Table of Contents
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
www.gewuv.com
GEW UV e-Brick installation and operating manual
1 of 49
Table of Contents
Related Manuals for GEW e-Brick 9kW
Summary of Contents for GEW e-Brick 9kW
- Page 1 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...
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Page 2: Table Of Contents
Noise & Vibration....................... 21 4.5.4. Radiation ........................22 4.5.5. Gases, Vapours, Dust ....................22 4.6. Electrical Data ........................22 4.6.1. Block diagram......................22 4.6.2. Interface details ......................23 4.6.3. SELV ports ........................ 25 GEW UV e-Brick installation and operating manual 2 of 49... - Page 3 Installation and Commissioning ..................48 11.3. Warranty Validation Certificate ( WVC )................ 48 11.4. Warranty terms ......................48 11.5. Making a Claim ......................48 11.6. Purchase of spare parts....................49 GEW UV e-Brick installation and operating manual 3 of 49...
- Page 4 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 operating manual 4 of 49...
- Page 5 Remove 220V 2007 0605 references, change HV DC fuse type. UL related updates 19 November 0816 Further UL updates: 2007 fuses and labelling 14 November 1032 Minor corrections and 2008 amendments GEW UV e-Brick installation and operating manual 5 of 49...
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Page 6: Product Description
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 complete system would also include GEW UV dryer(s) e.g. VCP, custom cabling, fan cooling, ducting and a human machine interface (HMI) to control the operation of the system. -
Page 7: Related Documentation
1.1.5. North American & Canadian Standards Reference Title NFPA79:2002 Electrical Standard for Industrial Machinery UL508 Standard for Industrial Control Equipment SPE-1000-99 Model Code for the Field Evaluation of Electrical Equipment GEW UV e-Brick installation and operating manual 7 of 49... -
Page 8: Symbols Used
1.1.6. Symbols used The following markings are used on GEW e-Brick products and system components: Symbol Reference Description ISO7000 – 0434 Caution, risk of danger. Note: Documentation must be consulted in all cases where this symbol is marked Caution, risk of electric shock IEC 60417 –... -
Page 9: Transport, Handling, Storage
See following tables for dimensions of the e-Brick product variants, and standard packaging: Standard packaging e-Brick variant Length (mm) Width (mm) Height (mm) Weight (kg) 12kW 1010 e-Brick product e-Brick variant Length (mm) Width (mm) Height (mm) Weight (kg) 22.5 12kW 22kW GEW UV e-Brick installation and operating manual 9 of 49... -
Page 10: Handling
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 carry handles GEW UV e-Brick installation and operating manual 10 of 49... -
Page 11: Installation & Commissioning
To ensure stability the carry handles act as fishplates to lock the units together, see Figure 2. Figure 2: Stacking GEW UV e-Brick installation and operating manual 11 of 49... -
Page 12: Fitment Of Optional Feet
3.1.2. Fitment of optional feet To position 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... -
Page 13: Permanent Mounting
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 manual... -
Page 14: Space Needed For Use And Maintenance
Power dissipation (W) 12kW 22kW 1400 Table 2: Power dissipation Figure 5: Installation clearances GEW UV e-Brick installation and operating manual 14 of 49... -
Page 15: Environmental Conditions
3.3.6. Electromagnetic compatibility The e-Brick is designed to comply with the relevant EMC legislation for industrial installations: EN61000-6-4:2007 EMC – Emission Standard for industrial environments EN61000-6-2:2005 EMC – Immunity for industrial environments GEW UV e-Brick installation and operating manual 15 of 49... -
Page 16: Connection To Power Supply
3.4.2. Residual current devices The internal EMC filters of the e-Brick are designed with a maximum earth leakage of 20mA; this should be taken in to account when specifying residual current protection devices. GEW UV e-Brick installation and operating manual 16 of 49... -
Page 17: General Recommendations
3.5. General recommendations If you experience difficulties in setting up this product, contact GEW at the address given at the front of this manual. If in doubt, ask! We are always ready to help. 3.5.1. Installation e-Brick systems should be installed by GEW service technicians or, alternatively, by GEW factory trained personnel. -
Page 18: Waste Removal & Disposal
Silica gel / Dispose of in normal industrial waste stream paper sachet Pallet Timber GEW pallets are suitable for reuse. Alternatively, recycling facilities exist in most areas Table 5: Recycling standard packaging GEW UV e-Brick installation and operating manual 18 of 49... -
Page 19: Product Information
UV curing to be controlled automatically. 4.2. Applications The e-Brick is specifically designed for powering GEW UV dryers and, in certain applications, IR dryers; contact GEW for details of compatible UV and IR dryers. Warning! System efficiency and safety may be compromised and/or the e-Brick may be damaged by the use of non-genuine GEW UV lamps or dryers. -
Page 20: Indicators
Under no circumstances should either lamp output terminal be electrically connected to chassis ground; this will invalidate the e-Brick warranty and is likely to result in severe damage to the e-Brick. GEW UV e-Brick installation and operating manual 20 of 49... -
Page 21: General Data
Advice! The actual current consumption of the e-Brick is dependent on 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;... -
Page 22: Radiation
3.3.6 for relevant standards. Warning! The e-Brick forms part of a GEW UV drying system, providing essential safety functions. The UV dryer in the system presents some risk of exposure to UV radiation; this risk is minimised by application specific shielding. Refer to the relevant UV dryer user guides and system installation manuals for further information. -
Page 23: Interface Details
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 systems, where a ‘Volt free’... - Page 24 Figure 7(a): Rear panel (22kW Master) connection details P1 & P7 P8 only fitted not fitted on Profibus on slave master e-Brick Figure 7(b): Rear panel (22kW – 33276/33485 Variant) connection details GEW UV e-Brick installation and operating manual 24 of 49...
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Page 25: Selv Ports
The e-Brick internal 24V power supply is classified as Safety Extra Low Voltage (SELV) in accordance with clause 2.3 of EN60950. The e-Brick is designed for connection of GEW approved equipment only to ports P1-P8. With the exception of lamp output terminals [P3A-B] and mains input terminals [P5A (9/12kW) or P5 A-C (22kW)] interfaces are SELV;... - Page 26 Lamp+ Lamp+ and Lamp- NOT SELV Lamp- Shutter_Motor- Warning! No user accessible signals! Shutter_Motor+ +24V All signals relate to the GEW UV dryer. Safety_switch For safety reasons, connection shall only Over_temp_switch be made using GEW lamp cables Shutter_open Shutter_closed Chassis_in...
- Page 27 RS485B RS485 bus || P2-2 E-stop ‘Volt free’ contact input from E-stop output on previous master / slave e- E-stop_rtn Brick. No connection No connection No connection RS485_rtn RS485 Screen GEW UV e-Brick installation and operating manual 27 of 49...
- Page 28 9 way ‘D’ type connector (not shown in Figure 7). Pin connection Signal name (Slave) Rating / connection Profibus_A Profibus network Profibus_B Profibus network RS485_rtn RS485 Screen GEW UV e-Brick installation and operating manual 28 of 49...
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Page 29: Option: Gravure Purge Hardware
‘deselected’ i.e. the contactor is OFF. 4.6.4.2. External traffic light functionality ‘Individual Ready’ n/o contact status: OPEN traffic light GREEN CLOSED traffic light RED GEW UV e-Brick installation and operating manual 29 of 49... -
Page 30: Conformity
4.7. Conformity Equipment Electronic Power Supply Models: e-Brick 9kW / e-Brick 12kW / e-Brick 22kW In accordance with the following Directives: 2006/95/EC The Low Voltage Directive 2004/108/EC The Electromagnetic Compatibility Directive 98/37/EEC The Machinery Directive has been designed and manufactured to the following specifications: EN12100-1:2003 Safety of Machinery –... -
Page 31: Product Application
GEW for details of compatible UV and IR dryers. The e-Brick power supply is a component part of a GEW UV drying system. A complete system would also include GEW UV dryer(s) e.g. VCP, custom cabling, fan cooling, ducting and a human machine interface (HMI) to control the operation of the system. -
Page 32: Stop Functions Including Emergency Stop
For safety reasons, the embedded control software will prevent an e-Brick system from running until all safety interlocks are in place and lamp temperatures are within acceptable limits. Following installation and commissioning by GEW, the system shall be operated in accordance with the relevant HMI software manual. -
Page 33: Risk Reduction
5.6. Risk Reduction The GEW engineering team has considered safety of the equipment at every stage of the design process. However, certain hazards remain because of the nature of the application. To avoid accident or injury, operators should be aware of the hazards associated with UV drying systems. -
Page 34: Misuse And Prohibited Usages
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. -
Page 35: Maintenance Information
• Always replace security seals after service operations 6.3.1. Firmware update GEW service technicians may update the embedded software in an e-Brick system using a PC with suitable software and a data interface cable (GEW part 25677). 6.3.2. Safety devices Refer to section 4.4 for details of the safety devices designed in to the e-Brick. -
Page 36: Routine (Operator) Maintenance
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 installation and operating manual 36 of 49... -
Page 37: Fault Finding Guidelines
Advice! All faults that may be corrected by the operator are indicated by the HMI. In the event of a fault occurring that cannot be cleared by the operator, please refer to GEW or your local agent for service. Warning! There are no user serviceable parts inside the e-Brick;... -
Page 38: Individual Faults
Check the physical state of the lamp; change the lamp if it operated for >1000h. Instructions for changing the lamp are given in the lamp head user manual. If a new lamp fails, call GEW for advice. • Let the lamp cool down before re-striking. - Page 39 Check electrical connections between the e-Brick and the damper • Check that the damper operates normally, check for air blockage • Check flexible ducting for obstructions Note! The system will still run with this warning present GEW UV e-Brick installation and operating manual 39 of 49...
- Page 40 If necessary, deselecting affected slave e-Brick will allow system to run Other Some applications may have additional fault codes; refer to the specific software warnings. users manual for explanations of other fault codes. GEW UV e-Brick installation and operating manual 40 of 49...
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Page 41: Parts List
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: End Of Life Information
Please contact your local authority for details of the nearest licensed recycling facility. Where necessary, and only with prior written consent, equipment may be returned to GEW for recycling. GEW UV e-Brick installation and operating manual 42 of 49... -
Page 43: Emergency Information
Warning! NEVER use or store flammable solvents near the e-Brick. GEW UV e-Brick installation and operating manual 43 of 49... -
Page 44: Maintenance Procedures
The procedure is illustrated in Figure for a 9kW e-Brick; the same procedure applies to the filters for 12/22kW units. Figure 10: Intake air filter change procedure GEW UV e-Brick installation and operating manual 44 of 49... -
Page 45: Exhaust Filter Change
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 manual 45 of 49... -
Page 46: Uv System Maintenance Schedule
Evidence of carrying out recommended maintenance procedures is required to validate claims under the GEW warranty (a suitable template is available from GEW for use by customers). -
Page 47: Filter Service Record
40 1000 1040 1080 1120 1160 1200 1240 1280 1320 1360 1400 1440 1480 1520 1560 1600 1640 1680 1720 1760 1800 Print additional copies of this sheet as required GEW UV e-Brick installation and operating manual 47 of 49... -
Page 48: Product Warranty Statement
In the event of a problem becoming apparent contact the company who supplied the product, with a description of your claim. They will either deal with the problem themselves or contact GEW for assistance. In either event, if you do not get a prompt response, please contact us and we will help. -
Page 49: Purchase Of Spare Parts
All spare parts are subject to a 12 month return to base warranty, this applies only to the part itself. GEW 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.