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e-brick installation and user manual

1. 32 5 6 Risk Reduction 33 5 6 1 Remaining risks Hazard reduction and safeguards 33 5 6 2 Misuse and prohibited usages 34 5 7 Fault identification and repair 34 5 8 Personal Protective Equipment 34 5 9 Training required 34 6 Maintenance information 35 6 1 Safety inspections 35 6 2 Functional Testing 35 6 3 Specialist inspection amp repair 35 6 3 1 Firmware update
2. 48 11 1 General 48 11 2 Installation and Commissioning 48 11 3 Warranty Validation Certificate WVC 48 11 4 Warranty terms 48 Included 48 Excluded 48 11 5 Making a Claim 49 11 6 Purchase of spare parts 49 GEW UV e Brick installation and operating manual 3 of 49 Figures Figure 1 T slot detail showing carry handles 11 Figure 2 Stacking 12
3. 35 6 3 2 Safety devices 35 6 4 Routine operator maintenance 36 6 4 1 Air filter cleaning replacement 36 6 5 Fault finding guidelines 36 6 5 1 General faults 37 6 5 2 Individual faults 37 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
4. 43 8 1 Fire fighting 43 8 2 Potential hazards 43 9 Maintenance procedures 44 9 1 Unskilled 44 9 1 1 Visual inspection 44 9 1 2 Intake filter change 44 9 1 3 Exhaust filter change 45 9 2 Skilled 45 10 UV System Maintenance Schedule 46 10 1 Filter service record 47 11 Product Warranty Statement
5. Check all electrical connections relating to the lamp Check the physical state of the lamp change the lamp if it has operated for gt 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 GEW UV e Brick HMI software operating manual 15 of 18 Safety switch failure On systems with lamp heads mounted on hinged brackets this alarm will indicate that the lamp head has been hinged open Check that the lamp is firmly seated in the outer casing Check that the lamp head is closed hinged head If this fault occurs with the lamp head hinged closed then check the alignment of the interlock arm with the interlock switch at the front of the lamp head Lamp over temperature The lamp head overheats Overheating may be caused by problems in the lamp head Advice Let the lamp cool down before re striking Check that the fan is running and that its rotation is correct Check that the damper operates normally check for air blockage Check flexible ducting for obstructions Check electrical connections between the e Brick and the lamp head Check the lamp chassis is fully inserted in the lamp head ensure that the plug to the lamp head is fully engaged Shutter failure Shutter failure while the printing machine is running Check electrical connections betwee
6. FIT NEW LAMP Replacing a lamp is a reversal of the procedure above Unwrap a new lamp from its container holding it by its ceramic end caps Fit the lamp carefully into the reflector assembly The lamp has a slender neck at each end take particular care not to knock the lamp If you touch the surface of the UV lamp clean the area with the wipe provided with the replacement lamp Ensuring an unobstructed path refit the lamp cables replace the cold filter and clamp block sub assembly securing it with the 4 x hexagonal cap head bolts Before fully tightening check the lamp for freedom of movement it should have a loose fit when the screws are tight Insert the lamp chassis assembly into the lamphead body and re tighten the locking assembly GEW UV system operating manual Issue 1 00 Sept 2005 E systems Lamp Change page 4 of 4
7. X X 4000 Check cables to lamp terminals X 2000 Lubricate shutter pivots PTFE silicone lubricant X X 2000 Powerbrick and HV upright cabinets Clean or replace cabinet filter X X X 500 Clean out dust X 500 Check terminals tighten if necessary report any terminal damage X 4000 Check cabinet cooling fan X 4000 e Brick Check filters X 40 Clean or replace intake and exhaust filters X X 500 If necessary wipe down exterior surfaces of enclosure with a lint free cloth slightly dampened with water or Isopropyl Alcoho lPA X 500 System cooling fan amp Ozone filter where applicable Check duct inlet X 40 Check for vibration X 4000 Inspect Ozone filter replace filter panels when the granules coloured purple when new have turned brown X X 4000 Water Chiller where fitted Drain and refill using the recommended amount of anticorrosion additive see chiller manual for specific details X X 5000 GEW UV e Brick installation and operating manual 46 of 49 10 1 Filter service record System installation date ___ ___ ___ Record continued from previous sheet _______ Hours run Filter type Checked Replaced Operator Intake Exhaust e g 40 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
8. 5 3 1 Firmware update 5 3 2 Safety features 5 3 3 Output power curve for e Brick system 5 3 4 Using the HMI 7 3 4 1 Starting up the UV system 7 3 4 2 Selecting lamps 9 3 4 3 Setting power levels 9 3 4 4 Switching off 10 3 4 5 Configuration Shutter test Lamp change function 11 3 4 6 Production profiles 11 3 4 7 Consumable parts 12 3 4 8 GEW Warr
9. The 9 12 22kW e Brick requires a 3 Phase mains supply with a Protective Earth connection 3P E note that no neutral connection is made The 3 6kW e Brick requires a single phase mains supply with a Protective Earth connection Refer to Table 5 for operating Voltage range and peak supply current per phase Power factor is typically 0 9 for all e Brick variants so no additional power factor correction is required e Brick variant Nominal Supply Voltage V Supply Voltage V Peak current phase A Supply Frequency Maximum Power 3 6kW 240V 216 264V 20 50 60Hz lt 4kW 9kW 415V 374 528V 25 50 60Hz lt 9 6kW 12kW 415V 374 528V 25 50 60Hz lt 13 1kW 22kW 415V 374 528V 57 50 60Hz lt 24kW Table 5 Electrical supply 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 performance is maintained for the full operating voltage range detailed in Table 5 e Brick variant Output voltage V Output current A Efficiency 3 6kW 9kW 12kW 22kW Refer to GEW Table 6 Performance data 4 5 3 Noise amp Vibration The e Brick contains fans to cool the power electronics these generate some noise but this is likely to
10. 16 3 3 1 Temperature 16 3 3 2 Humidity 16 3 3 3 Altitude 16 3 3 4 Contaminants 16 3 3 5 Vibration shock and bump 16 3 3 6 Electromagnetic compatibility 16 3 4 Connection to power supply 17 3 4 1 Essential electrical installation data 17 3 4 2 Residual current devices 17 3 5 General recommendations 17 3 5 1 Installation 17 3 5 2 Modifica
11. 2 gCAN GEW CANbus 3 E stop 4 E stop_rtn Volt free contact input from E stop output on previous master slave e Brick 5 N c 6 N c 7 gCAN_rtn GEW CANbus E GEW UV e Brick installation and operating manual 27 of 49 4 6 3 8 P7 System fan interface Pin connection Signal name Rating connection 1 Fan_healthy 2 Fan_healthy_rtn Volt free contact input from fan overload auxiliary Also available on P1 P5 3 Fan_start out 7 Fan_start_rtn 24VDC relay output to drive fan contactor coil Also available on P1 P5 4 N c 5 Frame_safety_switch 6 Frame_safety_switch_rtn Volt free contact input from optional frame safety switch E 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 MON_RS232_Tx 2 MON_RS232_Rx 7 MON_RS232_0V Factory use only 3 Profibus_B 4 Profibus_RTS 5 Profibus_GND 6 Profibus_5V 8 Profibus_A 9 N c Housing Profibus_cable_shield Profibus network GEW UV e Brick installation and operating manual 28 of 49 4 7 Conformity Equipment Electronic Power Supply Models e Brick 3 6kW e Brick 9kW e Brick 12kW e Brick 22kW In accordance with the following Directives 73 23 EEC Th
12. Block diagram 22 4 6 2 Interface details 23 4 6 3 SELV ports 23 GEW UV e Brick installation and operating manual 2 of 49 4 7 Conformity 29 5 Product application 30 5 1 Intended use of the e Brick 30 5 2 Manual controls 30 5 2 1 Configuration switches 30 5 3 Setting and adjustment 31 5 4 Stop functions including emergency stop 32 5 5 Sequence of operation
13. 15 Table 3 Supply connection specification 17 Table 4 Recycling standard packaging 18 Table 5 Electrical supply data 21 Table 6 Performance data 21 GEW UV e Brick installation and operating manual 4 of 49 Document Issue Status Issue Date ECN Edited Checked Approved Notes 0 1 15 Dec 2006 BPB First release 1 0 16 January 2007 0605 BPB GEW UV e Brick installation and operating manual 5 of 49 EC DECLARATION OF INCORPORATION We hereby declare that the following machinery is intended to be incorporated into other machinery and must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with essential health and safety requirements of the MACHINERY DIRECTIVE 98 37 EEC the LOW VOLTAGE DIRECTIVE 73 23 EEC and ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 89 336 EEC Machinery Description Manufacturer UV DRYER TYPE VCP ECP HCP XC UV DRYER TYPE NUVA NUVAplus CONTROL CABINET TYPE e Brick 3 6kW 9kW 12kW 22kW and derivatives CONTROL CABINET TYPE p Brick CONTROL CABI
14. GEW UV DRYING SYSTEM e Brick EC INSTALLATION amp 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 amp Service telephone 44 0 1737 824510 sales gewuv com www gewuv com GEW UV e Brick installation and operating manual 1 of 49 Table of Contents EC DECLARATION OF INCORPORATION 6 1 Product Description 7 1 1 Related documentation 8 1 1 1 GEW Product manuals 8 1 1 2 European EN Standards 8 1 1 3 British Standards 8 1 1 4 Guidance notes 8 1 1 5 Symbols used
15. Figure 3 Fitment of optional feet 13 Figure 4 Cabinet mounting 14 Figure 5 Installation clearances 15 Figure 6 Tamper evident seal 18 Figure 7 Rear panel connection details 24 Figure 8 Typical HMI settings screens 31 Figure 9 Typical Alarm Warning and Fault History screens 36 Figure 10 Intake air filter change procedure 44 Figure 11 Exhaust air filter change procedure 45 Tables Table 1 Glossary of symbols used 9 Table 2 Power dissipation
16. MCB or system electrical isolator Lamp s will be switched off instantaneously If master e Brick is isolated in this way there will be no system cooling control refer to warning below On restarting lamps will be deselected by default and shutters closed automatically Software shutdown HMI Lamps will be switched off instantaneously System cooling correctly controlled 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 is maintained to the e Brick when an system E stop event occurs this will ensure that the shutters operate correctly and lamps are properly cooled Advice Depending on lamp temperature the stop method and the duration of the stop it may take a few minutes to restart an e Brick system The embedded control software will only allow the e Brick to run when all safety interlocks are in place and lamp temperatures are within acceptable limits 5 5 Sequence of operation 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 GEW UV
17. 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 approved recycling facility 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 8 Emergency information 8 1 Fire fighting Warning Only fire extinguishers of the dry powder type should be used on this equipment 8 2 Potential hazards The e Brick is a component of a UV drying system which although designed for safety presents some remaining hazards 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 GEW UV e Brick installation and operating manual 43 of 49 9 Maintenance procedures 9 1 Unskilled The e Brick forms part of a UV drying system which requires preventative maintenance operations in accordance with the s
18. assembly by unlocking the chassis door with the allen key supplied Remove the 4 cap head bolts to remove the chassis reflector cassette from the outer casing If the shutter is in the closed position gently push open With a 8 mm socket driver remove the M5 nuts and M5 washers securing the lamp lead at both sides You will notice that the main H T leads remain secure when you undo the lamp leads VCP eCP hCP NUVAplus GEW UV system operating manual Issue 1 00 Sept 2005 E systems Lamp Change page 2 of 4 REMOVE COLD FILTER Remove the 4 x hexagon cap head bolts two at each end of the reflector assembly VCP eCP hCP NUVAplus This releases the two clamp blocks that hold the cold filter the long glass segment with U shaped cross section Lift both clamp blocks and cold filter together pressing inwards to prevent the cold filter from falling out Set this sub assembly aside with care and if necessary wipe clean the cold filter with a lint free cloth moistened with isopropyl alcohol VCP eCP hCP NUVAplus GEW UV system operating manual Issue 1 00 Sept 2005 E systems Lamp Change page 3 of 4 REMOVE OLD LAMP Holding the lamp by the ends the lamp can now be lifted out VCP eCP hCP NUVAplus Ensure safe disposal of the old lamp CLEAN REFLECTOR The reflector assembly can be cleaned whilst the lamp is removed Clean with a soft cloth dampened with isopropyl alcohol IPA
19. can be rectified without further diagnosis for example an overheated lamp that has now cooled down pressing the icon will clear the fault After clearing a fault press the icon to return to the main screen to restart the system Advice Always check Fault Screen before resetting any undiagnosed fault The Log icon allows a time coded list of faults to be displayed this may be of assistance during fault finding GEW UV e Brick HMI software operating manual 13 of 18 3 5 1 Warning indicators The e Brick has three indicator LEDs one for the internal 24V supply status a second to show the main contactor K1 status and a third to indicate fault status If the K1 LED fails to light when the lamp is selected and no other fault is present please refer to GEW for service support 3 5 2 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 operator may have triggered an emergency stop of the printing machine Check external emergency stop e stop circuitry and switches Check panel circuit breakers in external equipment Check e stop links between e Bri
20. differs depending on the application all systems require commissioning by trained personnel This manual should be referred to alongside the user manuals and installation information for the other components in the system This user manual has been prepared in accordance with the guidelines set out in EN12100 and EN60204 GEW UV e Brick installation and operating manual 7 of 49 1 1 Related documentation 1 1 1 GEW Product manuals Document Title VCP user manual ECP user manual NUVA user manual e Brick HMI Software Operating Manual 1 1 2 European EN Standards Standard Title EN12100 1 2003 Safety of Machinery Basic terminology methodology EN12100 2 2003 Safety of Machinery Technical principles EN1050 1997 Safety of Machinery Principles of risk assessment EN12198 1 2000 Safety of Machinery Assessment and reduction of risks arising from radiation emitted by machinery EN12198 2 2002 Safety of Machinery Assessment and reduction of risks arising from radiation emitted by machinery EN12198 3 2002 Safety of Machinery Assessment and reduction of risks arising from radiation emitted by machinery EN954 1 1997 Safety of Machinery Safety related parts of control systems EN60204 1 1998 Safety of Machinery Electrical equipment of machines EN61010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use EN61000 6 4 2001 Electromag
21. e Brick installation and operating manual 32 of 49 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 5 6 1 Remaining risks Hazard reduction and safeguards The remaining hazards are associated with Ozone Mercury Ultra Violet Radiation UVR moving parts high temperatures and high voltages 5 6 1 1 Ozone O3 Warning The UV lamp generates Ozone the gas is normally ducted to atmosphere along with the exhaust air Alternatively air may be safely discharged to the factory via an Ozone filter Ozone irritates the lungs if a pungent smell of Ozone is detected check the ducting for air tightness Ensure that the ducting is correctly installed and in place at all times If ozone filters are fitted ensure they are changed according to the maintenance schedules set out in the installation manual 5 6 1 2 Mercury Hg Warning UV lamps contain small quantities of Mercury 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 t
22. in the chassis Check electrical connections between the e Brick and the lamp head Check the lamp chassis is fully inserted in the lamp head ensure that the plug to the lamp head is fully engaged If no fault found try reinserting the affected chassis restart the system and reselecting lamps Other warnings Some applications may have additional fault codes refer to the specific software users manual for explanations of other fault codes GEW UV e Brick HMI software operating manual 17 of 18 GEW UV e Brick HMI software operating manual 18 of 18 3 6 HMI Flow chart General operation screens Start up screen Main operator screen Global screen Configuration menu Alarm screen Start Stop Shutter Multi key Production profiles Consumable parts Validate warranty REPLACING THE UV LAMP e Systems This chapter explains how to fit a new UV lamp including the removal and disposal of the old UV lamp TOOLS Set of hexagon allen keys and an 8mm socket required PREPARATION Deselect the required lamp number on the touch screen for the lamp you wish to change Allow the lamp to cool down and press the lamp change button on the touch screen so this turns red This will open the shutter on all deselected lamps GEW UV system operating manual Issue 1 00 Sept 2005 E systems Lamp Change page 1 of 4 REMOVE CHASSIS VCP eCP hCP NUVAplus Pull out the lamp chassis
23. manual 11 of 18 3 4 7 Consumable parts This screen shows the GEW part numbers for consumable parts on the system to assist the customer when ordering spare parts 3 4 8 GEW Warranty When a system is not commissioned by GEW a pop up message appears every 20 hours reminding the customer that the system is not under warranty To validate the warranty enter the password supplied by GEW service Touch the screen to clear the pop up message for a further 20h Note The GEW warranty shall not apply until the system has been correctly commissioned GEW UV e Brick HMI software operating manual 12 of 18 3 5 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 do not remove covers under any circumstances Please note that if factory security seals are broken the warranty is void Should any fault occur the alarm pop up appears on the HMI and the fault code is recorded on the fault screen The system will still run with a fault however the operator must deselect the faulty lamp on the HMI Press to access the faults screen which displays icons for the faults that have occurred for each lamp Icons are defined in sections 3 5 1 and 3 5 3 below If the fault
24. 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 GEW UV DRYING SYSTEM e Brick EC TOUCHSCREEN TS8006 EC SOFTWARE 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 amp Service telephone 44 0 1737 824510 sales gewuv com www gewuv com GEW UV e Brick HMI software operating manual 1 of 18 Table of Contents 1 Scope 4 2 Product Description 4 2 1 Related documentation 4 2 1 1 GEW Product manuals 4 2 1 2 European EN Standards 4 3 Human Machine Interface
25. 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 11 Product Warranty Statement 11 1 General GEW products are manufactured to the highest standards of mechanical and electrical reliability We support all our products with a comprehensive warranty We treat all warranty issues seriously and will respond promptly to their resolution 11 2 Installation and Commissioning It is essential that products are installed and commissioned correctly Warranty is valid only when an installation is performed by GEW engineers themselves An engineer from an approved GEW agent or distributor A certified GEW installer Please check with GEW if you have any doubts about who is installing your system 11 3 Warranty Validation Certificate WVC Each new system once commissioned is issued with a WVC this is dated and validates the warranty start date and system specific details Until this certificate is issued the warranty is not activated The warranty applies to the specific system at a specific location It is not transferable to other locations 11 4 Warranty terms The following applies unless different terms and conditions of warranty have been agreed and confirmed in writing Included a All new products are covere
26. 3 System Emergency stop 20 4 4 4 Contactor 20 4 4 5 Temperature amp cooling 20 4 4 6 Output protection 20 4 5 General Data 21 4 5 1 Electrical supply 21 4 5 2 Performance Ratings 21 4 5 3 Noise amp Vibration 21 4 5 4 Radiation 22 4 5 5 Gases Vapours Dust 22 4 6 Electrical Data 22 4 6 1
27. 9 2 Transport Handling Storage 10 2 1 Storage 10 2 2 Dimensions 10 2 3 Handling 11 3 Installation amp Commissioning 12 3 1 Fixing anchoring 12 3 1 1 Freestanding applications 12 3 1 2 Fitment of optional feet 13 3 1 3 Permanent Mounting 14 3 2 Space needed for use and maintenance 15 3 3 Environmental conditions
28. NET TYPE HV GEW EC Limited REDHILL Surrey RH1 5NB United Kingdom This equipment has been designed and manufactured in accordance with the following European standards EN12100 1 2003 Safety of Machinery Basic terminology methodology EN12100 2 2003 Safety of Machinery Technical principles EN1050 1997 Safety of Machinery Principles of risk assessment EN954 1 1997 Safety of Machinery Safety related parts of control systems EN60204 1 1998 Safety of Machinery Electrical equipment of machines EN61010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use EN61000 6 4 2001 Electromagnetic Compatibility Emission Standard for industrial environments EN61000 6 2 2001 Electromagnetic Compatibility Immunity for industrial environments EN60529 1992 Degrees of protection provided by enclosures PrEN1010 1 Safety of Machinery Safety requirements for the design and construction of printing and paper converting machines An operating manual and other technical data has been supplied with the equipment A technical construction file for this machinery is retained at GEW EC Limited NAME Mr M C Rae B Eng C Eng M I MECH E POSITION Managing Director Being the responsible person appointed by the manufacturer established in the EC and employed by GEW EC Limited Kings Mill Lane South Nutfield REDHILL Surrey RH1 5NB England GEW UV e Brick installati
29. Stand by power Press on speed Auto power 0Vdc Press speed 10Vdc Figure 1 Lamp output power curve The lamp output power is adjusted by 4 parameters Max power 0 100 This sets the maximum power supported by the lamp The value is a of the maximum power output of the e Brick For a 9kW e Brick a value of 80 limits the maximum power to 7 2kW GEW UV e Brick HMI software operating manual 5 of 18 Min power Standby 100 This sets the minimum power applied to the lamp when the shutters open The value is a of the maximum power output of the e Brick If max power were set at 7 2kW a value of 30 sets the minimum power to 2 16kW Burn in level 0 100 This is the power applied to the lamp when striking up This factory set value is a of the maximum lamp power For example 60 would represent 60 of the max power value if max power were 7 2kW and burn in 60 burn in power would be 4 3kW Stand by power 0 100 This is the power of the lamp when the shutters are closed This factory set value is a of the max power value For example 10 would represent 10 of the max power value if max power were 7 2kW and standby power 10 standby power would be 720W Press on speed 0 100 This is the speed at which the lamp power starts ramping up The value is a of the 0 10Vdc press speed signal for example 10 would represent 1Vdc Refer to Figure 1 for a graphical view of these parameters Notes Press on speed value is s
30. an cooling ducting and a human machine interface HMI to control the operation of the system Systems vary in complexity and the scope of supply differs depending on the application This manual should be referred to alongside the user manuals and installation information for the other components in the system 5 2 Manual controls The e Brick has no manual controls operation is controlled by the GEW system HMI In some applications an RS485 based serial data protocol may be implemented on the customers HMI 5 2 1 Configuration switches The e Brick has eight configuration DIP switches accessible by removing a cover plate on the rear of the product These switches are factory set and should not require further adjustment Default Setting DIP Switch Function Master Slave Last Slave 1 Master ON Slave OFF ON OFF OFF 2 HMI RS485 ON RS232 OFF OFF OFF OFF 3 HMI RS485 terminator ON OFF OFF OFF 4 HMI CANbus terminator ON OFF OFF OFF 5 e Brick network terminator ON ON OFF ON 6 GEW Service only ON OFF OFF OFF 7 Select 2 lamps ON OFF OFF OFF 8 p Brick ON OFF OFF OFF Master settings Slave settings Last slave furthest slave from master e Brick Key ON OFF GEW application specific GEW UV e Brick installation and operating manual 30 of 49 5 3 Setting and adjustment The e Brick requires no setting or adjustment after ins
31. anty 12 3 5 Fault finding guidelines 13 3 5 1 Warning indicators 14 3 5 2 General faults 14 3 5 3 Individual faults 15 3 6 HMI Flow chart 18 Figures Figure 1 Lamp output power curve 5 GEW UV e Brick HMI software operating manual 2 of 18 Document Issue Status Issue Date S w ECN Edited Checked Approved 1 0 29 Nov 2006 EC 1 0 0 HMI 1 0 0 BPB BJC GEW UV e Brick HMI software operating manual 3 of 18 1 Scope This document describes the user interface for the e Brick with a GEW TS8006 Colour LCD TouchScreen 2 Product Description The UV drying systems manufactured by GEW EC Limited are designed for the instantaneous drying of inks varnishes and adhesives that are sens
32. ariant Current phase A Supply cable size mm2 MCB rating A 3 6kW 20 4 20 9kW 20 4 25 12kW 25 4 25 22kW 57 16 63 Table 3 Supply connection specification Advice Every e Brick system is supplied with an electrical wiring diagram containing system specific installation information Advice Electrical installation standards vary worldwide and local regulations shall be observed 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 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 To validate the system warranty a system specific code must be entered on completion of installation and commissioning When a system has not been commissioned by GEW a message will appear on the HMI every 20 hours reminding the customer that the system is not under warranty SYSTEM NOT UNDER WARRANTY PLEASE CONTACT GEW TEL 44 0 1737 824510 To validate the warranty enter the password supplied by GEW service GEW UV e Brick installation and operating manual 17 of 49 3 5 2 Mod
33. at 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 approved calibrated test equipment Use only approved components during maintenance 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 28628 6 3 2 Safety devices Refer to section 4 4 for details of the safety devices designed in to the e Brick Advice If any safety feature is compromised or failure suspected always refer to GEW for service GEW UV e Brick installation and operating manual 35 of 49 6 4 Routine operator maintenance The e Brick forms part of a UV drying system which requires preventative maintenance operations in accordance with the schedule in section 10 6 4 1 Air filter cleaning replacement Warning Isolate power 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 filt
34. be insignificant in the context of the environment the product is installed in e Brick variant Fans Noise level dBA 1m 3 6kW 2 60 8dBA 9kW 2 60 8dBA 12kW 4 68 2dBA 22kW 6 71 7dBA Measured in open environment at 1m from air intake ambient noise level 48dBA GEW UV e Brick installation and operating manual 21 of 49 4 5 4 Radiation In normal use the e Brick generates electromagnetic radiation within allowable limits refer to 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 4 5 5 Gases Vapours Dust The e Brick power supply 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 Contactor Switch mode Converter Ignitor Embedded Control Press interface P1 Lamp output P3 UV monitor Shutters PT100 Chassis Power in
35. cations For freestanding use the shelf or surface should be stable and capable of bearing the full weight of the e Brick s and associated cabling Units may be stacked a maximum of four high using the location features on the top and base of the housing To ensure stability the carry handles act as fishplates to lock the units together see Figure 2 GEW UV e Brick installation and operating manual 12 of 49 Figure 2 Stacking 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 GEW UV e Brick installation and operating manual 13 of 49 3 1 3 Permanent Mounting For permanent mounting brackets must be attached to the housing using the T slots on the base of the unit Ensure that the mounting surface e g cabinet door print station side panel is sufficiently 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 manual 14 of 49 3 2 Space needed for use and maintenance The e Brick requ
36. chedule in section 10 Maintenance of the e Brick is limited to visual inspection of associated cabling for damage and replacement of air filters 9 1 1 Visual inspection Examine all cables associated with the UV drying system and confirm that cables conduit and connectors are in good condition 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 filter medium removed and replaced The procedure is illustrated in Figure 10 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 9 1 3 Exhaust filter change Warning Isolate power before changing or checking filters A coarse filter medium is used in the exhaust port this is unlikely to need changing unless it is contaminated in some way The procedure is illustrated in Figure 11 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 con
37. ck units are intact communications cables linking master slave slave slave carry the e Brick e stop links Fan failure The fan fails to operate when a lamp is started Check the electrical supply to the fan Check the MCB supplying power to the fan reset if necessary Check the thermal overload device on the fan If the switch has been tripped reset it by pressing 1 button on the switch housing then reset the fault on the touch screen On systems where an external air handling unit is used in place of the GEW system fan this fault may show if the cooling air pressure does not reach a predetermined threshold within 90s of starting the cooling system System Safety Switch Check the functionality of the system safety switch Check integrity of wiring and connectors for the system safety switch GEW UV e Brick HMI software operating manual 14 of 18 3 5 3 Individual faults Burn in failure The lamp burns in until it reaches a certain operating voltage and running temperature If the lamp does not reach this voltage within 4 minutes or achieve temperature within 10 minutes then the lamp will trip and the burn in failure will appear This type of failure usually occurs if the lamp is overcooled Check that orange damper unit is operating correctly Check the supply voltage is within the operating voltage range of the e Brick and fan as specified on the rating plate Flo
38. d as soon as the printing machine is started impression on In automatic mode power is applied progressively once the printing machine is running Full preset power to the lamps is achieved when the speed reaches the percentage shown under the yellow icon Thus if the percentage is specified as 50 then full power to the lamps will be achieved when the speed of the printing machine has reached half full speed This percentage value can be adjusted using the numeric keypad that appears when the value is touched on the screen Set the new percentage then press the enter key on the keypad to confirm the value 3 4 4 Switching off Lamps may be switched off globally or individually To switch lamps off globally press the red button To switch off a lamp individually simply deselect it touch and hold the appropriate lamp number on lamp selection screen for two seconds then release it The background then changes colour to indicate deselection The delay helps to avoid unintentional deselection of lamps Warning When the final lamp has been switched off the fan s will continue to run on for five minutes allowing the lamp heads to cool down Advice When the fans have stopped running switch off the mains isolator to each control unit then switch off the mains supply GEW UV e Brick HMI software operating manual 10 of 18 3 4 5 Configuration Shutter test Lamp change function Customer access to Production Profiles Cons
39. d 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 in advance b Products installed by unapproved personnel c Products modified or adjusted in any way d Products moved or relocated to other locations after issue of the original WVC e Parts subject to fair wear and tear f All glass components g Damage to power supplies and control by the use of non GEW spare lamps h Damage caused by products not maintained according to our instruction manual i Any consequential loss howsoever caused GEW UV e Brick installation and operating manual 48 of 49 GEW UV e Brick installation and operating manual 49 of 49 11 5 Making a Claim 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 11 6 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
40. dling limits and if necessary use lifting equipment Refer to section 5 8 for details of recommended Personal Protective Equipment The e 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 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 11 of 49 3 Installation amp Commissioning During installation and throughout the working life of the UV system observe the following Avoid knocking or banging the e Brick or UV dryers Always keep service cables and ducting away from busy areas such as walkways and away from potential hazards such as forklifts When moving the equipment never strain cables or unscrew quick release plugs Apply power to the system only when all connections have been made and tested Note Illustrations show the 9kW e Brick 12 and 22kW products 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 appli
41. e Low Voltage Directive 89 336 EEC 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 Basic terminology methodology EN12100 2 2003 Safety of Machinery Technical principles EN1050 1997 Safety of Machinery Principles of risk assessment EN954 1 1997 Safety of Machinery Safety related parts of control systems EN60204 1 1998 Safety of Machinery Electrical equipment of machines EN61010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use EN61000 6 4 2001 Electromagnetic Compatibility Emission Standard for industrial environments EN61000 6 2 2001 Electromagnetic Compatibility Immunity for industrial environments EN60529 1992 Degrees of protection provided by enclosures PrEN1010 1 Safety of Machinery Safety requirements for the design and construction of printing and paper converting machines GEW UV e Brick installation and operating manual 29 of 49 5 Product application 5 1 Intended use of the e Brick 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 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 f
42. e 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 Internal fuses Warning Fuses are not user serviceable GEW authorised personnel should carry out replacement Mains input Model Rating GEW 9 12kW 25A 38mm 10mm ceramic fuses size HRC 25621 22kW 63A MCB and Residual Current Device RCD User accessible on rear panel of product 25160 25161 3 6kW 20A 38mm 10mm ceramic fuses size HRC 27469 Internal supplies Model Rating GEW HV DC 3 6 9 12kW 2A Anti Surge TR5 PCB mounted 27266 HV DC 22kW 600V 2A 31 75mm 6 35mm Rapid F ceramic fuse 27265 LV DC 4A PolySwitch thermal fuse PCB mounted N a Shutter motor 1A PolySwitch thermal fuse PCB mounted N a GEW UV e Brick installation and operating manual 19 of 49 4 4 2 Indicators The e Brick has three LED indicators on the rear panel 24V is green when the internal 24V supply is on K1 is green when the main contactor in the e Brick is enabled the third LED OK is green in normal operation but red when a fault occurs 4 4 3 System Emergency stop The e Brick can only be enabled if the system em
43. ection Signal name Rating connection 9 12kW 3 6kW 22kW A1 A1 A1 L1 A2 B1 L2 A3 C1 L3 A2 N Mains supply input for ratings see Table 5 L1 L3 amp N connections NOT SELV Frame Frame Frame PE B1 B1 F1 Fan_healthy B2 B2 F2 Fan_healthy_rtn Volt free contact input from press Also available on P7 B3 B3 F3 Auxiliary_n o B4 B4 F4 Auxiliary_n o_rtn Volt free auxiliary n o contact output Contact rating 1A 24Vdc 120Vac B5 B5 F5 Auxiliary_n c B6 B6 F6 Auxiliary_n c_rtn Volt free auxiliary n c contact output Contact rating 1A 24Vdc 120Vac B7 B7 F7 Chiller_OK B8 B8 F8 Chiller_OK_rtn Volt free contact input from chiller 4 6 3 6 Protective Earth terminal An M6 stud is provided on the rear 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 P60 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 HMI_Comms_Tx RS232 to HMI or RS485 4 HMI_Comms_Rx RS232 from HMI or RS485 5 Ext_CAN CANbus interface for customer 6 Ext_CAN CANbus interface for customer 7 HMI_Comms_rtn 0V for communications E P60 Communications port Slave in Pin connection Signal name Slave Rating connection 1 gCAN GEW CANbus
44. ents in the system 2 1 Related documentation 2 1 1 GEW Product manuals Document Title VCP user manual ECP user manual NUVA user manual TouchScreen HMI Software manual 2 1 2 European EN Standards Standard Title EN12100 1 2003 Safety of Machinery Basic terminology methodology EN12100 2 2003 Safety of Machinery Technical principles EN1050 1997 Safety of Machinery Principles of risk assessment EN954 1 1997 Safety of Machinery Safety related parts of control systems EN60204 1 1998 Safety of Machinery Electrical equipment of machines GEW UV e Brick HMI software operating manual 4 of 18 3 Human Machine Interface The e Brick Human Machine Interface HMI has been designed for maximum ease of use A single HMI screen enables monitoring and controlling of up to 16 lamps in a system For a graphical overview of the HMI structure please refer to section 3 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 standard USB cable 3 2 Safety features The HMI forms part of the safety features of the e Brick UV drying system and should only be operated by suitably trained personnel Advice If any safety feature is compromised or failure suspected always refer to GEW for service 3 3 Output power curve for e Brick system Lamp Power Max power Set point adjustable Min Power
45. er checks and changes for reference in the event of a warranty claim see section 10 1 for a suggested format 6 5 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 do not remove covers under any circumstances Please note that if factory security seals are broken the warranty is void Should any fault occur the alarm pop up appears on the HMI and the fault code is recorded on the fault screen Figure 9 Icons are defined in sections 6 5 1 and 6 5 2 below Figure 9 Typical Alarm Warning and Fault History screens GEW UV e Brick installation and operating manual 36 of 49 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 operator may have triggered an emergency stop of the printing machine Check external emergency stop e stop circuitry and switches Check panel circuit breakers in external equ
46. ergency stop E stop contacts on the Press connector P1 are closed enabling the internal safety relay The internal controls monitor the E stop status using auxiliary contacts on the safety relay as a safety measure the relay can still disable the supply in the 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 is enabled from the HMI screen 4 4 5 Temperature amp cooling Fan failure detection Generates warning to HMI Internal temperature warning Generates warning to HMI Over temperature trip Automatic shutdown of e Brick 4 4 6 Output protection Voltage limit Output voltage is limited to a specified maximum Current limit Output current is limited to specified maximum Short circuit protection Output circuitry will tolerate an indefinite short circuit Warning 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 4 5 General Data 4 5 1 Electrical supply
47. et to 0 for most systems This function is available to the press operator for greater flexibility The maximum power of each lamp can be limited by adjusting the set point parameter for each lamp see set power level screen The ramp can be adjusted individually by using the speed parameter for each lamp see set power level screen Advice e Brick power output is linear with no preset power steps GEW UV e Brick HMI software operating manual 6 of 18 3 4 Using the HMI 3 4 1 Starting up the UV system Initialisation When switching on the printing machine the operator should Ensure three phase or if applicable single phase supply is available Switch on the mains isolators for each e Brick or print station cabinet Most e Brick systems will have electric shutters but for dryers with pneumatic shutters switch on the compressed air supply After initialising 30s delay the touch screen should display the GEW logo Press anywhere on the logo to display lamp information The first column indicates lamp selection transparent lamp deselected solid green lamp selected The second column indicates the detected lamp type UV lamp cassette IR lamp cassette The third column is a bargraph display of the lamp power and current status transparent lamp off flashing yellow burn in Voltage flashing amber burn in temperature flashing g
48. full power for five minutes before attempting to remove or open any lamp head then proceed with caution Operators should always be vigilant NEVER use flammable solvents near the UV dryers when the lamps are in operation If a fire should break out follow the procedure posted for the building Only fire extinguishers of the dry powder type should be used on this equipment 5 6 1 6 High voltages Warning UV lamps operate at high voltages typically 450V to 1400V depending on lamp type additionally when striking the lamps ignitor circuitry will generate pulses in excess of 2kV These voltages present a possible danger of electric shock or fire Do not mount other equipment 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 identification and repair Warning There are no user serviceable parts inside the e Brick do not remove covers under any circumstances Please note that if factory security seals are broken the warranty is void Refer to GEW or your local agent for service 5 8 Personal Protective Equipment Due to their weight it is advisable to wear safety shoes when installing e Brick p
49. ght section of the panel is used to set the global relationship between the power of the lamps and the speed of the printing machine the left side is used to set individual lamps Touch any value to change it having entered a new power or speed level confirm it with the enter key on the pop up keypad Set individual lamps Set all lamps Press Speed Lamp power GEW UV e Brick HMI software operating manual 9 of 18 Lamp power controls Whether power level is set globally or individually the controls look the same In each display the left hand control sun icon is for pre setting the maximum lamp power The right hand control motor icon sets the relationship between the speed of the printing machine and lamp power Refer to Set speed power relation paragraph below for a full explanation Preset lamp power Lamp power is indicated by a percentage simply press the value and type in a new one using the numeric keypad When the printing machine is started up the actual power levels rise to their preset values either immediately or progressively depending on the selection of manual or automatic mode Set speed power relation Manual Automatic Two operating modes are available manual or automatic A red icon with a crossed out motor symbol indicates manual mode A yellow motor icon indicates automatic mode Touching the icon toggles between the two modes In manual mode preset power is reache
50. if the e Brick does not sense the lamp cassette in the chassis Check electrical connections between the e Brick and the lamp head Check the lamp chassis is fully inserted in the lamp head ensure that the plug to the lamp head is fully engaged If no fault found try reinserting the affected chassis restart the system and reselecting lamps Other warnings Some applications may have additional fault codes refer to the specific software users manual for explanations of other fault codes GEW UV e Brick installation and operating manual 40 of 49 6 6 Parts list 6 6 1 Recommended spares Item GEW part number Notes Intake filter medium 10485 Filter insert Exhaust filter medium 24504 Filter insert 3 6 9 12kW Exhaust filter medium 25392 Filter insert 22kW GEW UV e Brick installation and operating manual 41 of 49 7 End of life information GEW products are designed for reliability and will with regular preventive maintenance provide a long service life However in future the host press system and ancillary equipment such as the UV system may become surplus to requirement and will need to be dismantled or disposed of 7 1 De commissioning dismantling and disposal Warning Isolate power before dismantling the UV system Warning Before dismantling a UV system refer to section 5 6 on hazards Having isolated the mains power the equipment may be dismantled by unplugging connectors
51. ifications Each GEW UV system is engineered to meet the requirements of a given installation Any change in requirements may require re commissioning or modification of the system always refer to GEW 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 broken or damaged the GEW warranty will be void Figure 6 Tamper evident seal 3 5 4 Location of equipment The user should ensure that no electrical controls are obstructed Always site equipment to allow reasonable access for servicing The installer should ensure that clearances around the equipment fall within the safety regulations for use of electrical equipment Impact from vehicles such as forklift trucks must be prevented typically by installing a protective crash barrier This is the responsibility of the customer Loose cables between distribution panels the printing machine and the UV dryers must be protected by galvanized trunking This is the responsibility of the customer 3 6 Waste removal amp disposal Refer to Table 4 for information on recycling e Brick packaging materials Standard Packaging Material Recycle me
52. ipment Check e stop links between e Brick units are intact communications cables linking master slave slave slave carry the e Brick e stop links Fan failure The fan fails to operate when a lamp is started Check the electrical supply to the fan Check the MCB supplying power to the fan reset if necessary Check the thermal overload device on the fan If the switch has been tripped reset it by pressing 1 button on the switch housing then reset the fault on the touch screen On systems where an external air handling unit is used in place of the GEW system fan this fault may show if the cooling air pressure does not reach a predetermined threshold within 90s of starting the cooling system System Safety Switch Check the functionality of the system safety switch Check integrity of wiring and connectors for the system safety switch 6 5 2 Individual faults Burn in failure The lamp burns in until it reaches a certain operating voltage and running temperature If the lamp does not reach this voltage within 4 minutes or achieve temperature within 10 minutes then the lamp will trip and the burn in failure will appear This type of failure usually occurs if the lamp is overcooled Check that orange damper unit is operating correctly Check the supply voltage is within the operating voltage range of the e Brick and fan as specified on the rating plate Flow switch fai
53. ires little maintenance following installation but clearance is required to allow adequate cooling of the internal electronics Allow the following clearances see Figure 5 gt 500mm from the air intake gt 300mm from the exhaust outlet gt 25mm 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 3 6kW 300 9kW 475 12kW 900 22kW 1500 Table 2 Power dissipation Figure 5 Installation clearances GEW UV e Brick installation and operating manual 15 of 49 3 3 Environmental conditions 3 3 1 Temperature Operating temperature range is 5 C to 40 C 3 3 2 Humidity Relative Humidity RH lt 50 at 40 C non condensing 3 3 3 Altitude To a maximum of 1000m above mean sea level 3 3 4 Contaminants Filters are provided to protect the e Brick against moisture and dust ingress to IP32 in accordance with EN60529 3 3 5 Vibration shock 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 Electromagne
54. is running Check electrical connections between the e Brick and the lamp head Check the shutter mechanism for ink build up If necessary clean with isopropyl alcohol Check micro switches Check for mechanical jam A Shutter test can be performed while the lamps are off but selected on the HMI Press the shutter test icon to the left of the HMI This will drive the shutter to the fully open position Press the icon once more to close the shutters If a fault occurs 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 open Check that shutters open and that the micro switch is released Press the shutter test icon A hiss of air should be heard with the selected lamps the shutters should then close Check shutters position and that the micro switch is activated Check inside the interface box to confirm that the tubes carrying compressed air to the lamp head are intact Damper Failure A fault warning is logged if the damper cable is not connected or the damper is more than 10 out from the requested position for more than 30 second
55. itive to ultra violet UV light A typical web colour printing press comprises several printing stations in line each station applying ink of a different colour The ink printed on the first station must be thoroughly dry before entering the second station to avoid contaminating the press A drying unit containing a high power UV lamp is located between print stations The web passes through a web slot in the drier and travels past the lamp UV drying is effectively instantaneous allowing the press to be run at high speed An extra drying unit may be located at the end of the web for drying varnish applied after the final printing 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 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 Systems vary in complexity and the scope of supply differs depending on the application all systems require commissioning by trained personnel This manual should be referred to alongside the user manuals and installation information for the other compon
56. l systems where a Volt free contact input is specified the externally connected equipment should be interfaced by a relay capable of switching 24Vdc at lt 0 5A Applying voltages to these inputs may cause serious damage to the e Brick and invalidate the GEW warranty 4 6 3 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 3 6 9 12kW or P5 A C 22kW interfaces are SELV it is recommended that connections are only made to equipment that complies with the SELV safety classification Certain ports may exceed SELV voltages 30VDC 60Vrms within the specified ratings shown in 4 6 3 1 to 4 6 3 9 GEW UV e Brick installation and operating manual 23 of 49 P1 P6 P7 only fitted on master e brick P8 P6 P7 LED K1 24V OK DIPswitch cover plate P5 P60 P1 P8 only fitted on Profibus master e brick P2 P4 P3 Figure 7 Rear panel connection details P1 P7 P8 24V P1 amp P7 only fitted on master P8 only fitted on Profibus master e brick PE K1 P6 P2 P4 P3 P5 Figure 7 a Rear panel 22kW Master connection details GEW UV e Brick installation and operating manual 24 of 49 4 6 3 1 P1 Press interface Pin connecti
57. lure Cooling water supply to the lamp head has failed Check that water cooling is on Check that all the hoses are connected to lampheads and cooler Ensure that all valves are set to the open position The water flow through the switch may be insufficient check water hoses for kinks and blockages GEW UV e Brick installation and operating manual 37 of 49 PSU failure A fault has been detected within the e Brick Check 3 phase supply is on and that all three phases are available Check 24V LED is illuminated if not then internal 24Vdc may be faulty Check K1 LED illuminates when lamp is selected Ensure that the lamp 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 PSU drive fault A fault has been detected within the e Brick control circuitry Switch off power to the affected e Brick Restore power and attempt to restart lamp If fault continues to appear call GEW for service Lamp failure No current flow was detected through the lamp Warning When resolving a lamp failure it is important to let the lam
58. n the e Brick and the lamp head Check the shutter mechanism for ink build up If necessary clean with isopropyl alcohol Check micro switches Check for mechanical jam A Shutter test can be performed while the lamps are off but selected on the HMI Press the shutter test icon to the left of the HMI This will drive the shutter to the fully open position Press the icon once more to close the shutters If a fault occurs 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 open Check that shutters open and that the micro switch is released Press the shutter test icon A hiss of air should be heard with the selected lamps the shutters should then close Check shutters position and that the micro switch is activated Check inside the interface box to confirm that the tubes carrying compressed air to the lamp head are intact Damper Failure A fault warning is logged if the damper cable is not connected or the damper is more than 10 out from the requested position for more than 30 seconds Check electrical connections between the e B
59. netic Compatibility Emission Standard for industrial environments EN61000 6 2 2001 Electromagnetic Compatibility Immunity for industrial environments EN60529 1992 Degrees of protection provided by enclosures PrEN1010 1 Safety of Machinery Safety requirements for the design and construction of printing and paper converting machines 1 1 3 British Standards Reference Title BS7671 2001 Requirements for Electrical Installations IEE Wiring Regulations Sixteenth Edition 1 1 4 Guidance notes Reference Title URN04 1106 UK Government Department of Trade and Industry Product Standards Electrical Equipment implementing the Low Voltage Directive URN95 650 UK Government Department of Trade and Industry Product Standards Machinery GEW UV e Brick installation and operating manual 8 of 49 1 1 5 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 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 installati
60. on Signal name Rating connection A1 Station_ready A7 Station_ready_rtn Volt free relay output to press Contact rating 1A 24Vdc 120Vac A4 Fan_start A10 Fan_start_rtn 24VDC relay output to drive fan contactor coil also available on P7 B1 E stop B2 E stop_rtn Volt free contact input from press A5 Fan_healthy A11 Fan_healthy_rtn Volt free contact input from press Also available on P7 A6 Speed 0 10V speed signal from press ISO A12 Speed_rtn 0V reference for press speed signal ISO A2 Ready A8 Ready_rtn Volt free relay output to press Contact rating 1A 24Vdc 120Vac A3 Fault A9 Fault_rtn Volt free relay output to press Contact rating 1A 24Vdc 120Vac B3 HMI_Comms_rtn 0V for communications B4 Ext_CAN_rtn 0V ISO for Canbus interface B5 HMI_Comms_Tx RS232 to HMI or RS485 B6 HMI_Comms_Rx RS232 from HMI or RS485 B7 Ext_CAN CANbus interface for customer B8 Ext_CAN CANbus interface for customer B9 Aux 24V 200mA maximum thermally fused output B10 Impression B11 Impression_rtn Volt free contact input from press B12 0V 0V reference for e Brick 4 6 3 2 P2 Communications port out P2 Communications port Master amp Slave Pin connection Signal name Rating connection 1 gCAN GEW CANbus 2 gCAN GEW CANbus 3 E stop 4 E stop_rtn Volt free safety relay ou
61. on and operating manual 6 of 49 1 Product Description The UV drying systems manufactured by GEW EC Limited are designed for the instantaneous drying of inks varnishes and adhesives that are sensitive to ultra violet UV light A typical web colour printing press comprises several printing stations in line each station applying ink of a different colour The ink printed on the first station must be thoroughly dry before entering the second station to avoid contaminating the press A drying unit containing a high power UV lamp is located between print stations The web passes through a web slot in the drier and travels past the lamp UV drying is effectively instantaneous allowing the press to be run at high speed An extra drying unit may be located at the end of the web for drying varnish applied after the final printing 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 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 Systems vary in complexity and the scope of supply
62. on and operating manual 9 of 49 2 Transport Handling Storage 2 1 Storage The standard packaging comprises a sealed polythene bag with silica gel pack to protect against condensation due to temperature variation the e Brick is fitted with preformed protective end caps and placed in a tri wall cardboard container which provides transit and storage protection A number of e Brick packages may be palletised for ease of handling during shipment 22kW products are packed in a sealed polythene bag with 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 Length mm Width mm Height mm Weight kg 3 6kW 535 440 440 15 9kW 760 440 440 26 12kW 1010 440 440 37 e Brick product e Brick variant Length mm Width mm Height mm Weight kg 3 6kW 400 280 275 12 9kW 625 280 275 22 5 12kW 875 280 275 33 22kW 875 560 275 85 GEW UV e Brick installation and operating manual 10 of 49 2 3 Handling Warning e Brick units can be heavy gt 25kg so should be handled with care to avoid injury Observe your company s manual han
63. p cool before attempting to restart the system Check all electrical connections relating to the lamp Check the physical state of the lamp change the lamp if it has operated for gt 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 Safety switch failure On systems with lamp heads mounted on hinged brackets this alarm will indicate that the lamp head has been hinged open Check that the lamp is firmly seated in the outer casing Check that the lamp head is closed hinged head If this fault occurs with the lamp head hinged closed then check the alignment of the interlock arm with the interlock switch at the front of the lamp head Lamp over temperature The lamp head overheats Overheating may be caused by problems in the lamp head Advice Let the lamp cool down before re striking Check that the fan is running and that its rotation is correct Check that the damper operates normally check for air blockage Check flexible ducting for obstructions Check electrical connections between the e Brick and the lamp head Check the lamp chassis is fully inserted in the lamp head ensure that the plug to the lamp head is fully engaged GEW UV e Brick installation and operating manual 38 of 49 Shutter failure Shutter failure while the printing machine
64. printing machine the lamp shutters will open and lamp power will be controlled in accordance with the preset parameters Monitor the lamps To monitor the state of all lamps on a single screen touch the 1 to 16 icon to display the monitor screen The screen shows a numbered icon for each available lamp the colour of the icons is significant The first column indicates lamp selection transparent lamp deselected solid green lamp selected The second column indicates the detected lamp type UV lamp cassette IR lamp cassette The third column displays the lamp power and current status transparent lamp off flashing yellow burn in voltage flashing amber burn in temperature flashing green ready with shutter closed solid green lamp on with shutter opened solid blue cooling solid red faulty lamp To return to the lamp selection screen touch or 1 to 8 on the monitor screen Note that the button will turn off all the lamps Screen Saver To prolong the life of the LCD screen and backlight the HMI will display a Screen Saver message if it is not touched for ten minutes and shortly afterwards a blank screen Touching the screen or any key will restore the display immediately Selection Lamp type UV or IR Status and Power GEW UV e Brick HMI software operating manual 8 of 18 3 4 2 Selecting lamp
65. put P5 24V DC Supply Auto Damper P4 EMC Filter Fan interface P7 Optional Profibus Interface P8 Comms out P2 Comms HMI in P6 P60 GEW UV e Brick installation and operating manual 22 of 49 4 6 2 Interface details Refer to sections 4 6 3 1 to 4 6 3 9 for connection details for P1 to P8 on the e Brick Figure 7 shows the positions of the connectors on the rear panel for the 3 6 9 12kW products Connectors are arranged differently for the 22kW e Brick refer to Figure 7 a P1 P2 P4 P6 P7 P8 are identical P5 Power input and P3 Lamp output are functionally identical but have larger connectors and terminal inserts to handle higher voltages and currents Please note the following Note These connections apply to e Brick products with embedded control electronics 29328 29355 3 6kW 28496 28497 9kW 28524 28525 12kW and 9 12 22kW derivatives Refer to e brick user manual rev2 1 for 26365 amp 26366 12kW 26367 26368 amp 26391 9kW 25158 amp 26790 22kW and derivatives of these models Refer to issue 1 0 of this manual for connection details of 23326 amp 23329 12kW 24101 24104 amp 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 externa
66. ransfer it to a cardboard box or other expendable container To protect the refuse operator put the container in a thick plastic bag Dispose of the bagged container with the normal industrial waste or in accordance with local arrangements for disposal of mercury 5 6 1 3 Ultra Violet Radiation UVR Warning Ultra violet radiation UVR is harmful to skin and eyes UV dryers have adequate shielding fitted to prevent accidental exposure of the operator to UVR but it is essential to take care when operating the UV drying system UVR is present in the ranges UV A UV B UV C and UV V Observe the following Ensure that the shielding is kept in place at all times and is properly adjusted Do not look directly into the lamp head while the lamp is on Avoid prolonged exposure of your hands in the area along the light shields Wear protective clothing and eye protection if prolonged exposure is unavoidable GEW UV e Brick installation and operating manual 33 of 49 5 6 1 4 Moving parts Warning Cooling fans are supplied with inlet and outlet ports uncovered take care when fitting ducting to these ports Fans should never be run with ports uncovered this may cause injury by ejecting loose objects at high speed or trapping the hands 5 6 1 5 High temperatures Warning Hot surfaces and electrical energy can cause fires to break out High temperatures occur inside the UV dryer Allow the dryer to cool from
67. reen ready with shutter closed solid green lamp on with shutter opened solid blue cooling solid red faulty lamp Select lamps Select the required lamps or accept the existing selection as described in 3 4 2 Preset power levels Preset the power levels of the selected lamps globally or individually as described in 3 4 3 Lamp hours Lamp hours for each lamp are displayed by pressing the H icon on the lamp information screens Two hour counts are maintained total system hours run and a resettable hour count for each lamp The hours run can be reset by pressing the hours figure A message reset lamp hour will then appear as shown The operator has to confirm by pressing Y to clear the figure Press N to cancel Status and Power Selection Lamp type UV or IR GEW UV e Brick HMI software operating manual 7 of 18 Start the lamps When the required lamps have been selected and their power levels have been preset press the green button to start them The exhaust fans will start up and a coloured bar will be displayed for each lamp the colour of the bars is significant transparent lamp off flashing yellow burn in Voltage flashing amber burn in temperature flashing green ready with shutter closed solid green lamp on with shutter opened solid blue cooling solid red faulty lamp Start running Start the
68. rick 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 HMI software operating manual 16 of 18 PT100 Thermocouple failure A fault warning is logged if the lamp cable is not connected if the PT100 fails or if the temperature reaches its top range Check electrical connections between the e Brick and the lamp head Check the lamp chassis is fully inserted in the lamp head ensure that the plug to the lamp head is fully engaged Replace PT100 if failure is suspected Note The system will still run with this warning present Warning Prolonged running with a PT100 warning may cause serious damage to lamps or lamp head components Communication Failure If a communication failure is detected with an e Brick slave more information is now available on the HMI 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 fault found try restarting system and reselecting lamps If necessary deselecting affected slave e Brick will allow system to run Chassis Fault This error message occurs if the e Brick does not sense the lamp cassette
69. roducts Warning Other protective equipment may be required while installing an e Brick system If necessary consult your local Health and Safety representative for advice 5 9 Training required Although designed for ease of installation GEW systems should be installed and commissioned by GEW service technicians Alternatively some customers and OEMs have their own GEW trained personnel Please contact GEW Customer Service for information on installation training for your GEW UV system GEW UV e Brick installation and operating manual 34 of 49 6 Maintenance information Warning There are no user serviceable parts inside the e Brick do not remove covers under any circumstances Please note that if factory security seals are broken the warranty is void Refer to GEW or your local agent for service 6 1 Safety inspections The e Brick forms part of a UV drying system which requires inspection operations in accordance with the schedule in section 10 6 2 Functional Testing The e Brick forms part of a UV drying system which requires functional testing in accordance with the schedule in section 10 6 3 Specialist inspection amp repair For attention of GEW EC Limited service department Warning Danger of electric shock or death Observe the following during service operations Isolate the unit from the mains before attempting maintenance removing covers cables or light shielding Ensure th
70. s 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 PT100 Thermocouple failure A fault warning is logged if the lamp cable is not connected if the PT100 fails or if the temperature reaches its top range Check electrical connections between the e Brick and the lamp head Check the lamp chassis is fully inserted in the lamp head ensure that the plug to the lamp head is fully engaged Replace PT100 if failure is suspected Note The system will still run with this warning present Warning Prolonged running with a PT100 warning may cause serious damage to lamps or lamp head components Communication Failure If a communication failure is detected with an e Brick slave a warning is displayed on the HMI Check Fault screen to identify which e Brick has failed to communicate Check electrical connections to the affected slave GEW UV e Brick installation and operating manual 39 of 49 Check 24V LED is illuminated if not then internal 24Vdc may be faulty Check K1 LED illuminates when lamp is selected If no fault found try restarting system and reselecting lamps If necessary deselecting affected slave e Brick will allow system to run Chassis Fault This error message occurs
71. s This is only true when the system is in local mode as described in 3 4 5 Advice During start up the UV System recalls its last working state and to save time will automatically select those lamps by default Note that it is not possible to select or deselect a lamp when the press is running Interchanging an UV IR lamp will automatically deselect this lamp Lamp type Most systems are UV lamp heads only A number 1 to 16 identifies each UV lamp head In case of an UV and IR system IR following the station number identifies an IR lamp head The selection between UV and IR type is done automatically when the lamp chassis is fitted to the casing Select amp deselect The buttons on the lamp selection screen show the available lamp number on a coloured background white lamp deselected green lamp selected Select a lamp press the appropriate lamp number the background changes to green to indicate a successful selection Deselect a lamp touch the appropriate lamp number for two seconds release it and the background changes colour The delay helps to avoid unintentional deselection of lamps 3 4 3 Setting power levels This is only true when the system is in local mode as described in 3 4 5 Global Settings Power levels may be set globally same level for every selected lamp or individually To set a global or individual lamp power level first press the globe button The ri
72. sidered skilled and shall be carried out by GEW service technicians or engineering personnel GEW UV e Brick installation and operating manual 45 of 49 10 UV System Maintenance Schedule Advice To ensure consistent performance GEW UV drying systems should be inspected at the intervals shown in the following schedule more frequent checks may be necessary depending on operating conditions 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 Maintenance Item Check Clean Replace Frequency hours General Drain air regulator pneumatic shutters only X 40 Straighten flexiduct X 40 Check air filters on Lamphead Heatsink Cabinet grilles amp apertures X 500 Check reflector cassette for dust build up X 500 Check and replace all air inlet filter media X X 1000 Check integrity of all cables connectors and ducting X 1000 Check all connectors for evidence of contact wear or damage X 2000 UV Lamp Remove lamp chassis from lamphead clean as required Cold filter where fitted UV lamp amp reflector use Isopropyl alcohol Heat sink base amp 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
73. tallation all functions are controlled by the GEW system HMI A number of HMI software packages are available refer to the relevant software manual for full details A typical HMI setting screen is shown in Figure 8 Lamp selected Lamp power Hour counter Lamp type Change all lamps Set relationship between press speed and lamp power e g 50 would give full power at 50 of maximum press speed Figure 8 Typical HMI settings screens Using these screens the user is able to select a lamp set the required power level set the power ramping and monitor lamp service hours Warning During commissioning application specific parameters may be entered by the installation technician In normal use and to maintain the system warranty preset parameters shall not be altered without referring to GEW GEW UV e Brick installation and operating manual 31 of 49 5 4 Stop functions including emergency stop The e Brick or an e Brick based system may be stopped in three of ways Stop method Initiation e Brick Response System Emergency stop E stop External system opens E stop contact inputs to master e Brick Automatic breaking of e Brick E stop loop to deselect all slave lamps Lamps will be switched off instantaneously System cooling correctly controlled System communications will remain functional allowing quicker restart Electrical isolation Switching off individual e Brick
74. thod Cardboard outer container Corrugated tri wall cardboard Cardboard recycling facilities exist in most areas Moulded end cap Stratocell 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 4 Recycling standard packaging GEW UV e Brick installation and operating manual 18 of 49 4 Product information 4 1 Description of the e Brick The e Brick is a highly integrated power supply designed specifically for powering GEW 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 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 4 3 Prohibited usages All applications other than those specifically detailed in 4 2 above ar
75. tic compatibility The e Brick is designed to comply with the relevant EMC legislation for industrial installations EN61000 6 4 2001 EMC Emission Standard for industrial environments EN61000 6 2 2001 EMC Immunity for industrial environments GEW UV e Brick installation and operating manual 16 of 49 3 4 Connection to power supply Warning A qualified electrician must make the connection to the mains supply The 9 12 22kW e Brick requires a 3 Phase mains supply with a Protective Earth connection 3P E note that no neutral connection is made The 3 6kW e Brick requires a single phase mains supply with a Protective Earth connection All variants require 1 Permanently installed wiring fed by a suitably rated Miniature Circuit Breaker MCB to protect each phase of the incoming mains supply cable and allow isolation of an individual e Brick For North America and Canada Moulded Case Circuit Breakers MCCB shall be used for branch circuit protection 2 A suitably rated supply disconnection device to allow isolation of the mains supply to the e Brick installation It is recommended that this shall be easily accessible by the operator 3 4 1 Essential electrical installation data Refer to Table 3 for peak mains supply current suggested minimum supply cable cross sectional area and MCB ratings for e Brick product variants These recommendations are in accordance with BS7671 2001 Table 4D2A reference method 11 e Brick v
76. tions 18 3 5 3 Markings and tamper evident seals 18 3 5 4 Location of equipment 18 3 6 Waste removal amp disposal 18 4 Product information 19 4 1 Description of the e Brick 19 4 2 Applications 19 4 3 Prohibited usages 19 4 4 Safety features 19 4 4 1 Internal fuses 19 4 4 2 Indicators 20 4 4
77. tput to E stop input on next slave e Brick Contact rating 1A 120Vac 3A 24Vdc 5 GEW_RS232_TxD 6 GEW_RS232_RxD Factory use only 7 gCAN_rtn GEW CANbus E GEW UV e Brick installation and operating manual 25 of 49 4 6 3 3 P3 Lamp output Pin connection Signal name Rating connection 3 6 9 12kW 22kW A1 A1 Lamp A2 B1 Lamp C1 C1 Shutter_Motor C2 C2 Shutter_Motor C3 C3 24V 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 PhotoD C12 C12 PhotoD B1 B2 B3 B4 B5 B6 B7 B8 B9 PT100 B10 PT100_rtn B11 PhotoD B12 PhotoD 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 1 24V Auto damper 24V supply 2 0V Auto damper 0V return 3 Control_voltage_0 0 10V output to damper 4 Damper_feedback_0 0 10V feedback from damper 5 Flow_OK Volt free contact input from flow switch water cooled applications only 6 Control_voltage_1 0 10V output to damper 7 Damper_feedback_1 0 10V feedback from damper E GEW UV e Brick installation and operating manual 26 of 49 4 6 3 5 P5 Power input Pin conn
78. umable parts list for system and GEW Warranty validation screens Service technician access to Configuration and Commissioning screens Shutter multi function key to left of touch screen Four symbols are displayed under the index page a This icon displays the impression status b This icon shows the shutter status shutter symbol changes from open to closed c This button toggles between local and remote mode In local the GEW screen drives the system while in remote it is the manufacturer screen that controls the system this feature may not be available on all systems d These icons show the press interface Ready and Fault signal status Speed shows the current 0 10V press speed signal as a percentage Shutter multi function key This key performs two functions When the system is not running this key will open close all shutters If the system is running this button operates the shutter of all de selected lamps allowing a quick change of lamp without stopping the press a c b d 3 4 6 Production profiles This screen is used to store and retrieve up to 10 production profiles The operator can create and select profiles Lamp power and auto power ramp settings are listed for each station Profiles can be downloaded or uploaded to from the UV system Upload Download Select stored create new profile Save profile GEW UV e Brick HMI software operating
79. w switch failure Cooling water supply to the lamp head has failed Check that water cooling is on Check that all the hoses are connected to lampheads and cooler Ensure that all valves are set to the open position The water flow through the switch may be insufficient check water hoses for kinks and blockages PSU failure A fault has been detected within the e Brick Check 3 phase supply is on and that all three phases are available Check 24V LED is illuminated if not then internal 24Vdc may be faulty Check K1 LED illuminates when lamp is selected Ensure that the lamp 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 PSU drive fault A fault has been detected within the e Brick control circuitry Switch off power to the affected e Brick Restore power and attempt to restart lamp If fault continues to appear call GEW for service Lamp failure No current flow was detected through the lamp Warning When resolving a lamp failure it is important to let the lamp cool before attempting to restart the system

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