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Everything you wanted to know about UV Lamps

By John G. BracelandPublished: May 7, 2012

The use of UV light as a curing technology has been around for a long time. In the last fewyears it has become more popular since the technology on the lamps and the materials sidehas greatly improved. Applications are now on sheetfed, web and wide format inkjetequipment. The major advantages of UV inks are:

1) Press sheets are dry when they come off the press

2) Higher throughput speed than Infra Red drying

3) No Volatile Organic Compounds released in the air

4) Resist smudging and abrasion

5) UV Coatings havea wet look

6) Do not havesolvents to penetrate uncoated stocks

norder to find out more about UV and how it works I went to an expert who has beenworking with UV technology for over 20 years, Norm Fitton, President of Anniversary UV.Most printers buy UVsystems which may be supplied by the manufacturer of theequipment

but made by someone else. Understanding how UV lamps work can improve their performanceand save you money.

There are different types of UV lamps for different applications. Low pressure UV lamps maybe used for disinfecting purposes, curing nails and dental fillings, or water purification. Theype of lamp used in printing applications is usually a medium pressure, linear (straight tubes),

mercury vapor arc lamp. Medium pressure UV lamps cure inks and coatings instantly. It is aphotochemical not a heat process. It allows the equipment to run at very high speeds forextended periods.

General use light bulbs have a filament. The electricity causes the filament to glow, producingight. Medium pressure UV lamps do not have a filament. They utilize a high voltage charge toonize a mercury/gas mixture in the lamp creating a plasma that emits UV light. This systemrequires a high voltage/amperage power supply (typically a magnetic ballast transformer witha high voltage capacitor bank). The ballast is wired in series with the lamp and performs twounctions. Initially, the ballast provides a high voltage charge to strike or ionize themercury. Then, once the mercury is ionized, the ballast reduces the voltage and amperagerequired to keep the mercury ionized and emit a stable stream of UV light.

These lamps generate a specific wavelength to cure the inks or coatings. Currently, most ofhese lamps operate at 300 to 600 watts per inch with some newer systems using lamps that

generate up to 1000 watts per inch. So a 30 inch UV bulb may be capable of an output of30,000 watts. They also operate at very high temperatures (850 to 950 Celsius or 1550 to1750 Fahrenheit).

This type of UV lamp is made from Quartz. A general glass product would not be able towithstand the high temperatures. An inert gas (usually argon) is pumped into the quartzsleeve and then mercury is added to achieve the proper elect rical spec ification. Iron andgallium are occasionally added to achieve special wavelengths. The tubes are sealed and thecorrect electrical end-f ittings are added to complete the lamp.

These lamps need a powerful cooling system to offset the high operating heat. They areusually air or air and water cooled. They also use reflectors to maximize the ultraviolet lightdelivered to the substrate. There must be an even flow of air or water across the lamp forproper curing. If lamps run too cool they may not cure the ink or coating. Some systems useoutside air for cooling. As the seasons change, depending on your geographic location, youmay need to adjust your fan speed or increase/decrease water temperature to maintainproper cooling.

Contamination is another problem that can affect lamp performance. Due to the high heat aircontaminants such as spray powder from other presses or dust particles can bake on theamps creating a haze. This decreases the performance of the lamps. Ideally, even after

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extended use the quartz should be completely clear.

Here are some things you can do to increase the life and performance of your lamps.

Make sure lamps are run at the proper operating temperature with an even flow of airor water over the ent ire tube. Adjust fan speeds by season if necessary to maintainproper temperature. If the system is also water cooled, as a general rule of thumb,the water temperature should be maintained as close to 72 degrees as possible.

Clean lamps weekly with alcohol on a clean cotton cloth to reduce contamination.Dont rub too hard.

Check and change filters in the cooling system regularly to make sure they are notclogged.

Rotate the lamps a quarter turn in the same direction each week.

Replacement UV lamps can be ordered from the OEM manufacturer or other lampdistributors/manufacturers throughout the US. The quality of the bulb is important and not allbulbs are manufactured to the same set of tolerances. In order to get the best match, if youare ordering from someone other than the OEM manufacturer, here are some tips to get theright bulb:

Provide a working sample - an unbroken used lamp as long as it will still light- allowssupplier to measure physical and electrical signature

Get a part # (not serial #) plus physical measurements such as total tip to tip length,electrode to electrode length (arc), outer diameter of quartz in mm, end fittingdescription, to confirm part # is correct

Determine the exact physical and electrical measurements-

Total tip to tip length, electrode to electrode length (arc), outer diameter of quartz in mm,and end fitting description

Lamp operating voltage and amperage (operating electrical signature from ballasttransformer to lamp)

Proper maintenance as well as shopping around for sources can help you get the most fromhese systems.

Thanks to Norm Fitton from Anniversary UV ([email protected] (610) 838-2784)or help in putting this article together.

Email | Print | Order Reprints

ohn G. Braceland is Managing Director for Graphic Arts Alliance a member run purchasingcooperative. He is also President of JB Solutions, a company that creates and managespurchasing cooperatives in various industries. Previously, he was President and owner ofBraceland Brothers, a multi-plant printing company headquartered in Philadelphia, PA.

Please offer your feedback to John. He can be reached at [email protected].

Discussion

By Buck Crowley on May 08, 2012

Great article. To add, you should own an inexpensive UV meter and check the output of yourUV lamps at least once a month. It will spot a pending problem before you start printingwaste.Buck @ BuckAutomation.com

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