QC250 UV Curing Module Product Specification. April 2017

Transcription

1 QC250 UV Curing Module Product Specification April 2017 QC250 UV Curing Module Product Specification April 17, 2017

2 QC250 UV Curing Module Product Specification April 17, 2017

3 QuickCure UV modular system The QuickCure UV modular system was developed for the machine designer tasked with upgrading traditional UV bulb curing systems to a more reliable UV- LED platform. This system features the QC250 10x10 LED curing board, which is offered in three wavelength options, 385nm, 395nm or 405nm coupled with 2 multifunction controller boards optimized to deliver 16W/cm 2 at the curing surface. The QC250 curing board and controllers allows for quick conversion to LED technology where the benefits for curing inks, coatings and adhesives can be immediately realized. This high reliability, multi function board system gives a designer flexibility to keep their expertise in machine design and cooling in house, a combination that produces a much faster, customizable and more affordable solution for their customer base. These modules can be used in singular fashion, or side- by- side tiled arrays to seamlessly irradiate any sized conveyor or web- based system. When operated at nominal current, within a 5mm working distance from the front face of the LED emitters, the QuickCure QC250 lamp ultraviolet lamp module provides approximately 16W/cm2 radiation with a uniformity of better than 5%. The low profile connectors on each end of the array allow for operation at these close- working distances. Designing with a customizable modular based system, It all starts with the light source. In our case, it is a 25mm X 25mm area loaded with 100 very powerful and efficient 395nm die. Each die is about 1mm square in size and packs a powerful punch. The QC250 lamp if properly cooled can attain 16W/cm2 air cooled and much higher if water- cooled or a chiller is deployed.

4 Benefits of UV LEDs in Curing You have seen the future of UV curing and it involves the use of LEDs. Here are some of the important advantages of UV LED generated light. Utilizes much less power than conventional light fixtures Instant on/off with no detrimental impact on the life and radiance of the UV LED. Targeted wavelength for precise curing applications Long lifetimes even at high irradiance One sided light, no need for shutters or reflectors on the backside of the light Mercury- free, no ozone creation Heat directed away from target.

5 QC250 Design Benefits Our modular approach saves money We know as a machine builder you have been in the curing and drying business for many years. We know you have experience directing and focusing light, keeping your fixture cool, powering and controlling your fixture, and building a finished solution that meets and exceeds your customer s needs. Many available solutions being offered are very costly and don t allow you to keep that in house advantage and flexibility. A perfect solution is to combine a great UV LED lamp source with those in- house capabilities to offer an affordable conversion to a higher reliable platform. LED Wavelengths LEDs are the perfect solution for curing because they offer a very precise wavelength range to the work surface. Compared to traditional light sources an LED light source will not contain harmful UV wavelengths, which can cause harm to the material being cured. The QC250 lamp is available at 385nm; 395nm and 405nm and can additionally be customized to combine these wavelengths for specific curing needs. Applications for the QC250. Curing and drying in these applications. - Inks & Printing, digital, screen, flexo, injet, sheetfed - Industrial & Medical, parts, components, 3D print cure - Coatings for wood and metals - Adhesives, curing, bonding, sealing - Spot Curing

6 Feature Lamps are sold in 1 segments COB technology for high density UV LED lamp design Temperature monitor built into the lamp with PLC access Power variable feature on control board Max power set on control board Low profile design Flexible Wavelength Design Designing with LEDs Engineering, design and assembly in the U.S.A. Benefit Easy maintenance and upgrades. Easily replace damaged lights not the whole fixture Tailor systems for your customers High power radiance 16W / cm 2 air cooled 16+W cm 2 water cooled or chiller Control heat for longer LED life Control radiance by pot or analog voltage input Lower operating costs Limit power from source to 5 or 7 AMPS Allows for close proximity to work surfaces Easily interchange wavelength options into the machine design LEDs allow the designer to request a custom board and LED layout. Allows machine designers to offer many new customized options Local support who value customers and long term relationships

7 QC250 System Components QC250- LAM Lamp These thermally efficient 1mm metal core board optimize 100 high power LEDs for high density and high irradiance operations. Each row of 10 die is individually controlled for maximum control and flexibility. 2 pins are available for monitoring the temperature probe on the board. LED Component Performance Typical Electrical Operating Specifications Item Symbol Value Unit DC Forward Current I f 5000 ma Junction Temperature T j 85 C Forward Voltage (typical) V f 34 V Maximum Electrical Specifications Item Symbol Value Unit Continuous DC Current I f 7000 ma Pulsed DC Current* I f 10,000 ma Junction Temperature T j 125 C *<10% duty cycle Optical Performance Performance Parameter Typical Symbol Unit Peak Wavelength λd nm Spectral Full Width Half Maximum λ nm Min Working Distance (between chip and surface) Active Curing Area 25 mm x 25 mm mm Dist I f 5,500 I f 7,000 ma 3mm W/cm 2 Irradiance at target at working distance 5mm W/cm 2 7mm W/cm 2 9mm W/cm 2 11mm W/cm mm

8 Electrical Schematic The QC250 module is constructed using 100 high power UV LEDs in an array of 10 rows and 10 columns. Each column is wired in series, and the anode and cathode terminations are on opposite ends of each module. The cathode end of the module is terminated with a low profile 10- pin header (Hirose P/NDF14-10P- 1.25H) and the Anode end is terminated with a 15- pin header (DF14-15P- 1.25H).

9 Life and Reliability The general lifetime of an LED operated at nominal current and temperature ratings, provide lifetimes in excess of 50,000 hours as defined by the parameter L80, the time at which the device output will have decayed to 80% of its original output. The predominant factors that can negatively affect this L80 lifetime are excessive current and excessive heat, as both of them tend to increase dopant migration across the junction of the semiconductor material. Of these two, heat is commonly the largest factor. As is common with most chemical reactions, the diffusion rate doubles with every 10 C increase in operating temperature. Therefore, monitoring the operating temperature and ensuring that it is maintained within the target range is critical to ensuring a robust and reliable system installation. The QC250 lamp modules are designed with the latest generation of UV LED technology to provide high radiance with long lifetime. The LEDs are manufactured using a proprietary Gallium Nitride (GaN) heterostructure integrated onto a sapphire (Al 2 O 3 ) substrate that provides the exceptional thermal performance required. Both anode and cathode terminals are constructed of gold (Au) for enhanced thermal and electrical properties. The success of the QC250 modules is in their ability to increase the energy density of these individual LEDs with an array that balances the need for high output irradiance (W/cm2), high uniformity (<5% variation at 5mm) and while maintaining a temperature profile that allows for long lifetime. For the QC250 modules this balance has been achieved by maintaining the junction temperature of the LEDs at 85 C, which results an average L80 value of over 20,000 hours.

10 Important UV Precautions The photo biological safety of these LEDs have been tested by an accredited laboratory according to standards established by IEC/EN 62471:2008 Photo biological Safety of Lamps and Lamp Systems. IEC/EN defines exposure limits in the wavelength range nm and the biological hazards vary depending on wavelength ranges of exposure. This testing report is provided upon request (KTR#: CEC issued May 29, 2013). The QC250 Lamp Module emits high power ultraviolet radiation that may be hazardous to eyes and skin. Do not operate lamp without protective eyewear and clothing! Never stare directly at the device, and avoid prolonged exposure. The QC250 device is a Class 2 Risk as defined by IEC/EN 62471:2008 Photo Biological Safety of Lamps and Lamp Systems. Therefore, caution should be exercised to limit exposure of both eyes and skin.

11 The QC250 lamp products emit high- powered light in the 385nm to 405nm range, and therefore unprotected users are subject to photo keratitis, conjunctivitis, photo retinitis, retinal burn, cataracts, erythema, and elastosis. The user should always wear approved protective eyewear and clothing when testing or operating these lamps. IEC/EN defines exposure limits for each risk group as follows: The QC250 modules are a Class 2 Risk group, and the primary hazard is the Blue Light Radiance which poses a potential risk of photochemical

12 QC250- CMP Control Boards Lamp ANODE Board The ANODE board powers the entire unit. A 7- pin terminal block provides easy connection. User provides 36VDC using off- the- shelf DC power supply capable of at least 200W (Digikey P/N ND or equivalent). Anode board provides 12VDC for the onboard blower and 5VDC for the onboard Temperature monitor circuit and for the onboard PWM generator. The TEMP output provides a real time analog temperature signal of the LEDs based on the formula Where T = 100 * ( V ) T is the temperature in degrees Celsius V is the signal measurement in Volts

13 The maximum operating specification is 85C (1.35V) in order to ensure 20,000 hour operation. The user should always monitor this signal during testing and during OEM installations and shut the unit down if the temperature of the part exceeds this value. CATHODE Board The CATHODE board includes active feedback current regulators (10 channels - one for each string on the module). These regulators are factory set at 500mA per string, and cannot be changed by the user. Therefore, the total current draw for these EVAL KITs is 5.0Amps and produces about 16 mw/ cm 2 at 5mm working distance. With more extensive heat sink and airflow, the user can push up to 700mA per channel (7.0 Amps total), which produces close to 22 W/cm2. The CATHODE board includes an onboard PWM circuit operating at 62kHz. This switches the current regulated sources on and off with a duty cycle from 0-100% which allows full range dimming of the QC250 lamp module. An analog voltage controls the PWM duty cycle, and that voltage may be generated either locally or remotely. The switch in the center of the CATHODE board selects between the local (manual) mode and the remote mode. In the manual mode (switch down) the analog signal that controls the PWM duty cycle is controlled by the on- board potentiometer. Adjusting the potentiometer allows the user to easily adjust the PWM duty cycle over the entire range of 0-100%. This local adjustment mode is useful to set a particular irradiance value during feasibility testing. When the switch is in the up position, a remote analog signal (0-10VDC or 4-20mA) at the CTRL pin provides a way for a PLC or PC to adjust the PWM duty cycle over the entire range of 0-100%. This remote adjustment mode is useful to control the dose on the fly, especially in applications where the speed of the material moving underneath the illuminator may change (or potentially stop).

14 Thermal Management of the QC250 LED Board Thermal Management The QC250 lamp modules operate at a nominal electrical power density of approximately 150W per square inch, and therefore careful engineering design is required for proper electrical and thermal operation. In order to run these modules at their full potential, an adequate current controlled source must be provided, and an adequate thermal conduction path must be provided. Never attempt to operate the QC250 lamp module without a current controlled power supply or without proper thermal management! The EVAL- 160 kit ensures proper current regulation and thermal management, providing a quick and simple way in which to perform feasibility tests for a particular application. Thermal Design Specifications and Considerations The high UV output of the QC250 lamp module is made possible by two key technologies. The first is a highly stable and efficient semiconductor light emitting diode substrate die. The second is a highly efficient thermal design, which allows for the heat to be removed from the die quickly and extremely efficiently in order to keep the junction temperature at levels that allow for high output and long lifetime. To develop a sufficiently effective cooling system, one could perform a detailed thermal analysis using Finite Element Analysis (FEA) software. However, fairly accurate approximations may be made using the following simple thermal impedance model.

15 QC250 Mechanical & Technical Specifications A temperature sensor (P/N MCP9700A) provides an accurate monitoring of the approximate junction temperature of the LED die. The lamp module should never be operated without monitoring this device. This temperature sensor provides an accurate analog output signal proportional to the temperature of the device in degrees Centigrade. Provide 5VDC on pins 11/12 and the output at pins 13/14 provide the temperature as given by the following formula: T = 100 * (V 0.50) where T is C and V is in volts The maximum continuous operating temperature for the QC250 lamp is 85 C. The actual temperature of your final system can be influenced by many other factors including change in airflow, change in ambient temperature, change in humidity, etc. Solder Dielectric UV Die T junction R th (Heatsink) R th (dielectric) MCPCB R th (MCPCB) Thermal Paste R th (paste) R th (heatsink) Heatsink T ambient FAN

16 Actively monitor the temperature and ensure that the junction temperature does not remain above 85 C for an extended period of time (85 C corresponds to a sensor value of volts). CAUTION: Never allow the temperature of the device to exceed 85 C for a prolonged period or the lifetime of the lamp module may be shortened. For simple convective airflow, the approximate size of heatsink required to maintain a target junction temperature is fairly simple to estimate by summing all of the thermal impedance values between the LED junction and the ambient air. R th (system) = R th (solder) + R th (dielectric)+ R th (MCPCB)+ R th (paste)+ R th (heatsink) The thermals impedance values for the QC250 modules are as follows: Thermal Impedance Value ( C/W) R th (solder) 1.8x10-5 R th (dielectric) R th (MCPCB) 5.0x10-4 R th (paste)* 1.1x10-4 R th (heatsink) * High quality silver paste Value per inch of the 4 x 4 x 1 heatsink used in the QC250- EVAL160 KIT. For this example, Rth(system) = 1.8x x x = C/W As can be seen, painstaking design efforts have reduced the thermal impedance of all elements within the QC250 module. This is what allows such high power densities and long lifetimes. The largest thermal impedance of these QC250 systems will be the heatsink, and therefore primary factor in deploying these systems is in designing of these heatsink assemblies. To calculate the approximate die junction temperature, one needs to first calculate the wattage of the QC250 module. Under nominal condition the module is run at 5.0 Amps and has a nominal voltage drop of approximately 34 volts, resulting in a power load of around 170 watts. Assuming an the ambient air temperature of 25 C, the LED junction temperature would then be estimated as ΔT = 170 W * C/W ΔT = 101 C

17 ΔT = T junction T ambient = 101 C T junction = 126 C As can be seen, this system would be operating at the maximum allowable junction temperature specification. Additionally, if the ambient temperature deviated from 25 C the junction temperature would be further increased. For all applications, it is desirable to ensure that the die temperature remain at or below 85 C (under all potential ambient conditions) to ensure reliability and long operating lifetimes. For the convection cooling calculations above, the surface area and free airflow volume are the primary factors in the heat sink s thermal impedance. Increasing the airflow across the heatsink can reduce the heat sink s thermal impedance by what is commonly called a Thermal Impedance Adjustment Factor as given in the table below: Thermal Impedance Adjustment Factor* Airflow Linear Feet Per Minute (LFM) Thermal Impedance Adjustment Factor (TIAF) *Adjustment factor data courtesy Aavid Thermalloy For forced air systems, the impedance of the heat sink is then reduced by multiplying the heat sink s free air convection thermal impedance rating by the above correction factors. The design task is to calculate the required airflow that will reduce the thermal impedance of the heat sink to a value that ensures that Tjunction is below the required specification. In the example above, we then calculate the adjusted total thermal impedance as: ΔT = T junction T ambient = 85 C - 25 = 60

18 60 C = 170 W * R th (forced air) R th (forced air) = C/W Therefore, the reduction in system impedance is given by: ΔR th (forced air) = ( ) = C/W All of this reduction must come from the heatsink, which accounts for C/W in convection. Therefore, the change in heatsink impedance in the forced air system is given by: ΔR heatsink (forced air) = = C/W Therefore, the Thermal Impedance Adjustment Factor (TIAF) required to meet this level of performance is on the order of: TIAF = R heatsink (forced air) / R heatsink (convection) TIAF = /0.470 TIAF =.483 From the table this suggests that this example heatsink configuration requires an airflow of approximately 300 ft/min (LFM). To determine a proper fan, select an appropriate fan or blower that will interface properly with your heatsink, and then calculate the cross- sectional area of the exit port. For blowers, this is usually a rectangular duct at the exit port, and for axial fans this is just the surface area of the fan blades as given by πd 2 /4 where D is the diameter of the fan blades. Fans are rated in CFM (cubic feet per minute), so to convert the LFM requirement to CFM you must multiply the LFM value by the cross- sectional area of the output. In the example above we select a fan with 4 diameter. The cross- sectional area of the fan is Area = πd 2 /4 = 4π = 12.6 in 2 = =.087 ft 2 and therefore, the required CFM rating is given by: CFM = 300 ft/min *.087 ft 2 CFM= 25 CFM

19 Notes for the Designer: 1) The CFM ratings listed for all fans are specified under the no load condition (zero pressure drop). These specifications are therefore always a best case scenario which is seldom achieved in real world designs. Attaching the fan to a heat sink will always present some back pressure to the fan that will reduce the actual CFM flow rates. Review all fan data sheets before making final design choices, and test all configurations to ensure proper operation. 2) Keep in mind that when comparing blowers to axial fans, blowers tend to have better capabilities for generating pressure and maintaining their flow rates under pressure as compared with similarly specified axial fans. This can be important when flow rates are high and the flow impedance across the fins creates high levels of backpressure. 3) Remember that the above calculations assume that the ambient temperature is always 25 C, that humidity is low, that airborne contaminants are not present, and that all heat sink surfaces are free of dirt, grease and debris. Most of these assumptions may not be valid, especially as the system ages in industrial environments. During the design phase, ensure sufficient margins of deviations from these ideal conditions. Of greatest importance is understanding the potential for ambient temperature drift over the course of the day/year, and designing for the absolute maximum ambient temperature that the system is likely to encounter. 4) Trust and verify. Design your system with some level of safety margin so that you can trust that the system will run flawlessly under all conditions. But verify performance in real time to avoid costly downtime. Despite best intentions, stuff happens. Fans jam, current regulators fail, ambient temperatures spike. Never operate a system without continual monitoring the temperature on each module, and have fail safes that protect the system from catastrophic failure should the unforeseen happen.

20 *Average irradiance of fifteen 395nm devices on a standard 10x10 array operating at 5000mA with Tj = 85C. Radiant Flux measured at a 5mm working distance. Excessive heat or current increase the rate of lumen decay. Lumen Maintenance Item Symbol Value Unit Rated Irradiance* I f 16 W/cm 2 Lumen Maintenance L80 20,000 hrs * 5mm Working Distance time at which irradiance drops to 80% of the original value

21 QC250 LED Board Evaluation Kit This QuickCure UV modular system evaluation kit can be purchased to instantly evaluate the performance of the QC250 curing board and controls

22 QC250 LED Board Evaluation Kit The evaluation kit is made up of 4 components, a high power COB lamp, heat sink, fan and controller boards. These 4 components can be purchased together as a solution to drop into your curing and drying environments. Or you as a machine builder can mix and match what components you need for your machine and unique operating needs.

23 QC250 LED Board Evaluation Kit BLOWER ANODE CONTROL BOARD CATHODE CONTROL BOARD MOUNTING SCREWS W/ SHOULDER WASHERS LAMP

24 QC250- BLO Blower Fans can be purchased in 1 and 4 segments. BASE MATERIAL BEARING TYPE SPEED NOISE LEVEL MAX AIR FLOW RATED VOLTAGE WEIGHT PLASTIC EVER LUBRICATED BEARING (LONG LIFE BEARING) /- 10% RPM <31 dba 42 CFM 12 VDC 149 g

25 QC250- SNK Heat Sink The heat sink can be purchased in any length starting at 1. This design allows air to but circulated from the top of the fixture for maximum heat extraction. Please see section on Thermal Management. TYPE BASE MATERIAL WEIGHT PER INCH EXTRUDED ALUMINUM HEATSINK 6063 ALUMINUM.40 LB

26 QC250- DEV160Quad Modular Unit

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28 Custom LED Board and Heat Sink Designs Marktech can offer custom designs of LED curing boards along with heat sink and cooling solutions. Please contact our technical sales staff at the following: 3 Northway Lane N Latham, NY