GEW UV DRYING SYSTEM

OPERATING MANUAL

ISSUE 1.1 – JANUARY 2006

GEW (EC) Limited

Kings Mill Lane, South Nutfield
REDHILL, Surrey RH1 5NB, England
Telephone: +44 (0)1737 824500 Fax: +44 (0)1737 823822
Spares & Service telephone: +44 (0)1737 824510
www.gewuv.com [email protected]
GEW UV DRYING SYSTEM OPERATING MANUAL

VCP TOUCH SCREEN CONTROLLER VERSION

TABLE OF CONTENTS

EC Declaration
General
Safety Precautions
Cabinets
Installation
Touch Screen Controller
Error Diagnostics - Touch Screen
Maintenance Schedule
VCP Lamp Change
Product Warranty Statement

GEW UV system operating manual Issue 1.1 – January 2006 Table of Contents - page 1 of 1
 GEW (EC) Limited
Kings Mill Lane, South Nutfield, REDHILL, Surrey RH1 5NB, England
Tel: +44 (0)1737 824500 Fax +44 (0)1737 823822
Tel: +44 (0)1737 824510 (Spares & Service only)
[email protected] www.gewuv.com

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 93/68/EEC and ELECTROMAGNETIC
COMPATIBILITY DIRECTIVE 89/336/EEC.

Machinery Description Manufacturer

UV DRYER, TYPE VCP, ECP, HCP GEW (EC) Limited
UV DRYER, TYPE NUVA, NUVAplus REDHILL
Surrey
CONTROL CABINET, TYPE e-Brick 3.6kW,
9kW, 12kW, 22kW and derivatives RH1 5NB
United Kingdom
CONTROL CABINET, TYPE p-Brick
CONTROL CABINET, TYPE HV

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 system operating manual Issue 1.1 – January 2006 EC Declaration - page 1 of 1
GENERAL
INTRODUCTION
The UV drying systems by GEW (EC) Limited are manufactured for the instantaneous drying of the
kind of inks, varnishes and adhesives that are sensitive to ultra violet light.
A typical web colour printing press comprises several printing stations in line, each applying ink of
a different colour. The ink printed on the first station must be thoroughly dry before entering the
second, and so on. The drying units, with a UV lamp in each, are located between printing
stations. The web passes through a `web slot' in the drier and travels past the lamp. Drying under
the UV drying unit 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.
In each lamphead is a pneumatically operated shutter. Whilst the press is running the shutter
remains open. When production stops the shutter closes to prevent UV radiation damaging the
articles being dried.

REFLECTORS
Behind the UV lamp in the lamphead of each unit is either a reflector with a bright aluminium
surface or a reflector with a dichroic surface – according to the model of drying unit. The dichroic
reflecting surface absorbs infra-red radiation whilst reflecting ultra-violet light to the substrate.
Compared with a standard aluminium reflector, the dichroic reflector gives a 50% reduction in heat
and 5% increase in UV.

UV LAMPS
The web passes through slots in the sides of the drying unit - which is built to accommodate a UV
lamp of power and length appropriate to the type of application and the web width of the printing
press.

GEW UV system operating manual Issue 1.1 – January 2006 General - page 1 of 3
CROSS SECTIONS

WEB

(shutter closed) (shutter open)

Cross section of lamphead

CABINETS
Control cabinets of the UV drying systems vary in size depending on the kind of control system
supplied and the number and power of the lampheads fitted. The cabinets employed are:
• Upright cabinet. Multi-lamp systems, with anything from one to four lampheads, can be
powered from one upright cabinet. The cooling fan is mounted on a separate frame.
• ‘Power Brick’ stackable unit. Each Power Brick may be built to drive one or two lamps.
The cooling fan is mounted on a separate frame.
Systems with as many lampheads as needed can be achieved by employing multiple cabinets.

CONTROLLERS
Each GEW UV drying system employs either a Touch Screen Control or a Text Panel Interface.
Refer to the chapter of this manual that describes your particular type of controller for details.
The system is powered electrically by a three-phase mains supply connected to an isolator switch
mounted in the cabinet and controllable from outside the cabinet.
The system also requires a supply of clean and dry compressed air at a pressure of 5 bar for
driving the shutter. The air supply must be piped from a compressor – which is not supplied as
part of the system.

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The control cabinet is connected to each lamphead by a flexible conduit of 25 mm diameter. The
conduit carries the air line and electrical cables. The air line provides power for opening and
closing the pneumatic shutter. A pair of HT cables provides electrical power to the UV lamp. A
third cable carries the LT signals from sensors in the lamphead to the control cabinet.
In all systems cooling air is drawn through the lampheads via flexible ducting by the fan.
The warm air is expelled either to the outside air or into the work space. Expulsion to the outside
air requires rigid ducting – the ducting being supplied by the customer. Expulsion into the work
space requires an ozone filter fixed to the fan.
Common to all systems is an independent temperature controller, which electronically maintains
the temperature of the lamphead at an optimal level by adjusting the air flow. The temperature is
set by the factory and needs no further adjustment.

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SAFETY PRECAUTIONS
Important safety precautions are described in this chapter. Please read it carefully.

HANDLING
During installation and throughout the working life of the UV system, take care with handling.
Observe the following:
• Avoid knocking or banging the lamphead or its controller.
• Always keep service cables and ducting away from busy areas such as walkways, and
away from potential hazards such as fork lifts.
• When moving part of the equipment, never strain cables, and never unscrew quick release
plugs.

CLEANING
Whilst following the procedures set out in the maintenance schedule in this manual, observe the
following general points on cleaning:
• Keep the lamphead clean. Do not allow dust to build up.
• Turn off the lamp and allow it to cool before any cleaning solvents are used near the
lamphead.

HAZARDS
Safety of the equipment at every stage of the design process has been carefully considered by the
designer, but certain hazards remain because of the nature of the application. These are hazards
associated with ozone, mercury, ultra violet radiation (UVR), moving parts, high temperatures, and
high voltages. Operators should be aware of such hazards and guard against them.

Ozone (O3)
Ozone is generated by the UV lamp and carried away with the exhaust air, through ducting to the
outside air, or to an ozone filter discharging into the factory air. Ozone irritates the lungs. If you
detect a pungent smell of ozone, check the ducting for air tightness.
At all times ensure that the ducting is sound, and that it remains in place and intact. If ozone filters
are fitted, ensure they are changed according to the maintenance schedules set out in this manual.

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Mercury (Hg)
UV lamps contain small quantities of mercury, which is a toxic substance to be handled carefully.
Wash hands thoroughly after handling UV lamps. Dispose of broken lamps safely by the following
means:
Put on heavy gloves (rubber or other impervious variety).
• Cover the mercury and broken glass with sand.
• Collect the waste mixture with dustpan and brush, and transfer it to a cardboard box or
other expendable container.
• To protect the refuse operator, put the 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.

Ultra violet radiation

Ultra violet radiation (UVR) is harmful to skin and eyes.
The equipment is shielded to reduce UVR emissions to safe levels. Ensure that the shielding is
kept in place at all times and is properly adjusted. Do not look directly into the lamphead 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.
Adequate shielding is fitted to prevent accidental exposure of the operator to UVR, but take care
when operating the unit. Radiation is present in the ranges UV-A, UV-B, UV-C.

Electric shock
Electrical potentials of more than 6,000 volts are present in the unit, representing possible danger
of electric shock or fire. All access to the unit is `safety secured.' Isolate the unit from the mains
before attempting maintenance.
• Only a qualified electrician should carry out electrical work on the unit. If in doubt, contact
the supplier.
• Isolate the unit from the mains before making any attempt to remove covers, cables, or light
shielding.
• Ensure that the capacitors have been discharged be leaving the system switched off for 5
minutes before carrying out any maintenance.
• Do not mount other equipment so that it could interfere with the safe operation of the
system. When testing or trouble shooting, all high voltage safety circuits must be left in
place.

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Physical danger
Take care when fitting ducting to the inlet and outlet ports of the fan. The rotating fan is initially
supplied with its inlet and outlet ports uncovered. The fan should never be run with ports
uncovered, in which condition it could cause injury by ejecting loose objects at high speed or
trapping the hands.
High temperatures occur inside the lamphead. Allow the dryer to cool from full power for about
twenty minutes before attempting to remove or open any lamphead.

Fire
Hot surfaces and electrical energy can cause fires to break out. Operators should always be
vigilant. NEVER use flammable solvents near the lampheads when the lampheads 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.

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CABINETS
This chapter defines leading dimensions of control cabinets of the ‘upright cabinet’ and the ‘Power
Brick’ cabinet types.

UPRIGHT CABINET
The overall dimensions of the upright cabinet are indicated in the figure below. All dimensions are
in millimetres.

Remove front and rear

panels when moving
cabinet with forklift truck

Power switch
The power switch is located on the front of the upright cabinet. It is indicated by the letter A on
the sketch.

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Handling
When it is necessary to relocate the upright cabinet it may be moved by fork-lift truck or similar
lifting device.
Remove the bottom front and rear cover and move the forks to the maximum width that will allow,
to fit between the cabinet feet.

Lifting by fork lift

Alternatively the upright cabinet may be moved by crane. There are lifting holes located in the top
surface of the cabinet at its four corners.

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POWER BRICK CABINET
The overall dimensions of the Power Brick cabinet are indicated in the figure below. All
dimensions are in millimetres.

Power switch
The power switch is located on the front of the Power Brick cabinet. It is indicated by the letter A on
the sketch.

Handling
To move a cabinet by fork lift truck, remove the front and rear panels of the plinth base of the
cabinet. Carefully insert the forks. Place wooden blocks on top of the forks to prevent damage to
paint work. Ensure the blocks are placed so that they pick up the front and rear bars of the cabinet.

Lifting by fork lift

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INSTALLATION
User's Requirements
The system must be installed initially by the supplier's qualified engineers. It is then commissioned
according to the user's requirements.
Each system is designed to meet a user's particular requirements. Modifications to those
requirements may demand re-commissioning or modifications to the system. The supplier must be
informed of proposed modifications before making changes to the system.

Locating Plant
The user should ensure that no electrical controls are obstructed. The user should also ensure that
clearances around the equipment fall within the safety regulations for use of electrical equipment.
Impact from vehicles such as fork lift trucks must be prevented - typically by installing a crash
barrier.

Lifting Plant
Refer to the chapter titled CABINETS for important information about handling cabinets by their
lifting eyes. Information is also given about transporting cabinets by fork lift or pallet truck.

Mains Power
Provide cables of a size adequate to meet the rating shown on the cabinet. The connection into the
supplier's cabinet must be made by a qualified electrician. Each cabinet must be individually
isolated with circuit breakers protecting the supply. Take care to tighten all power-terminal screws.

Cabinet Terminals
Because vibrations can loosen terminal screws during transit, always check the cabinet terminals
individually after transit.

Fan Connections
When connecting the fans, ensure that each has the correct direction of rotation. The correct
direction is indicated by an arrow on the fan. If the direction is incorrect, reverse it by exchanging
two of the three phases connected to the fan. Where the electrical supply to two fans is supplied
from a single cabinet, make any necessary reversal from the fan terminal box. Do not run the fans
in free air as this will cause the motors to overheat and burn out.

Control Circuit Fuse

Control circuit fuse protection is indicated on the wiring diagrams supplied. Depending on the
number of lampheads in the system, protection will be either by 6A circuit breaker or by integral 2A
fuse at the control transformer.

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Press Interface
On power brick cabinets, the plug identified “press interface” at the rear of the cabinet contains the
interface connections. See the wiring diagram supplied. On all other types of cabinet a 6X twisted
pair cable is provided for interface. See the wiring diagrams supplied.

Safety Connections
Safety rated contacts from the safety circuit of the printing machine must be wired into the control
cabinet. These are shown on wiring diagrams supplied. When these contacts are open, power to
both the lamp and the fan is removed. The system is re-set when the safety system of the main
printing machine is re-set.

Compressed Air
Connect the pressure regulator to an air supply that has a pressure of less than 10 bar. Set the
GEW supplied pressure regulator to 5 bar. Ensure the air supply is not contaminated with oil or
water.

Ducting to Atmosphere
Ensure that the dimensions of the exhaust duct are big enough to prevent the build-up of back
pressure, which would restrict the flow of air. The maximum allowable back pressure is 250
pascals measured at the fan outlet. Ducting must be airtight from the fan to the outside of the
building. Ducting must be made of galvanized mild steel, PVC or stainless steel. Seek professional
advice about the installation of ducting, particularly in multi-lamp systems in which manifold
exhausts are used. This is the responsibility of the customer.

Control Cabinets
Control cabinets must be sited such as to allow access for servicing from the front, and at any time.

Interconnecting
Trailing cables between the control cabinet and the printing machine, and Cables between the
control cabinet and the lampheads, should be protected by galvanized trunking. This is the
responsibility of the customer.

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Water cooling
Systems that require water cooling use a chiller unit to keep the water at a predetermined
temperature. The chiller is designed for operation within the indicated operating limits. These limits
apply to new systems and those that have been correctly installed and maintained. An
anticorrosion additive must be added to the water and antifreeze must also be added if the chiller
unit is to be positioned outside. The anticorrosion additive is initially supplied with the chiller. For
further information refer to the maintenance schedule at the back of this manual and also the
separate chiller manual.

DIFFICULTIES
If you experience difficulties in setting up the system, contact the supplier at the address given at
the front of this manual. If in doubt, ask! We are always ready to help.

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TOUCH SCREEN CONTROLLER (TSC)
INTRODUCTION
The TSC is an electronic colour screen, sensitive to touch, for operating the UV drying system. The
touch screen should be located where it is easily accessible by the operator of the printing
machine.
The TSC can handle up to sixteen lamps, numbered 1 to 16 and by touching ‘buttons' on the
screen you can select which lamps are to be active. A single screen monitors the overall status of
all lamps in the system.
This chapter explains how to switch on the basic equipment, set the power levels of the UV lamps,
switch individual lamps on or off and how to interpret and reset faults should any arise.

FLOW DIAGRAM
The following flow diagram summarizes the effects of pressing the various buttons.
Each grey arrow on the diagram points to the screen that will appear if you press the button
Indicated.
KEY TO FLOW DIAGRAM
A Current lamp selection - Touch arrow
again to display next four lamps.
B Lamp fault indicator screen - Displays
icons indicating faults, the RESET
button will reset every lamp.
C System overview - The # indicates
stepped power level as a number from
1 to 5. Vari-power is indicated as a
percentage. A higher percentage than
standby is displayed when burning in;
Blinks slowly when the lamp is ready;
Steady when lamp operating.
D STOP selected lamps.
E START selected lamps.
F Raise or lower the lamp power level.
G Raise or lower the machine speed.
H Set lamps globally: Same power level
for every lamp.
I Set lamps individually.

Note: Pressing the ‘Return’ button always takes you back to the main screen.

GEW UV system operating manual Issue 1.1 – January 2006 Touch Screen Controller - page 1 of 6
STARTING UP
Main switches When switching on the printing machine, the operator should:
• Switch on the compressed air supply.
• Ensure three-phase supply is available.
• Switch on the mains isolators for each control cabinet.
The touch screen should now display the GEW logo. Press anywhere on
the logo to display the details of the first four lamps:

Stepped Power display Vari-Power display

Select lamps Select the lamps you require - or accept the existing selection - as
described below under ‘Selecting Lamps.'
Preset power levels Preset the power levels of the selected lamps, either all together or
individually - as described below under ‘Setting Power Levels.'
Lamp hours Lamp hours for each lamp are displayed beneath the preset power level
column. The hours run can be reset by pressing and holding the hours
figure for approximately 2-3 seconds.

Start the lamps When the required lamps have been selected, and their power levels
have been preset, press the green button (labelled 1) to start them. The
exhaust fans will start up. For each selected lamp, the output power is
displayed as a bar graph (Stepped Power display) or as a number in
percent (Vari-Power display).
The green bar rises to Level 3 (Stepped Power display) or 60-100% (Vari-
Power display) and flashes rapidly as the lamp burns in. After 90 seconds
the power level drops to its stand-by value (level 1 for stepped power
display or 20-30% for Vari-Power display) and the green bar flashes
slowly.
Start running Start the printing machine running, the shutters in the lamp houses then
open and the green bars now indicate actual power levels and cease to
flash.

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Monitor the lamps To monitor the state of all lamps on a single screen, touch the green
button labelled 12 3 4 5 6 7 8. The monitor screen appears as shown:

The screen shows a numbered button for each of the 16 lamps. The
colour of each button is significant:
• Buttons for lamps switched on, and operating normally,
show green.
• Buttons for lamps that have faults are shown red.
• Buttons representing lamps unselected, or switched off, are
transparent (same colour as the background).
Note: Numeric values have been replaced by the symbol ‘<00’ in the
examples. In the case of a Stepped Power unit, they represent the
power level (1–5); in the case of a Vari-Power unit, they represent the
percentage power. In either case, the display indicates the power level
of the corresponding lamp. The indication of power level has three
visible states:
• A flashing percentage, higher than the stand-by level, is
displayed during burning in.
• Flashing slowly, indicates lamp burnt in - ready for use
• Steady, to indicate a lamp that is operating.

To revert to the lamp-selection screen, touch the return button .

In the case of a lamp fault that can be rectified without further
diagnosis (for example an overheated lamp that has now cooled down)
simply press the Reset button, then restart the system in the normal
way. Note: Always check Fault Screen before resetting any
undiagnosed fault.

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SELECTING LAMPS
Lamp numbers Each lamp-selection screen handles up to four lamps. The screens
shown in the example are for handling lamps numbered 1-4. To
select a lamp in the range 5-8, press the right arrow and press it
again to display lamps 9-12. The effect of arrow keys is depicted in
the flow diagram.
This is a ‘circular’ list, thus moving left from 1-4 by touching the left
arrow displays lamps 9-12, and so on.
Select & deselect At the top of the lamp-selection screen is a row of buttons, each
showing a lamp number on a white or green background. A white
background indicates an unselected lamp; a green background
indicates a selected lamp. To select a lamp, press the appropriate
lamp number. The white button containing that number then turns
green to indicate a successful selection.
To deselect a lamp, touch and hold the appropriate lamp number
for two or three seconds or until the background turns from green
to white. The delay is designed to avoid unintentional deselecting.
When the UV System is shut down, the system ‘remembers’
which lamps are selected and during the next start up, the
previous selection is maintained.

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SETTING POWER LEVELS
Global Settings Power levels may be set globally - the same level for every selected
lamp - or they may be set individually.
To set a global level, first press the globe button. The screen for the
global power setting appears. Having preset the power level, touch the
magenta button labelled OK. If the given values are acceptable the OK
button changes colour to confirm.

Stepped Power display Vari-Power display

Individual settings To set the power level for an individual lamp, touch the green power-
level indicator or percentage for that lamp. The screens for pre-setting
power levels for an individual lamp is shown below.

Stepped Power display Vari-Power display

Lamp power controls Whether power level is set globally or individually, the control buttons
look the same. In each display, the left-hand box of controls is for pre-
setting the maximum lamp power level. The right-hand control box is
to do with the speed of the printing machine as described later.

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Preset lamp power In the case of stepped power, preset lamp power is measured on a
scale of 1 to 5, as depicted by the red bar in the left-hand control box.
In the case of Vari-power, lamp power is indicated by a percentage.
To increase the preset power level, press the ‘+’ button; Press the ‘-’
button to decrease the power level.
When the printing machine is started up, the actual power levels rise
to their preset values immediately or progressively according to
whether you specify manual mode or automatic mode.
Modes Manual mode is indicated in the right-hand control box by a red icon
depicting a motor with a cross through it. A yellow icon depicting the
motor without a cross through it indicates automatic mode. Touching
the icon makes it toggle between the two modes.
Speed of printing The right section of the panel is used to set the relationship between
Machine the power of the lamps and the speed of the printing machine. When
in manual mode, full power is reached as soon as the printing
machine is started. The green bars represent actual power level and
rapidly rise to their respective preset maximum.
Manual mode is indicated on the screen by an icon depicting a motor
crossed out. The numerical value (expressed as a percentage)
beneath the icon is not relevant in manual mode, nor are the plus and
minus buttons.
In automatic mode, power is applied progressively once the printing
machine has been started up. 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 ‘+’ and ‘-’ buttons.
Set the new percentage; then press the Enter button to confirm the
value.
Note: Percentage value/adjustment is only relevant in automatic mode
(when the yellow icon is displayed).

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ERROR DIAGNOSTICS - TSC
Warning lights A Power-On light is situated on the front of every control unit. If it fails
to illuminate:
• Check the incoming power supply.
• Check fuses on control lines.
If the power light illuminates, but the fan or cooling unit fails to run
when the lamps are started:
• Check the fan motor circuit breaker. If the breaker has
tripped, reset it by pressing the black button on the switch
housing and resetting on touch screen. The switch is
located inside the control cabinet. Call GEW if this action
fails to start the fan.
• Check the MCB (Miniature Circuit Breaker) supplying
power to the cooling unit. Reset if necessary.
Lamp fault indicator If a fault occurs with a lamp unit, the touch screen will indicate the
following:
When in stepped power mode, a red cross appears under the
corresponding lamp number on the lamp selection screen.
When in vari-power mode, a percentage is shown on a red
background.
In both cases, by pressing the Alarm button (Bell icon), the fault
diagnosis screen will appear:

For each lamp marked with a red cross (or 0% on a red background)
the corresponding column of the fault diagnosis screen shows one or
more icons. Each icon denotes one of the faults listed below:

• Emergency stop

GEW UV system operating manual Issue 1.1 – January 2006 Error Diagnostics – TS - page 1 of 5
 • Communications fault
• Cooling fault
• Water supply fault
• Shutter failure
• Overheating Lamp failure
• Lamp failure
• Air pressure failure
• Fan failure
• Burn in failure
• Transformer failure
• Safety interlock
• Overheating cabinet failure
If the fault can be rectified without further diagnosis (e.g. an
overheated lamp that has now cooled down) then pressing the green
‘Reset’ button will reset the fault. Then press the red ‘Return’ button
to display the main screen to restart the system.
Emergency stop The safety circuit has tripped:
• Check external emergency-stop circuitry.
• Check panel circuit breakers.
• Check emergency-stop links between the UV cabinets.
Communications fault Communication between cabinets has stopped:
• Check that all cabinets are switched on and that PLC’s are
in RUN mode.
• Check interconnecting cable for damage and loose
connections.
Cooling fault The cooling unit has failed whilst the printing machine is running, or
some other fault has occurred in the control cabinet.
• Check the cooling unit control panel to see if the cooling
system has developed a fault. If it has, see the appropriate
appendix of this manual for diagnosis and remedy.
Water supply fault Cooling water to the lamphead has failed.
• Check that all the hoses are connected to lampheads and
cooler.
• If all valves are set to open position.
• Check water hoses for kinks.

GEW UV system operating manual Issue 1.1 – January 2006 Error Diagnostics – TS - page 2 of 5
Shutter failure Shutter failure while the printing machine is running.
• Check that the LT Signals plug is fully engaged.
• Initiate a shutter test by pressing the yellow ‘Spanner’
button, followed by the yellow ‘Shutter Control’ button in
the centre of the management screen. You should hear a
hiss of air, the shutters should then click open and remain
open. Check inside the cabinet to confirm that the tubes
that carry compressed air to the lamphead are intact.
• Check that the shutter mechanism is clean and free from
ink build-up.
Overheating/Interlock The temperature controller displays ‘Open’.
• Check between controller and lamphead, including the LT
Signals plug.
The lamphead overheats, or a lamphead safety interlock is open.
Overheating may be caused by problems in the lamphead:
• Check the lamp chassis is fully inserted in the lamphead.
• Check that the lamphead is fully lowered - and that the
roller actuator of the safety switch is extended.
• Check that the LT Signals plug to the lamphead is fully
engaged.
• Check the operation of the exhaust fan.
• Check flexible ducting for obstructions.
• Initiate a shutter test - If the UV lamp is switched off, the
shutter concerned will now open.
• Check the pneumatic shutter mechanism for ink build-up -
Clean, if necessary, with isopropyl alcohol.
• Check inside the lamphead for compressed air leaks.
Lamp failure When attending to lamp failure it is important to let the lamp cool
before attempting a restart.
• Check all electrical plug connections.
• Check lamp MCB’s in the control cabinet, reset any that
have tripped.
• If a lamp has operated for more than about 1,000 hours,
change it. Instructions for changing the lamp are given in
the chapter titled REPLACING THE UV LAMP.
• Check lamp cable connections in the lamphead.

GEW UV system operating manual Issue 1.1 – January 2006 Error Diagnostics – TS - page 3 of 5
 • If you fit a new lamp, and the new lamp fails, call GEW.
Air pressure failure This alarm will activate if the pressure of the compressed air supply
falls below 4 bar whilst the printing machine is running.
• Check the pressure reading on the gauge on the pressure
regulator in the control cabinet - Set the pressure to 5 bar.
• Drain the bowl in the pressure regulator of any water.
• When the shutters close, check that the air pressure does
not fall more than 1 bar.
• Check for compressed air leaks in the lamphead.
Fan failure The fan fails to operate when a lamp is started or some other fault
occurs with the control cabinet.
• Check the electrical supply to the fan.
• Check the overload switch to the fan. If the switch has
been tripped, reset it by pressing the black button on the
switch housing, then reset the fault on the touch screen.
Call GEW if this action fails to start the fan.
Burn in failure On transformer control systems the lamp burns in until it reaches a
certain voltage.
If the lamp does not reach this voltage within five minutes then the
lamp will trip and the burn in failure will appear on the TSC.
This failure usually occurs if the lamp is receiving too much cooling.
• Check that orange damper unit is operating correctly.
• Check in coming voltage is the same as the system set up
voltage. This is found on the GEW rating plate.
Transformer On transformer control systems if the main transformer overheats then
over temperature this failure will appear on the TSC.
• Check the cabinet filters are clean from dust and dirt.
• Check that the cabinet fans are working correctly.
• Check that the air drawn into the cabinet is not warm air
from another device.
Safety interlock On systems with lampheads that are mounted to hinged brackets, this
alarm will indicate once the lamphead is hinged open.
• If this fault occurs with the lamphead hinged closed then
check the alignment of the interlock arm with the interlock
switch at the front of the lamphead.

GEW UV system operating manual Issue 1.1 – January 2006 Error Diagnostics – TS - page 4 of 5
Cabinet over On all systems, the cabinet may overheat in the event of a failure in
temperature the cooling system.
• Check in coming voltage is the same as the system set up
voltage. This is found on the GEW rating plate.
• Check cabinet cooling fans and filters, clean if necessary.

SWITCHING OFF
Lamps may be switched off together or individually. To switch them
off altogether, press the red button (0) at the bottom of any lamp-
selection screen. To switch off a lamp individually, simply deselect it.
Pressing the button for the corresponding lamp and holding two to
three seconds will do this; after which the buttons’ background will
change from green to white. The delay is imposed to guard against
lamps being deselected inadvertently.
When the final lamp has been switched off, the fan(s) will continue to
run on for approximately ten minutes, allowing the lamphead to cool
down.
When the fans have stopped running, switch off the mains isolator to
each control unit. Finally, switch off the mains supply.

GEW UV system operating manual Issue 1.1 – January 2006 Error Diagnostics – TS - page 5 of 5
MAINTENANCE SCHEDULES
GENERAL MAINTENANCE
DESCRIPTION OF PROCEDURE FREQUENCY (HOURS RUN)
Check/Drain air regulator 40
Check/Straighten flexiduct 40
Check air inlet filters fitted to:
• lamphead 500
• heat sink 500
• cabinet 500

• air inlet grilles & apertures 500

Check reflector cassette for dust build-up 500

Check and replace all air inlet media 1,000
Check Cables/Tubes for integrity 1,000

UV LAMP
DESCRIPTION OF PROCEDURE FREQUENCY (HOURS RUN)
Remove lamp chassis from lamphead 500
Clean / cold filter (if fitted) 500
Clean reflector (isopropyl alcohol) 500
Clean UV lamp (isopropyl alcohol) 500
Clean heat sink base 500
Clean shutter 500
Replace UV lamp if drying performance is impaired 1,000
Check cables to lamp/terminals 2,000
Lubricate shutter pivots (PTFE/silicone lubricant) 2,000
Check micro switch operation 2,000
Inspect all plug connectors 2,000

GEW UV system operating manual Issue 1.1 – January 2006 Maintenance schedule - page 1 of 2
CABINET
DESCRIPTION OF PROCEDURE FREQUENCY (HOURS RUN)
Clean or replace cabinet filter 500
Clean out dust 500
Check all terminals, tighten if necessary, report if terminals appear burnt 4,000
Check cabinet cooling fan 4,000

FAN
DESCRIPTION OF PROCEDURE FREQUENCY (HOURS RUN)
Check duct inlet 40
Check for vibration 4,000

OZONE FILTER
DESCRIPTION OF PROCEDURE FREQUENCY (HOURS RUN)
Replace filter panels when the granules, initially coloured purple, have turned 4,000
brown.

RENEW REFLECTOR
DESCRIPTION OF PROCEDURE FREQUENCY (HOURS RUN)
When fitting a new lamp, examine the dichroic reflector (if fitted) and arrange for 4,000
renewal by your supplier if renewal is indicated.

WATER CHILLER
DESCRIPTION OF PROCEDURE FREQUENCY (HOURS RUN)
Drain and refill adding the recommended amount of anticorrosion additive. 5,000
See chiller manual for specific details.

All of the above checks at the specified hours are only a guideline. These checks and
replacements may need to be increased depending on various conditions.

GEW UV system operating manual Issue 1.1 – January 2006 Maintenance schedule - page 2 of 2
REPLACING THE UV LAMP
This chapter explains how to fit a new UV lamp, including the removal and disposal of the old UV
lamp (VCP Type, 10 – 45cm Length).

TOOLS

Set of hexagon allen keys and an 8mm socket required.

PREPARATION
Allow the dryer to cool down and then remove the 4 x retaining screws on the lamp chassis.

REMOVE CHASSIS
Pull out the lamp chassis assembly. Supporting both ends, turn it over and place it on a clean level
surface.

GEW UV system operating manual Issue 1.1 – January 2006 VCP Lamp Change – page 1 of 3
REMOVE COLD FILTER
Remove the 4 x hexagon cap head bolts, two at each end of the reflector assembly. 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.

REMOVE OLD LAMP

Using an allen key undo the four allen screws and remove the quartz filter end caps and quartz
filter.

Using a 13 mm socket undo the two lamp connectors and lift out the old lamp. Ensure safe
disposal of the old lamp.

GEW UV system operating manual Issue 1.1 – January 2006 VCP Lamp Change – page 2 of 3
CLEAN REFLECTOR
The reflector assembly can be cleaned whilst the lamp is removed. Clean with a soft cloth
dampened with isopropyl alcohol (IPA).

FIT NEW LAMP

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 replace the 4 x cap-head retaining
screws.

GEW UV system operating manual Issue 1.1 – January 2006 VCP Lamp Change – page 3 of 3
PRODUCT WARRANTY STATEMENT
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.

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.

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.

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 covered by a 12 month parts and labour warranty from the date on the
WVC.
b) Faulty parts will be replaced without charge
c) Full technical support and help from our service hotline.

GEW UV system operating manual Issue 1.1 – January 2006 Product Warranty Statement – page 2 of 2
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.

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.

PURCHASE OF SPARE PARTS

All spare parts are subject to a 12 month return to base warranty, this applies only to the part itself.
GEW keeps thousands of parts on stock to ensure a fast efficient response to any request for a spare
part. We will ship any part to any destination. For identification of parts refer to the CD with your system.
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 system operating manual Issue 1.1 – January 2006 Product Warranty Statement – page 2 of 2