GEW e-Brick 9kW Installation instructions

GEW UV DRYING SYSTEM
e -Brick
INSTALLATION & OPERATING MANUAL
…engineering UV
GEW (EC) Limited
Kings Mill Lane, South Nutfield
REDHILL, Surrey RH1 5NB, England
Telephone: [phone] Fax: [phone]
Spares & Service telephone: [phone]
[email protected]
www.gewuv.com
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Table of Contents
1. Product Description ................................................................................................................... 6
1.1. Related documentation....................................................................................................... 7
1.1.1. GEW Product manuals................................................................................................ 7
1.1.2. European (EN) Standards ........................................................................................... 7
1.1.3. British Standards ......................................................................................................... 7
1.1.4. Guidance notes ........................................................................................................... 7
1.1.5. North American & Canadian Standards ...................................................................... 7
1.1.6. Symbols used.............................................................................................................. 8
2. Transport, Handling, Storage..................................................................................................... 9
2.1. Storage ............................................................................................................................... 9
2.2. Dimensions......................................................................................................................... 9
2.3. Handling ........................................................................................................................... 10
3. Installation & Commissioning................................................................................................... 11
3.1. Fixing / anchoring ............................................................................................................. 11
3.1.1. Freestanding applications ......................................................................................... 11
3.1.2. Fitment of optional feet.............................................................................................. 12
3.1.3. Permanent Mounting ................................................................................................. 13
3.2. Space needed for use and maintenance.......................................................................... 14
3.3. Environmental conditions ................................................................................................. 15
3.3.1. Temperature.............................................................................................................. 15
3.3.2. Humidity .................................................................................................................... 15
3.3.3. Altitude ...................................................................................................................... 15
3.3.4. Contaminants ............................................................................................................ 15
3.3.5. Vibration, shock and bump........................................................................................ 15
3.3.6. Electromagnetic compatibility.................................................................................... 15
3.4. Connection to power supply ............................................................................................. 16
3.4.1. Essential electrical installation data........................................................................... 16
3.4.2. Residual current devices ........................................................................................... 16
3.5. General recommendations ............................................................................................... 17
3.5.1. Installation ................................................................................................................. 17
3.5.2. Modifications ............................................................................................................. 17
3.5.3. Markings and tamper evident seals........................................................................... 17
3.5.4. Location of equipment ............................................................................................... 17
3.6. Waste removal & disposal ................................................................................................ 18
4. Product information.................................................................................................................. 19
4.1. Description of the e -Brick ............................................................................................... 19
4.2. Applications ...................................................................................................................... 19
4.3. Prohibited usages............................................................................................................. 19
4.4. Safety features .................................................................................................................19
4.4.1. Internal fuses............................................................................................................. 19
4.4.2. Indicators................................................................................................................... 20
4.4.3. System Emergency stop ........................................................................................... 20
4.4.4. Contactor................................................................................................................... 20
4.4.5. Temperature & 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 & Vibration....................................................................................................... 21
4.5.4. Radiation ................................................................................................................... 22
4.5.5. Gases, Vapours, Dust ............................................................................................... 22
4.6. Electrical Data .................................................................................................................. 22
4.6.1. Block diagram............................................................................................................ 22
4.6.2. Interface details ......................................................................................................... 23
4.6.3. SELV ports ................................................................................................................ 25
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4.6.4. OPTION: Gravure purge hardware ........................................................................... 29
4.7. Conformity ........................................................................................................................ 30
5. Product application .................................................................................................................. 31
5.1. Intended use of the e -Brick............................................................................................. 31
5.2. Manual controls ................................................................................................................ 31
5.3. Setting and adjustment..................................................................................................... 31
5.4. Stop functions including emergency stop ......................................................................... 32
5.5. Sequence of operation ..................................................................................................... 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 & repair ........................................................................................... 35
6.3.1. Firmware update ....................................................................................................... 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..................................................................................................... 37
6.5.1. General faults ............................................................................................................ 37
6.5.2. Individual faults.......................................................................................................... 38
6.6. Parts list............................................................................................................................ 41
6.6.1. Recommended spares .............................................................................................. 41
7. End of life information .............................................................................................................. 42
7.1. De-commissioning, dismantling and disposal................................................................... 42
8. Emergency information............................................................................................................ 43
8.1. Fire fighting....................................................................................................................... 43
8.2. Potential hazards.............................................................................................................. 43
9. Maintenance procedures ......................................................................................................... 44
9.1. Unskilled ........................................................................................................................... 44
9.1.1. 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................................................................................................ 48
11.1. General .........................................................................................................................48
11.2. Installation and Commissioning .................................................................................... 48
11.3. Warranty Validation Certificate ( WVC )........................................................................ 48
11.4. Warranty terms ............................................................................................................. 48
11.5. Making a Claim ............................................................................................................. 48
11.6. Purchase of spare parts................................................................................................ 49
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Figures
Figure 1: T-slot detail showing carry handles ................................................................................. 10
Figure 2: Stacking ........................................................................................................................... 11
Figure 3: Fitment of optional feet .................................................................................................... 12
Figure 4: Cabinet mounting............................................................................................................. 13
Figure 5: Installation clearances ..................................................................................................... 14
Figure 6: Tamper evident seal ........................................................................................................ 17
Figure 7: Rear panel (Master) connection details ........................................................................... 23
Figure 8: Typical HMI settings screens........................................................................................... 31
Tables
Table 1: Glossary of symbols used................................................................................................... 8
Table 2: Power dissipation.............................................................................................................. 14
Table 3: Supply connection specification........................................................................................16
Table 4: Supply connection specification (22kW for Canada/USA) ................................................ 16
Table 5: Recycling standard packaging .......................................................................................... 18
Table 6: Electrical supply data ........................................................................................................ 21
Table 7: Performance data ............................................................................................................. 21
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Document Issue Status
Issue Date ECN Edited Checked Approved Notes
0.1 26 April 2005 BPB BCW First draft
0.2 13 July 2005 BPB MPG Second draft
1.0 26 July 2005 BPB MPG NJR First release
2.0 12 October
2005
0176 BPB LEF NJR Revised connector
designations; minor
corrections and additions.
2.1 28 March 2006 0312
0359
BPB Added 22kW e -Brick
information; minor
corrections and additions.
2.2 12 January
2007
0459
0605
BPB Remove 220V
references, change HV
DC fuse type.
UL related updates
2.3 19 November
2007
0816 BPB Further UL updates:
fuses and labelling
2.4 14 November
2008
1032 BPB PJB Minor corrections and
amendments
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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 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.
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1.1. Related documentation
1.1.1. GEW Product manuals
Document Title
GEW e-System Lamp Change Manual
GEW e -Brick Touchscreen 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
EN60204-1:2006 Safety of Machinery – Electrical equipment of machines
EN61000-6-4:2007 Electromagnetic Compatibility – Emission Standard for
industrial environments
EN61000-6-2:2005 Electromagnetic Compatibility – Immunity for industrial
environments
EN60529:1992 Degrees of protection provided by enclosures
EN1010-1:2004 Safety of Machinery – Safety requirements for the design and
construction of printing and paper converting machines
1.1.3. British Standards
Reference Title
BS7671:2008 Requirements for Electrical Installations
IEE Wiring Regulations Seventeenth 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
1.1.5. North American & Canadian Standards
Reference Title
NFPA79:2002 Electrical Standard for Industrial Machinery
UL508 Standard for Industrial Control Equipment
SPE-1000-99 Model Code for the Field Evaluation of Electrical Equipment
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1.1.6. Symbols used
The following markings are used on GEW e -Brick products and system components:
Symbol Reference Description
ISO7000 – 0434 Caution, risk of danger.
Note: Documentation must be consulted
in all cases where this symbol is marked
Caution, risk of electric shock
IEC 60417 – 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
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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)
9kW 760 440 440 26
12kW 1010 440 440 37
e -Brick product
e -Brick variant Length (mm) Width (mm) Height (mm) Weight (kg)
9kW 625 280 275 22.5
12kW 875 280 275 33
22kW 875 560 275 85
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2.3. Handling
Warning! e -Brick units can be heavy (>25kg) so should be handled with care to avoid injury.
Observe your company’s manual handling 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 the 9kW
e -Brick, 22kW products have four carry handles; always use all
handles when lifting the product.
C of G
Figure 1: T-slot detail showing carry handles
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