the system is properly set. Do not continue to turn the adjustment beyond the point where the LED turns on. - If the yellow LED is not lit when the in Set mode, slowly turn the adjustment counter-clockwise, stopping when the LED turns on. As in the previous step, do not continue to turn the adjustment beyond the point where the LED turns on. - Switch the system to Run Mode, (the yellow LED will immediately go out). - All segments of the bar graph should be on, indicating that the lamp is at 100% strength. If less than 100% is indicated, repeat the procedure. 5.3 Setting the lamp fault point (Note: if a fault point is not selected, the system will indicate a fault condition) - Select the intensity level where the system is to indicate that the lamp needs to be replaced. (10% to 80% in increments of 10%), - Set the dip switch corresponding to the chosen fault point to the on position, (left). Each dip switch represents a 10% increment from 80 to 10%. - Make sure that all other dip switches in the off position, (right) Example: The lamp is to be replaced when the intensity falls below 50% of the initial intensity. Set the fourth switch from the top ON position, (slide to the left). All other switches should be in the OFF position, (to the right). 5.4 Shutter Disable Feature, (applies to curing systems with shutters, only) When the chosen intensity fault point is reached the monitor will disable the shutter in the curing unit. To override this feature remove the enclosure lid from the monitor. Locate the slide switch positioned near the center of the top circuit board. Switch it from the ON position, (factory setting), to the OFF position. 5.5 Continuous Operation After completing the steps in sections 5.1 through 5.3, the system will continuously monitor the lamp output. It is normal for the highest LED bar that is lit to dim as it approaches the point of turning off. When the lamp output reaches the fault point, the red LED on the front panel will flash, the relay output will change state from closed to open and the curing unit shutter will be disabled. Note that when the curing system is first started, the monitor will indicate a fault condition until the lamp warms up to the point that the intensity exceeds the chosen fault point.
6 Care and Maintenance Caution! Avoid touching, contaminating or scratching the photo-sensor lens. The photosensor is located in the curing unit. Notice: The 891494 Light Intensity Monitoring System requires very little maintenance. To insure continued reliable operation, it is recommended that the photodiode lens be checked for cleanliness. Isopropyl alcohol should be used with a clean wiper to remove any contaminants. 7 Troubleshooting Condition Possible Cause Corrections The LED bar graph does not come on The curing lamp is not on. Check the lamp function. but the main power is on. The system is not set to 100%. Repeat procedure in section 5.2. None of the functions work and The unit is not plugged in. Check the main power. the main power indicator is out. The main fuse is blown. Check fuse in power module. The yellow LED will not light The lamp is not on. Check the lamp function. during the Set 100% procedure. The lamp output is too low. Check irradiance level of lamp. The system is not in SET mode. Switch toggle to Set mode. A fault is indicated while the LED The dip switches are not Check, re-set the dip switches. bars show intensity to be above properly set. the preset minimum point. The sensor is disconnected. Inspect sensor connections from curing system to monitor. The curing unit shutter will not operate. The shutter signal connections Refer to 4.1 Connections. are not properly configured. Faulty connection. Inspect solder connections on D-sub connectors. Check continuity across cables. The monitor does not disable the shutter Internal bypass switch is Check bypass switch state in when a fault occurs. set to OFF monitor.
Light Intensity Monitor Layout Run Mode Set Mode Lamp Fault Fault Point Lamp Strength Select 100% POWER ON 100% 50% Set to 100% 10% INTENSITY MONITOR I/O to PLC Light Sensor Input Shutter Output Warning Disconnect and Refer to Manual Before Servicing Unit. Foot Pedal
LED Bar Graph and Fault Point Select Switches Lamp Strength Fault Point Select
Warranty Henkel expressly warrants that all products referred to in this Instruction Manual for the Light Intensity Monitor, (hereafter called Product ), shall be free from defects in materials and workmanship. Liability for Henkel shall be limited, as its option, to replacing those Products which are shown to be defective in either materials or workmanship or to credit the purchaser the amount of the purchase price thereof (plus freight and insurance charges paid therefore by the user). The purchaser s sole and exclusive remedy for breach of warranty shall be such replacement or credit. A claim of defect in materials or workmanship in any Product shall be allowed only when it is submitted in writing within one month after discovery of the defect or after the time the defect should reasonably have been discovered and in any event, within 1 year after the delivery of the Products to the purchaser. This warranty does not apply to perishable items, such as fuses. No such claim shall be allowed in respect of products which have been neglected or improperly stored, transported, handled, installed, connected, operated, used or maintained. In the event of unauthorized modification of the Products including, where products, parts or attachments for use in connection with the Products are available from Loctite, the use of products, parts or attachments which are not manufactured by Henkel, no claim shall be allowed. No Products shall be returned to Henkel for any reason without prior written approval from Henkel. Products shall be returned freight prepaid, in accordance with instructions from Henkel. NO WARRANTY IS EXTENDED TO ANY EQUIPMENT WHICH HAS BEEN ALTERED, MISUSED, NEGLECTED, OR DAMAGED BY ACCIDENT, OR IF THE SYSTEM USED TO DISPENSE ANY LIQUID MATERIAL OTHER THAN LOCTITE PRODUCTS. EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION, HENKEL MAKES NO WARRANTY OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCTS. ALL WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND OTHER WARRANTIES OF WHATEVER KIND (INCLUDING AGAINST PATENT OR TRADEMARK INFRINGEMENT) ARE HEREBY DISCLAIMED BY HENKEL AND WAIVED BY THE PURCHASER. THIS SECTION SETS FORTH EXCLUSIVELY ALL LIABILITY FOR HENKEL TO THE PURCHASER IN CONTRACT, IN TORT OR OTHERWISE IN THE EVENT OF DEFECTIVE PRODUCTS. WITHOUT LIMITATION OF THE FOREGOING, TO THE FULLEST EXTENT POSSIBLE UNDER APPLICABLE LAWS, HENKEL EXPRESSLY DISCLAIMS ANY LIABILITY WHATSOEVER FOR ANY DAMAGES INCURRED DIRECTLY OR INDIRECTLY IN CONNECTION WITH THE SALE OR USE OF, OR OTHERWISE IN CONNECTION WITH, THE PRODUCTS, INCLUDING, WITHOUT LIMITATION, LOSS OF PROFITS AND SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER CAUSED BY NEGLIGENCE FROM HENKEL OR OTHERWISE.
Henkel Corporation 1001 Trout Brook Crossing Rocky Hill, CT 06067-3910 Henkel Automotive Technology Center 2455 Featherstone Road Auburn Hills, Michigan 48326 Henkel Canada Corporation 2225 Meadowpine Boulevard Mississauga, Ontario L5N 7P2 Henkel Ltda. Rua Karl Huller, 136 Jd. Canhema 09941-410 Diadema/SP, Brazil Henkel Capital, S.A. de C.V. Calzada de la Viga s/n Fracc. Los Laureles Loc. Tulpetlac, C.P. 55090 Ecatepac de Morelos, Edo. de México www.loctite.com Loctite is a trademark of Henkel Corporation, U.S.A. Copyright 2006. Henkel Corporation All rights reserved. Data in this operation manual is subject to change without notice. Manual P/N: 8900813, Date: 10/2006