System AeroLED2®
AeroLED2 is a next generation, higher power UV LED system for full cure, printing, coating and converting applications up to 70cm wide; AeroLED2 offers a 30% increase in electrical power (70W / cm), a 30% increase in UV dose (170mJ / cm2) and a 40% increase in UV irradiance (26W / cm2) compared to its predecessor, AeroLED.
AeroLED2 is also ArcLED compatible. Using the same fan and ducting arrangement as the industry standard E2C, customers have total flexibility to switch between UV arc and AeroLED2 on any station. No filters are required due to the high redundancy, making maintenance a breeze. Moreover any customers with GEW’s RHINO/RLT power supply platform can upgrade to LED within a matter of hours, by simply changing the cassettes and running a software upgrade.
Following its predecessor, in an AeroLED2 system air is extracted by a single centralised fan sited away from the press. There is no need for integrated fans or electronics in the individual lampheads, which eliminates the high pitched noise and risk of failure that these bring. AeroLED2 features the same LED chassis and core components as GEW’s LeoLED2 lamphead, for proven reliability. As with LeoLED2, the lamphead has tough watertight seals to protect the LED modules from ingress and to make cleaning easy and safe. Every aspect of the design has been carefully considered to deliver robust performance and long-term reliability.
AeroLED2’s efficient optical design enables the lowest energy usage of all GEW products. This delivers energy savings of up to 55% when compared to a conventional UV arc system. In addition to offering greatly reduced operating costs, printers upgrading to AeroLED2 are able to free up >50% of mains capacity, which can then be used to install new machinery and subsequently increase production capability. Two AeroLED2 systems have a lower electrical supply requirement than just one conventional arc UV system.
A further advantage of LED is its predictability and stability of UV output in the curing process. AeroLED2 delivers improved in process control by ensuring stable UV output year after year, and eliminates the uncertainty of conventional UV lamps, reflectors and mechanisms to ensure consistent production quality. As is the case with all new GEW UV products, AeroLED2 uses GEW’s RHINO power supply and control range, for ultimate reliability with Industry 4.0 approved, IoT Remote Monitoring as standard.
Benefits of AeroLED2
- Fully air-cooled – Single centralised fan system for quiet and reliable operation. No chiller required. Significantly reducing investment cost and power consumption. No heat exhausted onto press or into press room. Air can be ducted out.
- Cut your energy costs by up to 55%, with ROIs on new machinery less than 1 year. No ozone, no mercury.
- Most efficient curing – Large window gives maximum light extraction. Longer dwell time increases dose. LEDs now closer to window, meaning increased irradiance.
- Improved reliability – AeroLED2 and LeoLED2 share the same core components, enabling high volume, industrialised manufacture and improved reliability. Embedded temperature sensors constantly monitor the LEDs to ensure safe, long-term operation and reliability.
- Easy maintenance – Tough watertight seals protect LEDs from ingress and make for easy cleaning. GEW’s standard cassette design for easy maintenance. No integrated fans or electronics in lamphead. Robust air-cooled heatsinks are easily accessible.
- Longest LED warranty – AeroLED2 diodes have an expected lifetime of >30,000 hours. GEW offers up to 5 years warranty irrespective of running hours.
- Free up mains capacity with electrical requirements over 50% less than arc – 2 AeroLED2 systems require the same power as 1 E2C system!
Max electrical power
70W / cm
Wavelength
395nm**
**365nm, 385nm & 405nm available upon request
Irradiance at window
26W / cm²*
*Measured under standard GEW lab conditions with a standard lamphead configuration
Typical dose @ 100m / min
170mJ/cm2*
*Measured under standard GEW lab conditions with a standard lamphead configuration
Maximum length
70cm
Standard cross section
110mm W x 190mm H
Cooling
Air
Standard max operating temperature
35°C (95°F)
Standard max humidity
Non-condensing
Expected diode life time
30 000 hours
Patented Interchangeable Technology
Patented Interchangeable Technology ArcLED hybrid UV technology allows interchanging of a UV Arc lamp or LED array in the same housing. The video below illustrates the simplicity of this process.
Optimise your press with a mixture of Arc and LED curing on any station, for the ultimate flexibility. GEW has held granted patents covering ArcLED technology internationally since 2016.
Retrofit your press with GEW UV LED in less than one day
For GEW RHINO and RLT users, UV curing systems can be upgraded to AeroLED2 with minimal downtime by simply replacing the cassettes and running a software upgrade. The video below illustrates how simple this process is.
The table below illustrates the components needed for an AeroLED2 retrofit based on the existing UV curing technology on your press.
RHINO Power supply
Fail-safe operation
Military-grade design protects the UV system from damage caused by incorrect voltage, short-to-ground, dropped phases, mains spikes and lightning strikes. In the event of a serious mains disruption, the system powers down in a safe mode. RHINO is designed to run in the harshest conditions and at ambient temperatures of up to 40°C. The system is unaffected by dust, ink mist and other contaminants.
Lowest operating costs
With intelligent power management the current draw is balanced and harmonic distortion is minimised, reducing energy demand.
Minimal footprint RHINO Rack
A compact cabinet houses power supplies for up to 6 lamps and provides perfect cooling, atmospheric protection and mains power distribution.
5-year warranty available
Using GEW’s embedded service package gives total confidence in the reliability of GEW power electronics and minimises unplanned maintenance costs. GEW is the only UV supplier to offer this level of warranty.
Control
Embedded service
Using GEW’s embedded service package gives total confidence in the reliability of GEW power electronics and minimises unplanned maintenance costs. GEW is the only UV supplier to offer this level of warranty.
System performance reports
Regular reports are generated, detailing energy usage, uptime percentage and system performance. The Event Log continually records system use and operating parameters, ensuring the system is working at peak efficiency at all times.
Energy performance measurement
The RHINO control automatically logs energy use and displays it on screen at the touch of a button, showing kWh consumption in operation, at idle and % production uptime.
All photos by GEW (EC) Limited