E2c Uv System Spare Parts Manual

GEW E2C UV Lamphead Spare Parts Manual
Contact Details
Address: GEW (EC) Limited,

Crompton Way, Crawley,
West Sussex, RH10 9QR, UK.
Telephone: +44 (0) 1737 824500 – main switchboard
+44 (0) 1737 824510 – service and spares
Email: service@gewuv.com
spares@gewuv.com
sales@gewuv.com
Website: www.gewuv.com
Distributors: www.gewuv.com/contact
Copyright
Duplication (copying, printing, microfilm or other forms) and the electronic distribution of this
document is only allowed with explicit permission of GEW (EC) Limited. GEW (EC) Limited
reserves the right to change technical data without prior announcement. The general business
conditions and the regulations of the licence agreement do apply. All rights are reserved.
Page 2 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

Contents
1 About This Manual............................................................................... 4

1.1 Introduction ................................................................................................................ 4
1.2 Symbols, Warnings, Cautions and Information .......................................................... 4
2 Qualifying and Training Operators ..................................................... 4
3 Ordering and Fitting Spare Parts........................................................ 5
3.1 Ordering Spare Parts ................................................................................................. 5
3.2 Fitting Spare Parts ..................................................................................................... 5
4 Spare Parts for GEW E2C UV Lampheads ......................................... 6
4.1 Lamphead Main Components .................................................................................... 6
4.2 Spare UV Cassette, Complete ................................................................................... 7
4.3 Cassette Sub-components......................................................................................... 8
4.3.1 Standard UV Lamps ............................................................................................. 9
4.3.2 Actuator Assembly, Complete ............................................................................. 10
4.3.2.1 Actuator Assembly Sub-components ........................................................... 11
4.3.3 Door, Complete .................................................................................................. 14
4.3.3.1 Door Sub-components ................................................................................. 15
4.3.4 Chassis Components.......................................................................................... 16
4.3.5 Reflector Pair, Complete ..................................................................................... 18
4.3.5.1 Reflector Sub-components........................................................................... 19
Appendix A .............................................................................................. 22
Document Issue Status

Revision Date Comments
1.0 12.10.15 First issue. JNO.
2.0 09.03.17 Contactless shutter switch incorporated. References to minor actuator sub-
assemblies removed. JNO.
3.0 31.10.17 PT100 & thermal switch screws copied to Fig 6. Microswitch cover updated.
Reflector glass lengths added. Reference to DOC7032 in 4.1.6 added.
Appendix A updated. JNO.
4.0 29.01.19 Updated reflector upper for 55, 60 and 65cm cassettes. Updated HT
connector, new terminal pin retainer (E2C HV socket terminal kit). New
selection method for cassettes and lamps. Other minor updates. JNO.
DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 3 of 23

1 About This Manual

1.1 Introduction
This Spare Parts Manual lists the spare parts that may be replaced by the operator in
your GEW UV system. Read it carefully before attempting to service the equipment it
describes.
Always use trained and competent people for operations, maintenance, repairs or
modifications. 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.
Do not modify any GEW UV system without the prior written approval of GEW.
1.2 Symbols, Warnings, Cautions and Information
This document, and GEW equipment, use the symbols set out below. They highlight
possible dangers where you need to take safety precautions and follow good practice.
Failure to follow the Warnings and Cautions may invalidate your warranty.
WARNING: Risk of electric shock.
Caution: a reminder of safety practices, or directs attention to unsafe practices that

could result in personal injury or damage to the equipment, or its components, or to
the environment.
Caution: Hot surface.
WARNING: Risk of exposure to ultra violet light.
Essential documentation: Read before attempting to install or operate equipment.
Check list: Follow a structured set of checks to install or operate equipment.
Electronic copies of this document contain underlined links to essential documentation.
2 Qualifying and Training Operators

GEW UV systems may only be operated and maintained by properly qualified personnel.
Regular training courses are necessary to ensure personnel have the specialist
knowledge required.
Personnel must be provided with regular training on all safety aspects of GEW UV
systems and in particular on the safety regulations currently in force.
This requirement for qualifications and training also applies to local and national safety
regulations that may be applicable at the user’s location and are not mentioned in this
document.
GEW offers custom training for all installations. For further information contact GEW.

3 Ordering and Fitting Spare Parts

3.1 Ordering Spare Parts
GEW recommends that a supply of spares is carried at all times. GEW keeps a
comprehensive inventory of parts in stock to ensure a fast and efficient response to any
customer request. We will ship any part to any destination worldwide.
GEW are dedicated to helping customers operate their systems at the lowest possible
cost. We offer discounts on lamps, parts and service rates.
Caution: Only use GEW supplied spare parts. Use of any other parts will invalidate
your warranty and may result in damage to the system.
Spare parts are ordered from:
Address: GEW (EC) Limited,

Crompton Way, Crawley,
West Sussex, RH10 9QR, UK.
Telephone: +44 (0) 1737 824500 – main switchboard
+44 (0) 1737 824510 – service and spares
Email: service@gewuv.com
spares@gewuv.com
sales@gewuv.com
Website: www.gewuv.com
Distributors: www.gewuv.com/contact
When ordering spare parts please provide the following information:

• your system serial number (essential)
• lamphead type (eg. E2C)
• Lamphead number (ie. print station number)
• this document number and its revision.
This information helps us to ensure the correct parts are issued to you. Please see
example in section 4.2.
3.2 Fitting Spare Parts

Each section of this manual uses labelled drawings to show which parts of each
component in a GEW UV system may be replaced by the operator.
1. Identify the part you wish to replace on the relevant drawing.
2. Refer to the relevant service procedure.
3. If you are using and electronic copy of this document, click on the relevant service
procedure and a new window will open showing the procedure.
WARNING: Ensure the system is switched off and isolated from the electrical supply
before performing servicing.
Caution: Allow system to cool for at least five minutes before performing servicing.

4 Spare Parts for GEW E2C UV Lampheads
4.1 Lamphead Main Components
Figure 1 - GEW E2C UV Lamphead
Item Description GEW part no. Qty Service procedure

1 Contact GEW for all casing, shielding and mounting spares.
2 UV Cassette See section 4.2 1 DOC7007. See Appendix A.

4.2 Spare UV Cassette, Complete
Figure 2 - Spare UV cassette
Service procedure: DOC7007 E2C Cassette Removal and Replacement.
To aid in the quick and accurate selection of appropriate spare cassette, please state the cassette
type (E2C), the system serial number and the lamphead number (print station number). All
information can be found on the cassette door as shown in the example below.
Example: Cassette E2C - S12345 - 6

See section 4.3 for cassette sub-components.

4.3 Cassette Sub-components
Figure 3 - GEW UV Cassette major components
Item Description Reference Qty Service procedure

1 UV Lamp (mercury) Section 4.3.1 1 DOC7006. See Appendix A.
2 Actuator complete Section 4.3.2 1 See section 4.3.2.1.
sub-components Section 4.3.2.1 -
3 Door complete Section 4.3.3 1
4 Chassis components Section 4.3.4 1
5 Reflector complete Section 4.3.5 1 pair DOC7005. See Appendix A.

4.3.1 UV Lamps
To aid in the quick and accurate selection of a spare lamp, details of the cassette to which the
lamp is fitted are required. All details can be found on the cassette door as shown in the example
below. By giving only the information above, you will receive a direct replacement lamp for the one
originally specified. As your UV system configuration may have changed over time, we
recommend that you also supply GEW with the lamp serial number found etched on the lamp.
Please note that, for any UV system, lamp types may vary from lamphead to lamphead.
Lamp serial number
Example: Lamp E2C - S12345 - 6 - GEW1234567

Service procedure: DOC7006 E2C Lamp Replacement.

4.3.2 Actuator Assembly, Complete
Figure 4 – Actuator, cover and fixings

1 Actuator assembly 49377 1 See section 4.3.2.1.
2 Actuator cover 47127 1
3 Screw 15739 2
4 Screw 48852 8
5 Slider 47983 4
6 Washer 10950 2
7 Washer, earth 42285 2
8 Screw 48851 1
See section 4.3.2.1 for actuator sub-components.

4.3.2.1 Actuator Assembly Sub-components
Figure 5 - Actuator assembly 49377
Service procedures: E2C Actuator Change and others as specified below.

1 Connector set See Figure 6 1
2 Cover, microswitch 62054 1
Screw 10928 1
3 Shutter switch & cam 65009 1 DOC7009. See Appendix A.
Screw 48854 2
Grease (not shown) 65238 1
4 Main PCB 47392 1 DOC7008. See Appendix A.
Screw 48854 1
5 Valve screw 48025 2
6 Support, actuator 47438 1
7 4mm reducer 36617 1
8 O-ring 44682 2

9 Solenoid 44679 2 DOC7011. See Appendix A.

Screw 49059 4
10 Actuator 52986 1 DOC7004. See Appendix A.
Screw 10994 3
11 PT 100 53803 1 DOC7010. See Appendix A.
Screw 10928 1
PT 100 (Alternative) 48662 1
Screw (Alternative) 48854 1
12 Switch, temperature 49952 1
and clamp plate
Screw 48854 1
13 Plate, pivot 47123 1
14 Mechanism 47114 1
Screw 31224 2
Screw 10981 1
15 Block, terminal See note 1
below
Spacer, PTFE 40116 2
Screw 10964 1
Screw 10936 1
16 Retainer, terminal pin 73627 1
Screw 64309 1
NOTE:
Item 15 terminal block is not available separately. It now forms part of a kit “E2C HV SOCKET
TERMINAL KIT” as listed in section 4.3.4. Also included in the kit are item 15 Spacer and items
16 retainer and screw.

Figure 6 – Actuator assembly, connector set

1 Screw 52737 4
2 Frame 36926 1
3 Insert, 2-way See note below 1
4 Insert, pneumatic 14089 1
5 Insert, male 36604 1
6 Tube, pneumatic 37318 1
(150mm)
7 Insert, 12-way 14086 1
8 Contact, male 26909 12
9 Block, adaptor 57988 1
Spacer (Alternative) 47848 4
10 Earth braid 50272 1
NOTES:
Item 3 - parts shown are not available separately. These now form part of a kit “E2C HV
SOCKET TERMINAL KIT” as listed in section 4.3.4.
Items 7 and 8 are also supplied as part of the Main PCB (See Figure 5).

4.3.3 Door, Complete
Figure 7 – Door and fixings

1 Door assembly 49478 1
2 Screw 48852 4
3 Washer, earth 42285 2
4 Screw 48851 1
See section 4.3.3.1 for door sub-components.

4.3.3.1 Door Sub-components
Figure 8 - Door Assembly (49478)

1 Circlip, internal 47543 2
2 Washer 48011 1
3 Door screw 49146 1
4 Earth braid 50273 1
Screw 37846 2
Washer, earth 42285 2
5 Button, number 47956 1
6 Door assembly, partial Not available separately 1

4.3.4 Chassis Components
Figure 9 – Chassis components

1 Pivot door plate 49474 2 See section 4.3.5.1
2 Reflector upper See table below 1
3 Carrier set See table below 1
4 Carrier upper 49496 1
5 Carrier upper 49497 1
6 Block, terminal See note below 1
Spacer 40116 1
Screw 10936 1
Screw 10964 1
7 Screw 10928 1
Slider (washer) 47983 1

8 Plate, clamp See section 4.3.2.1 1

(Thermal Switch) (supplied with Item12)
Screw 48854 1
9 Screw (PT100) 10928 1
10 Screw 48852 8
11 Slider 47983 4
NOTE:
Terminal block item 6 is not available separately. It now forms part of a kit “E2C HV SOCKET
TERMINAL KIT” as shown in Figure 10 and listed in the table below. Also included in the kit is
item 6 spacer.
Reflector upper, carrier pair and terminal part numbers

Arc length 10 15 17.5 20 25 30 33 35 38
Item 2: 47133 48282 48053 48284 48285 48251 48196 48286 48287
Reflector upper
Item 3: 47134 48318 48051 48320 48321 48256 48193 48322 48323
Carrier set
E2C HV Socket 73275 73276 73291 73277 73278 73279 73280 73281 73282
Terminal Kit
Arc length 40 45 47 48 50 55 60 65
Item 2: 48288 48148 48289 48290 48291 51493 51001 68693
Reflector upper
Item 3: 48324 48144 48325 48326 48327 48203 48328 48329
Carrier set
E2C HV Socket 73283 73284 73285 73286 73287 73288 73289 73290
Terminal Kit
Pin insertion tool J7280

(included in kit)
Figure 10 – Typical E2C HV Socket Terminal Kit

4.3.5 Reflector Pair, Complete
Figure 11 – Reflector assembly pair
Service procedure: DOC7032 E2C Reflector Assembly Replacement.
Standard reflector pair part numbers

Arc length 10 15 17.5 20 25 30 33 35 38
Part no 50018 50019 50020 50021 50022 50023 50024 50025 50026
Arc length 40 45 47 48 50 55 60 65
Part no 50027 50028 50029 50030 50031 50032 50033 50034
See section 4.3.5.1 for reflector sub-components.

4.3.5.1 Reflector Sub-components
Figure 12 - Reflector sub-components

1 End cap 49837 2 DOC7005. See Appendix A.
2 End cap 49836 2
3 Screw 15739 4
4 Reflector glass See table below -
5 Reflector outer See table below 2
6 Reflector inner + pin See table below 1 set
7 Screw 10932 2
Slider 47983 2
Washer 10950 2
Note: Quantities stated are per pair of reflectors.
The reflector glass ID reference number must be aligned with the base of the inner length
when refitting, as shown in Figure 13.
If changing both sides of the reflector glass, ensure that the joints between panels on the
left and right hand sides are staggered, as shown in Figure 14.

Figure 13 - Reflector glass showing part number (ringed).
Figure 14 - Glass inserts must be positioned with staggered edges as shown.
Glass inserts and quantities per pair of reflectors (Figure 12, item 4)
Arc length GEW Part no.
47723 47724 47725 47726 47727 47728
(50mm) (65mm) (75mm) (100mm) (127mm) (150mm)
10 2
15 2 2
17.5 2 2
20 2 2
25 2 2
30 4 2
33 4 2 2
35 2 2 2
38 4 2 2
40 2 4
45 4 2 2
47 6 2 2 2
48 4 2 2 2
50 2 2 4
55 2 6
60 2 2 6
65 2 2 6

Reflector outer and reflector inner part numbers (Figure 12)

Arc length 10 15 17.5 20 25 30 33 35 38
Item 5: 47130 48257 48050 48259 48260 48249 48194 48261 48262
Reflector outer
Item 6: 53102 53103 53104 53105 53106 53107 53108 53109 53110
Reflector inner
Arc length 40 45 47 48 50 55 60 65
Item 5: 48263 48145 48264 48265 48279 48204 48280 48281
Reflector outer
Item 6: 53111 53112 53113 53114 53115 53116 53117 53118
Reflector inner

Appendix A
E2C Service Manuals:
DOC7004 E2C UV Lamphead: Pneumatic Actuator Replacement
DOC7005 E2C UV Lamphead: Reflector Glass Cleaning and Replacement
DOC7006 E2C UV Lamphead: Lamp Replacement
DOC7007 E2C UV Lamphead: Cassette Removal and Replacement
DOC7008 E2C UV Lamphead: Main Printed Circuit Board (PCB) Replacement
DOC7009 E2C UV Lamphead: Microswitch Replacement
DOC7010 E2C UV Lamphead: PT100 and Thermal Switch Replacement
DOC7011 E2C UV Lamphead: Solenoid Replacement
DOC7032 E2C UV Lamphead: Reflector Assembly Replacement.
Video:
VID7001 E2C Contamination Upgrade Kit 62057
VID7004 E2C 55 60 65 - Fitting Updated Reflector Upper
VID7005 E2C Lamp Change.

NOTES:

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GEW E2C UV Lamphead Spare Parts Manual

Address: GEW (EC) Limited,

Page 2 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

1 About This Manual............................................................................... 4

Document Issue Status

DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 3 of 23

1 About This Manual

Caution: a reminder of safety practices, or directs attention to unsafe practices that

WARNING: Risk of exposure to ultra violet light.

Essential documentation: Read before attempting to install or operate equipment.

Check list: Follow a structured set of checks to install or operate equipment.

Electronic copies of this document contain underlined links to essential documentation.

2 Qualifying and Training Operators

Page 4 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

3 Ordering and Fitting Spare Parts

Spare parts are ordered from:

Address: GEW (EC) Limited,

When ordering spare parts please provide the following information:

3.2 Fitting Spare Parts

DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 5 of 23

4 Spare Parts for GEW E2C UV Lampheads

4.1 Lamphead Main Components

Figure 1 - GEW E2C UV Lamphead

Item Description GEW part no. Qty Service procedure

Page 6 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

4.2 Spare UV Cassette, Complete

Figure 2 - Spare UV cassette

Service procedure: DOC7007 E2C Cassette Removal and Replacement.

Example: Cassette E2C - S12345 - 6

DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 7 of 23

4.3 Cassette Sub-components

Figure 3 - GEW UV Cassette major components

Item Description Reference Qty Service procedure

Page 8 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

Lamp serial number

Example: Lamp E2C - S12345 - 6 - GEW1234567

DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 9 of 23

4.3.2 Actuator Assembly, Complete

Figure 4 – Actuator, cover and fixings

Item Description GEW part no. Qty Service procedure

See section 4.3.2.1 for actuator sub-components.

Page 10 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

4.3.2.1 Actuator Assembly Sub-components

Figure 5 - Actuator assembly 49377

Service procedures: E2C Actuator Change and others as specified below.

Item Description GEW part no. Qty Service procedure

DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 11 of 23

9 Solenoid 44679 2 DOC7011. See Appendix A.

Page 12 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

Figure 6 – Actuator assembly, connector set

Item Description GEW part no. Qty Service procedure

DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 13 of 23

4.3.3 Door, Complete

Figure 7 – Door and fixings

Item Description GEW part no. Qty Service procedure

See section 4.3.3.1 for door sub-components.

Page 14 of 23 © GEW (EC) Limited 2019 DOC7003-EN-Rev4.0

4.3.3.1 Door Sub-components

Figure 8 - Door Assembly (49478)

Item Description GEW part no. Qty Service procedure

DOC7003-EN-Rev4.0 © GEW (EC) Limited 2019 Page 15 of 23

4.3.4 Chassis Components

Figure 9 – Chassis components