GEW e-Brick 12kW Installation & Operating Manual Download

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GEW UV DRYING SYSTEM

e-Brick

INSTALLATION & OPERATING MANUAL

…engineering UV

GEW (EC) Limited

Kings Mill Lane, South Nutfield

REDHILL, Surrey RH1 5NB, England

Telephone: +44 (0)1737 824500

Fax: +44 (0)1737 823822

Spares & Service telephone: +44 (0)1737 824510

[email protected]

www.gewuv.com

GEW UV

e-Brick

installation and operating manual

1 of 49

Summary of Contents for e-Brick 12kW

Page 1: ...neering UV GEW EC Limited Kings Mill Lane South Nutfield REDHILL Surrey RH1 5NB England Telephone 44 0 1737 824500 Fax 44 0 1737 823822 Spares Service telephone 44 0 1737 824510 sales gewuv com www gewuv com GEW UV e Brick installation and operating manual 1 of 49 ...

Page 2: ...mpatibility 15 3 4 Connection to power supply 16 3 4 1 Essential electrical installation data 16 3 4 2 Residual current devices 16 3 5 General recommendations 17 3 5 1 Installation 17 3 5 2 Modifications 17 3 5 3 Markings and tamper evident seals 17 3 5 4 Location of equipment 17 3 6 Waste removal disposal 18 4 Product information 19 4 1 Description of the e Brick 19 4 2 Applications 19 4 3 Prohib...

Page 3: ... Routine operator maintenance 36 6 4 1 Air filter cleaning replacement 36 6 5 Fault finding guidelines 37 6 5 1 General faults 37 6 5 2 Individual faults 38 6 6 Parts list 41 6 6 1 Recommended spares 41 7 End of life information 42 7 1 De commissioning dismantling and disposal 42 8 Emergency information 43 8 1 Fire fighting 43 8 2 Potential hazards 43 9 Maintenance procedures 44 9 1 Unskilled 44 9...

Page 4: ... 7 Rear panel Master connection details 23 Figure 8 Typical HMI settings screens 31 Tables Table 1 Glossary of symbols used 8 Table 2 Power dissipation 14 Table 3 Supply connection specification 16 Table 4 Supply connection specification 22kW for Canada USA 16 Table 5 Recycling standard packaging 18 Table 6 Electrical supply data 21 Table 7 Performance data 21 GEW UV e Brick installation and opera...

Page 5: ...ector designations minor corrections and additions 2 1 28 March 2006 0312 0359 BPB Added 22kW e Brick information minor corrections and additions 2 2 12 January 2007 0459 0605 BPB Remove 220V references change HV DC fuse type UL related updates 2 3 19 November 2007 0816 BPB Further UL updates fuses and labelling 2 4 14 November 2008 1032 BPB PJB Minor corrections and amendments GEW UV e Brick inst...

Page 6: ...The e Brick is a highly integrated power supply designed specifically for powering UV lamps in drying systems The e Brick features integrated controls and all necessary hardware to control the UV system including lamp cooling safety interlock features and a press interface allowing the UV curing to be controlled automatically The e Brick power supply is a component part of a GEW UV drying system A...

Page 7: ...ines EN61000 6 4 2007 Electromagnetic Compatibility Emission Standard for industrial environments EN61000 6 2 2005 Electromagnetic Compatibility Immunity for industrial environments EN60529 1992 Degrees of protection provided by enclosures EN1010 1 2004 Safety of Machinery Safety requirements for the design and construction of printing and paper converting machines 1 1 3 British Standards Referenc...

Page 8: ...e consulted in all cases where this symbol is marked Caution risk of electric shock IEC 60417 5019 Protective Conductor Terminal IEC 60417 5041 Caution hot surface 3 Three phase alternating current IEC 60417 5032 Alternating current EN50419 Equipment should not be disposed of in normal waste stream Table 1 Glossary of symbols used GEW UV e Brick installation and operating manual 8 of 49 ...

Page 9: ...h silica gel pack then secured to a pallet with a shock protection layer During transportation and prior to installation the e Brick shall be stored in its protective packaging The recommended storage temperature range is 25 C to 55 C with up to 24h at 70 C 2 2 Dimensions See following tables for dimensions of the e Brick product variants and standard packaging Standard packaging e Brick variant L...

Page 10: ...Brick features T slots allowing handles to be fitted or the attachment of lifting eyes when required see Figure 1 Ensure that handles are aligned with the Centre of Gravity of the unit this is clearly marked on the side of the housing Note Illustrations show the 9kW e Brick 22kW products have four carry handles always use all handles when lifting the product C of G Figure 1 T slot detail showing c...

Page 11: ...ducts are installed in a similar manner but their additional size and mass must be taken in to account 3 1 Fixing anchoring Depending on the application the e Brick can be freestanding or permanently mounted inside a cabinet e g an individual print station 3 1 1 Freestanding applications For freestanding use the shelf or surface should be stable and capable of bearing the full weight of the e Bric...

Page 12: ...n an e Brick stack off the ground four of the handle components GEW part 24974 may be attached to the housing using the T slots on the base of the unit Figure 3 Fitment of optional feet GEW UV e Brick installation and operating manual 12 of 49 ...

Page 13: ...ciently strong to support the weight of the e Brick and attached cabling four fixing points are recommended see Figure 4 Figure 4 Cabinet mounting Note the fixing brackets shown in Figure 4 are for illustration purposes only specific brackets or fixings will be determined by the application If necessary please contact GEW for advice and engineering support GEW UV e Brick installation and operating...

Page 14: ...mm from sides If the e Brick will be mounted in an enclosure rather than in free air it is essential that adequate ventilation is provided Refer to Table 2 for the rated power dissipation for each product variant this figure should be taken in to account when calculating overall system cooling requirements e Brick variant Power dissipation W 9kW 475 12kW 900 22kW 1400 Table 2 Power dissipation Fig...

Page 15: ...ck and bump It is recommended that the e Brick should be installed in a location where vibration is minimized and there is minimal risk of shock or bump forces If vibration is excessive for a given installation anti shock mountings may be required 3 3 6 Electromagnetic compatibility The e Brick is designed to comply with the relevant EMC legislation for industrial installations EN61000 6 4 2007 EM...

Page 16: ...re in accordance with BS7671 2008 Table 4D2A reference method E e Brick variant Current phase A Supply cable size mm2 MCB rating A 9kW 20 4 25 12kW 25 4 25 22kW 57 16 63 Table 3 Supply connection specification Refer to Table 4 for peak mains supply current suggested minimum supply cable cross sectional area and MCB ratings for e Brick product variants 33276 and 33485 These recommendations are in a...

Page 17: ...for advice before attempting to modify the UV system 3 5 3 Markings and tamper evident seals GEW products are clearly marked with safety warnings to draw attention to specific hazards Due to the hazardous voltages within the e Brick security screws are used to secure the housing in addition tamper evident seals see Figure 6 are fitted to indicate that covers have been removed If these seals are br...

Page 18: ...ratocell Polyethylene foam May be recycled where facilities exist Alternatively dispose of in normal industrial waste stream Plastic bag Polythene May be recycled where facilities exist Silica gel sachet Silica gel paper sachet Dispose of in normal industrial waste stream Pallet Timber GEW pallets are suitable for reuse Alternatively recycling facilities exist in most areas Table 5 Recycling stand...

Page 19: ...ically detailed in 4 2 above are prohibited Please contact GEW for engineering support for all other applications 4 4 Safety features Warning To avoid accident or injury do not attempt to bypass any safety function The e Brick is designed to be safe in normal operation and to fail safe in the event of adverse operating conditions or internal failure The following safety features are included 4 4 1...

Page 20: ... event of a control failure Warning Refer to 5 4 for essential safety information relating to E stop usage 4 4 4 Contactor The 3phase power to the main converter in the e Brick is switched on using an internal contactor By design the contactor coil can only be energised when the press E stop is enabled and a second relay is switched on The second relay is switched on by the embedded controller and...

Page 21: ...n the supply voltage and the power level demanded by the installation Please contact GEW service for the actual running current for any specific UV system configuration 4 5 2 Performance Ratings Refer to GEW for e Brick performance data output voltage and current are maintained for the full operating voltage range detailed in Table 6 e Brick variant Output voltage V Output current A Efficiency 9kW...

Page 22: ...y does not generate any gases vapours or dust Refer to 3 3 4 for recommended operating environment and exposure limits for contaminants Note that UV dryers will generate some Ozone O3 that is extracted to atmosphere by the cooling system Refer to the relevant UV dryer user guides and system installation manuals for further information 4 6 Electrical Data 4 6 1 Block diagram Master only RS485 bus C...

Page 23: ...s of these models Refer to issue 1 0 of this manual for connection details of 23326 23329 12kW 24101 24104 26376 9kW Warning Where Volt free outputs are specified the maximum contact rating of the internal relay contact is provided in the tables below if this rating is exceeded contact damage may occur and the GEW warranty will be void Warning To ensure isolation of the e Brick from external syste...

Page 24: ...Brick PE K1 P8 P6 P2 P4 P3 P5 Figure 7 a Rear panel 22kW Master connection details P8 only fitted on Profibus master e Brick P1 P7 not fitted on slave Figure 7 b Rear panel 22kW 33276 33485 Variant connection details GEW UV e Brick installation and operating manual 24 of 49 ...

Page 25: ...tput to drive fan contactor coil also available on P7 A2 0V 0V reference for e Brick B1 E stop B2 E stop_rtn Volt free contact input from press B3 Fan_healthy B4 Fan_healthy_rtn Volt free contact input from press Also available on P7 B5 Speed 0 10V speed signal from press C5 Speed_rtn 0V reference for press speed signal C1 Ready C2 Ready_rtn Volt free relay output to press Contact rating 1A 24Vdc ...

Page 26: ...V C4 C4 Safety_switch C5 C5 Over_temp_switch C6 C6 Shutter_open C7 C7 Shutter_closed C8 C8 Chassis_in C9 C9 PT100 C10 C10 PT100_rtn C11 C11 N C C12 C12 N C Lamp and Lamp NOT SELV Warning No user accessible signals All signals relate to the GEW UV dryer For safety reasons connection shall only be made using GEW lamp cables 4 6 3 4 P4 Autodamper interface Pin connection Signal name Rating connection...

Page 27: ...r of the e Brick housing to permit Protective Earth PE bonding during installation Note that the mains supply earth is through P5 4 6 3 7 P6 Communication port in P6 HMI Master Pin connection Signal name Master Rating connection 1 24V 24V output to HMI 2 0V 0V output to HMI 3 RS485A RS485 bus 4 RS485B RS485 bus 5 KEY No connection 6 5V_control No connection 7 N C No connection 8 RS485_rtn RS485 Sc...

Page 28: ...n 5 Frame_safety_switch 6 Frame_safety_switch_rtn Volt free contact input from optional frame safety switch 8 N C No connection 4 6 3 9 P8 Profibus interface Where an e Brick is supplied with an internal Profibus interface connection to the external system is made by a standard 9 way D type connector not shown in Figure 7 Pin connection Signal name Slave Rating connection 1 Profibus_A Profibus net...

Page 29: ...N CLOSED OPEN OPEN Off Selected IN CLOSED OPEN OPEN Main e Brick contactor OFF disabled by relay interlock Off Selected OUT OPEN CLOSED CLOSED Main e Brick contactor ON UV START 1 Attempted IN CLOSED OPEN OPEN Main e Brick contactor OFF disabled by relay interlock UV START 2 Cold start OUT OPEN CLOSED CLOSED Main e Brick contactor ON UV START 3 After gravure use OUT CLOSED OPEN CLOSED i Main e Bri...

Page 30: ...ical principles EN1050 1997 Safety of Machinery Principles of risk assessment EN954 1 1997 Safety of Machinery Safety related parts of control systems EN60204 1 2006 Safety of Machinery Electrical equipment of machines EN61000 6 4 2007 Electromagnetic Compatibility Emission Standard for industrial environments EN61000 6 2 2005 Electromagnetic Compatibility Immunity for industrial environments EN60...

Page 31: ...stem HMI 5 3 Setting and adjustment The e Brick requires no setting or adjustment after installation all functions are controlled by the GEW system HMI Refer to the e Brick touchscreen software operating manual for details A typical HMI setting screen is shown in Figure 8 Using these screens the user is able to select a lamp set the required power level set the power ramping and monitor lamp servi...

Page 32: ...led System communications will remain functional allowing quicker restart Warning To avoid lamp damage due to overheating or potential fire hazard in the web do not stop the system by simply isolating the power It is strongly recommended that power be maintained to the e Brick when a system E stop event occurs this will ensure that the shutters operate correctly and lamps are properly cooled Advic...

Page 33: ...y which is a toxic substance must be handled carefully Always wash hands thoroughly after handling UV lamps Dispose of broken lamps safely by the following means Wear heavy rubber gloves at all times Cover the mercury and broken glass with sand Collect the waste mixture with dustpan and brush and transfer it to a cardboard box or other expendable container To protect the refuse operator put the co...

Page 34: ...quipment so that it could interfere with the safe operation of the system When testing or troubleshooting all safety interlocks shall be in place and cables left intact 5 6 2 Misuse and prohibited usages The e Brick is designed solely intended for powering specific GEW UV and IR dryers All other applications are prohibited unless prior written consent has been obtained from GEW 5 7 Fault identific...

Page 35: ...ore attempting maintenance removing covers cables or light shielding Ensure that the internal capacitors have been discharged by leaving the system switched off for 5 minutes before carrying out any maintenance Isolation transformers shall be used at all times when working on live equipment Alternatively a mains supply with appropriate earth leakage protection 30mA RCD may be used Use only approve...

Page 36: ...before changing or checking filters The only components of the e Brick requiring regular maintenance are the air filters Filters shall be checked in accordance with the system maintenance schedule in section 10 always follow the procedures in section 9 Advice Record filter checks and changes for reference in the event of a warranty claim see section 10 1 for a suggested format GEW UV e Brick insta...

Page 37: ...story screen 6 5 1 General faults Water cooling unit chiller failure The cooling unit has failed while the printing machine is running Check chiller MCB and reset if necessary Ensure that the chiller is switched on The chiller may have developed a fault check the control panel to see if a fault is reported Refer to the chiller manual for further fault finding suggestions Emergency stop failure The...

Page 38: ...amp cable is connected Ensure that other cables are undamaged and correctly connected PSU over temperature The e Brick has reported a high internal temperature Let the PSU cool down before re striking Check that the cooling fans are running Check filters If the e Brick is mounted in a cabinet check for air blockages and that adequate cooling capacity has been allowed Lamp failure No current flow w...

Page 39: ...s it will be displayed on the fault screen Electric shutter test Press the shutter test icon Check that shutters open check that open switch is activated Press the shutter test icon Check that shutters close check that close switch is activated Pneumatic shutter test Press the shutter test icon A hiss of air should be heard with the selected lamps the shutters should then click open and remain ope...

Page 40: ...available on the HMI When a selected e Brick fails to communicate a pop up message appears COMMUNICATION FAILURE SEE FAULT SCREEN DESELECT LAMP ACCORDINGLY Check Fault screen to identify which e Brick has failed to communicate Check electrical connections to the affected slave Check 24V LED is illuminated if not then internal 24Vdc may be faulty Check K1 LED illuminates when lamp is selected If no...

Page 41: ...r Notes Intake filter medium 10485 Filter insert Exhaust filter medium 24504 Filter insert 9 12kW Exhaust filter medium 25392 Filter insert 22kW Exhaust filter medium 33365 Filter insert 22kW 33276 33485 GEW UV e Brick installation and operating manual 41 of 49 ...

Page 42: ...ards Having isolated the mains power the equipment may be dismantled by unplugging connectors and unbolting fixings from the host equipment As with any complex engineered product the e Brick contains a number of materials requiring different disposal or recycling methods In accordance with the European Waste Electrical and Electronic Equipment WEEE Directive these materials must be recovered by an...

Page 43: ...s associated with Ozone Mercury Ultra Violet Radiation UVR moving parts high temperatures and high voltages As a component of the UV drying system the specific hazards associated with the e Brick are high internal voltages high output voltages to the lamp head and high internal temperatures resulting from normal heating of electronic components Warning NEVER use or store flammable solvents near th...

Page 44: ...on Cables should be neatly routed and protected from damage at all times Warning Damaged cables must be repaired or replaced at the earliest opportunity to maintain system performance and safety 9 1 2 Intake filter change Warning Isolate power before changing or checking filters No tools are required when changing the intake filter the cover of the filter housing is simply unclipped and the old fi...

Page 45: ... The procedure is illustrated in Figure for the 9kW and 12kW products A similar procedure is followed for the two rectangular exhaust filters on the 22kW e Brick Figure 11 Exhaust air filter change procedure 9 2 Skilled All other maintenance operations are considered skilled and shall be carried out by GEW service technicians or engineering personnel GEW UV e Brick installation and operating manua...

Page 46: ...filter where fitted UV lamp reflector use Isopropyl alcohol Heat sink base shutter X X X X 100 Check drying performance replace UV lamp if necessary X X 1 000 When fitting a new lamp examine the dichroic reflector if fitted and arrange for renewal if required X X 4000 Check cables to lamp terminals X 2000 Lubricate shutter pivots PTFE silicone lubricant X X 2000 Powerbrick and HV upright cabinets ...

Page 47: ... Operator Intake Exhaust X X X ANO 40 80 120 160 200 240 280 320 360 400 440 480 520 560 600 640 680 720 760 800 840 880 920 960 1000 1040 1080 1120 1160 1200 1240 1280 1320 1360 1400 1440 1480 1520 1560 1600 1640 1680 1720 1760 1800 e g 40 Print additional copies of this sheet as required GEW UV e Brick installation and operating manual 47 of 49 ...

Page 48: ...ms The following applies unless different terms and conditions of warranty have been agreed and confirmed in writing Included a All new products are covered by a 12 month parts and labour warranty from the date on the WVC b Faulty parts will be replaced without charge c Full technical support and help from our service hotline Excluded a Curing performance of the equipment unless agreed in writing ...

Page 49: ...W keeps thousands of parts on stock to ensure a fast efficient response to any request for a spare part We will ship any part to any destination For identification of parts refer to the CD with your system Our web site has more information www gewuv com GEW are dedicated to helping customers operate their systems at the lowest possible cost We offer discounts on lamps parts and service rates ...

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