Looking to build a UV system for curing varnishes, instrument finishes, surfboards or other UV curing paints? We can help! We get many requests every week to help build systems that produce UVA or UVB for special applications, so we have put together a page to assist you. We only show you the parts you can buy from us, the other parts you will need are readily available at any Home Depot, Lowes or other building materials supplier. This information is based upon years of customer input and design and from dozens of letters on TanningBeds.org, a non-profit website that TanningLamps4Less underwrites, that helps people with older tanning systems and special UV devices.
The goal is to show you the basics of how to create your own UV system. You will need to do some homework to decide how to best design it, how many lamps you need, and how to configure the entire system. If you need assistance , you can call 1-800-274-1744 x126 and speak to me (Dennis) personally for help. I have helped build many dozens of different rigs for every purpose you can imagine.
The lamps I am recommending here are extremely powerful, and produce the highest amount of total UVB and UVB, when compared to other lamps. They are particularly strong in the following ranges: 285nm to 287nm, 310nm to 315nm and 360nm to 370nm. They are not narrowband, as they produce more than a single spectrum, but they cost about 90% less than a narrowband lamp and usually provide similar results. Like ALL UV lamps, you MUST wear certified, protective eyeware when using these lamps, in any device. They cost just a few dollars and can be found elsewhere on the site.
Begin by making some design decisions:
1. First you need to decide if you want to run the system in HO mode(High Output 100W), or VHO mode (Very High Output 160W). VHO mode will cost more but produces about 30% to 50% more output, so it will reduce your exposure time. It will also shorten the life of the lamp by about 30%. The ballast will power four lamps in HO mode and two lamps in VHO mode. The ballasts are 120V, 50/60 hertz, and draw about 2.4 amps each.
2. Decide how many lamps you will need. The lamps are F71 (about 69" long) and can be placed a few inches apart. This may be dictated by your choice of HO or VHO mode. Because the lamps have a reflector built inside each lamp (which makes the output about 30% stronger) you don't want to have the lamps spaced 12 inches apart if the item you are exposing will be less than 12 inches from the lamps.
3. Figure out the configuration for your device. Often, it is just two to four lamps in a row. Other applications may require building a device that surrounds the item. Here are a couple of examples:
A luthier in Hawaii uses these parts to build a 3 ft diameter octigonal device (8 sides) to power the lamps in HO mode. He builds handcrafted ukuleles and inserts the entire ukulele inside the device to expose the full surface of the instrument equally. It takes just a few minutes for the finish to cure.
Several companies in the US and Canada offer a UV coating for subways and have created simple, flat devices that use one ballast and two lamps powered in VHO mode. These are basically 2x6 wood rails with the lamp ends attached to the ends. It requires just a few minutes exposure and the device can be moved down the car easily, to allow complete curing in a few minutes.
A surfboard builder in New Hampshire modified this by just purchasing the lamps, then buying an old canopy tanning system, to run the lamps in HO, 100w mode. By using the existing 8 lamp slots in the canopy, he can cure one side of a surfboard in less than two minutes.
Once you are ready to start the process, you can buy and download the materials below:
1. Buy lamp ends and holders for the basic lamp holding. Often, it is just cheaper to go buy a generic 4 foot lamp fixture from a building supplier, cut it in half, and stretch it out to the desired length. You can use the bi-pin lamp ends and holders, but you won't need the ballast. Since these sell for $15-$20 for a two lamp system, it is likely the cheapest and simplest option. You will have to modify this system to your own needs, and there really isn't a way I can explain how to do this on a webpage. Call if you need help.
2. Use the SunHorse ballast. You can buy it here.
3. Use the ClearTech 120R lamp. You can buy it here and be sure to choose the F71 size. While you *can* use other tanning lamps, these are a new technology and will deliver up to twice the UV, plus last a lot longer, making them a better choice. Keep in mind that shipping is expensive, and it costs the same to ship ONE lamp as it does 24. Always order at least enough for one application and a spare set, or more. This will save you money in the long run.
4. Print out and use one of these wiring diagrams for VHO and HO modes of the SunHorse ballast.
Tanning lamps are not designed for applications other than tanning the skin, however, many have found them to be an affordable alternative to other dedicated UV systems. Ultimately, you must be the one to decide if they are the best alternative for your application, and we can't guarantee that they will work for your particular circumstance.
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