System Description
Debris Removal System Overview ........................................................6
Debris Removal System Components ..................................................9
Environment Specifications................................................................20
Possible Airborne Emissions...............................................................21
Consumables ....................................................................................22
Supported Media ..............................................................................23
6 Chapter 2 鈥? System Description
Debris Removal System Overview
The debris removal system (DRS) is an integral part of your Creo imaging
system, which includes the output device, printing media (plate or film),
and workstation. The DRS extracts and filters airborne emissions that are
released when imaging certain types of printing media.
In general there are two types of debris removal systems:
鈥? Systems with one flow measurement location at the system entrance
are known as Single Flow Measurement systems
鈥? Systems with two flow measurement locations, one at the system
entrance and one at the system exit are known as Dual Flow
Measurement systems
Single Flow Measurement Systems
Debris removal systems with one flow measurement location are used
when it is desirable to measure the air flow at the system entrance. The
measurement is made at the debris collection nozzle inside the output
device and is monitored to ensure that it remains above the minimum
required to maintain satisfactory collection efficiency.
This type of system uses a base configuration UDRC and is primarily used
with media that release only particulate emissions. The UDRC may
contain only a particulate filter, an odor control filter set, or a particulate
and chemical filter combination, with the specific filter type(s) chosen to
suit the application.
A single flow measurement system can be upgraded to a dual flow
measurement system if desired.
Debris Removal System Overview 7
Output device UDRC
Printing media
Debris collection nozzle
Q1
Filter(s)
Thermal
Firmware
head
Flexible hose
Data cable
Blower
Power
cable
Workstation
Figure 1: Single flow measurement system
Dual Flow Measurement Systems
Debris removal systems with two flow measurement locations are used
when it is desirable to measure the air flow at the system entrance and at
the system exit. The two measurements are monitored to ensure that the
flow rate remains above the minimum required to maintain satisfactory
collection efficiency and to ensure that the air entering the system is
filtered before it exits the system.
The air flow measurement at the system entrance is made at the debris
collection nozzle inside the output device, and the measurement at the
system exit is made at the outlet from the filter compartment inside the
UDRC.
This type of system uses a flow measuring configuration UDRC and is
primarily used with media that release both particulate and gaseous
emissions. The UDRC usually contains a particulate and chemical filter
combination, with the specific filter type(s) chosen to suit the application.
8 Chapter 2 鈥? System Description
Output device UDRC
Printing media
Debris collection nozzle
Q1
Filter(s)
Thermal
Firmware
head
Q2
Flexible hose
Data cable
Blower
Power
cable
Workstation
Figure 2: Dual flow measurement system
UDRC Configurations
The UDRC is available in different configurations. The configuration that
you need is based on the type of printing media that you image. The
UDRC configuration key is shown in Figure 3 on page 9.
Not all of the combinations of cabinet type and filter type are available.
Other configurations may become available as new media get qualified.
UDRC configuration information is located on the configuration label on
the back of the UDRC. For examples of configuration labels, see
Appendix B, Labels.
Debris Removal System Components 9
UDRC-XY
Filter type: P = Particulate filter only
C = Offset Chemical filter + Particulate filter
F = Flexo chemical filter + particulate filter
Cabinet type: B = Base configuration; standard flow
L = fLow measuring configuration; standard flow
H = base configuration; High flow
UDRC = Universal Debris Removal Cabinet
Figure 3: UDRC configurations
WARNING: Any attempt to modify a single flow measurement system
containing a particulate filter only for use with media that release gaseous
emissions can result in exposure to airborne emissions in excess of applicable
regulatory limits. Such exposure may result in discomfort, illness, injury, and/or
disability.
WARNING: Failure to replace a particulate or chemical filter in accordance with
Creo and/or the media manufacturer鈥檚 recommendations can result in exposure
to airborne emissions in excess of applicable regulatory limits. Such exposure may
result in discomfort, illness, injury, and/or disability.
Debris Removal System Components
The debris removal system consists of the following components:
鈥? Universal Debris Removal Cabinet (UDRC)
鈥? Debris collection nozzle
鈥? Connecting hose
鈥? Cables (data and power)
鈥? Firmware
Each component is described on the following pages. Figure 4 shows the
arrangement of these components in a typical debris removal system.
10 Chapter 2 鈥? System Description
Output device UDRC
Printing media
Debris collection nozzle
Filter(s)
Thermal
Firmware
head
Connecting hose
Data cable
Blower
Power
cable
Workstation
Figure 4: Components of a typical debris removal system
Universal Debris Removal Cabinet
The Universal Debris Removal Cabinet consists mainly of the filter
compartment, the filter(s), the blower, and the power indicator light.
The UDRC automatically removes airborne emissions released during
imaging. The airborne emissions are drawn from the output device into
the UDRC through the flexible connecting hose. Once inside the UDRC,
the airborne emissions are trapped in the filter(s), and the filtered air is
exhausted into the room.
Debris Removal System Components 11
When imaging is complete, the UDRC continues to run for a short period
of time to purge the connecting hose and filter compartment of remaining
airborne emissions. See Blower on page 16 for additional information.
Power indicator Cabinet lid
light
Cabinet latch
(underneath
handle)
Filter compartment
(inside)
Blower
(inside)
Figure 5: Front of the Universal Debris Removal Cabinet
WARNING: If the UDRC stops unexpectedly without purging the hoses or filter
compartment, airborne emissions may be present in the UDRC and connecting
hose. Avoid opening the UDRC or disconnecting any hoses. If you must access
the inside of the UDRC, wear a smock and protective gloves and use respiratory
protection to reduce exposure to airborne emissions.
The UDRC housing is made of plastic. Do not place heavy objects on or sit
or stand on the cabinet.
12 Chapter 2 鈥? System Description
Inlet
connection
The base configuration has no elec- The flow measuring configuration has
tronics enclosure. an electronics enclosure on the back.
Figure 6: Back of the Universal Debris Removal Cabinet
The UDRC has both casters and stabilizing feet. The casters are convenient
for moving the UDRC. Once the UDRC is in position with respect to the
output device, unscrew the stabilizing feet until the casters are lifted off the
ground and the UDRC is level and standing on the four stabilizing feet.
CAUTION: The UDRC should not be used or permanently positioned while
standing on its casters. Always use the stabilizing feet during operations.
Otherwise, in unusual situations where the cabinet lid is open and pressure is
put on the lid, the UDRC may topple over.
Filter Compartment
Access the filter compartment by opening the cabinet lid (see Figure 7). To
open the lid, press down on the cabinet lid (near the latch) with the heel of
one hand, and then release the latch with your other hand. When open, the
lid is restrained by a single cable. Do not push on the lid when it is open.
Debris Removal System Components 13
Cabinet latch
(exposed)
Filter inlet tube Inner lid
Edge of filter compartment Particulate filter
forms a seal against the
Filter
inner lid
compartment
Particulate filter gasket Deck
(forms a seal against
the inner lid)
Figure 7: The filter compartment
The edge of the filter compartment forms a seal against the inner lid. When
replacing a filter, do not bang the filter against the edge of the
compartment. Damage to the edge can cause an air leak from the outside
into the compartment, reducing the flow from the debris collection nozzle.
Depending on the extent of the air leak, filter life will be reduced and a low
flow error message may appear on your workstation.
Filters
Particulate Filter Only
In UDRCs containing only a particulate filter (see Figure 8 on page 14), the
filter fills the entire filter compartment. A particulate filter spacer sits at the
bottom of the filter compartment, and the particulate filter fits on top of
the spacer. Besides providing a space for airflow at the bottom of the filter
compartment, the filter spacer also centers the particulate filter in the
compartment.
14 Chapter 2 鈥? System Description
Particulate filter
Particulate filter and spacer
Particulate filter spacer
Figure 8: Particulate filter and spacer
Particulate and Chemical Filter Combination
In UDRCs containing a particulate and chemical filter combination (see
Figure 9 on page 15), the particulate filter is stacked on top of the chemical
filter inside the filter compartment.
A chemical filter spacer sits at the bottom of the filter compartment and
centers the chemical filter. A particulate filter spacer sits on top of the
chemical filter and centers the particulate filter in the compartment. It also
provides a space for airflow between the two filters.
The particulate and chemical filters shown in Figure 9 are typical but may
not be exactly the same type and size as the filters in your UDRC. The
correct filters for your UDRC are listed on the configuration label on the
back of the UDRC. See UDRC Configuration Labels on page 72.
Debris Removal System Components 15
Typical particulate filter
Particulate filter spacer
gasket
filter life sensor contact
Particulate and chemical
filter combination
Chemical filter top
Chemical filter bottom
Chemical filter spacer
Figure 9: Particulate and chemical filter combination
16 Chapter 2 鈥? System Description
Blower
The blower is located under a protective screen that prevents foreign
objects from entering the blower at the bottom of the filter compartment.
The blower provides suction to remove the airborne emissions from the
imaging area and into the UDRC.
The blower has a cooling air inlet that is located under the front of the
UDRC. Ensure that the air inlet is not blocked with paper or other foreign
objects. If the air inlet becomes blocked, the blower motor will overheat
and the built-in thermal protection will shut down the blower.
When imaging is complete, the blower will continue to run for a minimum
of 20 seconds and a maximum of 5 minutes. The 20 second minimum is
required to purge the hoses and filter compartment of any remaining
airborne emissions at the end of a plot. The blower will continue to run for
up to 5 minutes to minimize the detrimental effects of frequent start/stop
cycles that could occur when several plots are completed in succession
(with more than 20 seconds between plots). Only an authorized service
representative can adjust the time delay for the blower.
Power Indicator Light
The power indicator light is located on the top of the UDRC. When the
light is on, it indicates that the UDRC blower is running.
Debris Collection Nozzle
The debris collection nozzle is attached to the thermal exposure head that
is located inside the output device. Its primary function is to remove
airborne emissions from the imaging area. The debris collection nozzle
also helps keep debris off the final optical element of the thermal exposure
head.
The debris collection nozzle shown in Figure 10 on page 17 is typical but
may not be exactly the same as the nozzle as on your output device. The
nozzle used depends on the type of thermal exposure head that is installed
in your output device.
Debris Removal System Components 17
Figure 10: Typical debris collection nozzle
Connecting Hose
The connecting hose runs from the output device outlet to the UDRC
inlet. The connecting hose should be in a non-traffic area and should not
have any kinks.
Figure 11: Typical connecting hose鈥攆rom the output device to the UDRC
A break in the connecting hose will result in an air leak from the outside,
reducing the flow from the debris collection nozzle. Depending on the
extent of the air leak, filter life will be reduced and a low flow error message
may appear on your workstation.
18 Chapter 2 鈥? System Description
Cables
The connecting cables should be in a non-traffic area and should not have
any kinks.
CAUTION: Walking on or over the cables may eventually damage them or
loosen their connections, which may cause the UDRC to malfunction.
Data Cable
The data cable connects the UDRC to the output device and transfers data
between the UDRC and the output device.
Figure 12: Cable for transferring data
Power Cable
The power cable is a detachable cable. It is attached to the appliance inlet
of the UDRC. The plug end depends on the installation location.
Figure 13: Typical power cable
Debris Removal System Components 19
Firmware
The UDRC is fully automatic. The output device starts and stops the
UDRC as required. You do not need to turn the UDRC on or off (there is
no power switch). The UDRC is connected to a constant power supply that
is controlled by the output device.
The UDRC is controlled by firmware in the output device. The firmware
functionality differs, depending on whether the DRS is a single or dual
flow measurement system.
In a single flow measurement system, the firmware can detect the following
error conditions:
鈥? Open cabinet lid
鈥? No particulate filter installed
鈥? Upside down particulate filter
鈥? Full blockage of the debris collection nozzle
鈥? Poor blower performance
Note: These firmware features may not be enabled on some ThermoFlex庐
devices. Please consult your Creo representative.
In a dual flow measurement system, the firmware can detect all of the
above conditions, plus the following error conditions:
鈥? No chemical filter installed
鈥? Upside down chemical filter
鈥? Wrong type of chemical filter installed
鈥? Partial blockage of the debris collection nozzle
鈥? Leak in the connecting hose
鈥? Crushed connecting hose
Note: These firmware features may not be enabled on some ThermoFlex庐
devices. Please consult your Creo representative.
Under normal operating conditions, the DRS firmware relays two
messages when the filter(s) need to be replaced:
鈥? The first message states that the filter(s) are nearly full and suggests
that you have a replacement filter on hand.
20 Chapter 2 鈥? System Description
鈥? The second message states that the filter(s) are full and must be
replaced before imaging can continue. You can complete the current
plot before replacing the filter(s).
Note: These firmware features may not be enabled on some ThermoFlex庐
devices.
Environment Specifications
The UDRC should be installed in a clean prepress area, with the output
device (in accordance with the Universal Debris Removal Cabinet Site
Preparations & Requirements Document, Creo document number
725-00089A).
Ensure that the operating environment and electrical connection
requirements are observed when your UDRC is installed and when it is in
use.
The operating environment requirements for the UDRC are:
鈥? Temperature: 17掳C鈥?32掳C (63掳F鈥?90掳F)
鈥? Relative humidity:
20%鈥?70% for particulate filtration only
30%鈥?70% for particulate and chemical filtration
鈥? Elevation: up to 2225 meters (7300 feet)
鈥? Adequate outdoor air ventilation and air mixing, as defined in your
output device Site Preparations & Requirements Document and/or CTP
Media Imaging Performance Database, which is available from your
Creo representative
Proper ventilation and adequate air mixing in the room ensure that filtered
airborne emissions are properly dissipated and pockets of higher
concentration gases do not form.
WARNING: The particulate and chemical filtration of airborne emissions is not
100% efficient and must be complemented by adequate outdoor air room
ventilation. Failure to ensure adequate ventilation may result in exposure to
airborne emissions in excess of applicable regulatory limits and in possible
discomfort, illness, injury, and/or disability.
Possible Airborne Emissions 21
WARNING: For chemical filtration, lower than the specified relative humidity
may result in breakthrough of gaseous emissions prior to chemical filter
replacement. This may result in exposure to airborne emissions in excess of
applicable regulatory limits and in possible discomfort, illness, injury, and/or
disability.
WARNING: Failure to provide adequate air mixing in the imaging room could
cause increased concentrations of chemical compounds in certain areas. This may
result in exposure to airborne emissions in excess of applicable regulatory limits
and in possible discomfort, illness, injury, and/or disability.
The acoustic emissions of the UDRC are less than 62 dB(A) measured at
one meter in a free field.
Possible Airborne Emissions
All media qualified for imaging on the output device have been assessed for
airborne emissions of the substances specified by media manufacturers on
their MSDSs or other documents.
Important: It is your responsibility to ensure compliance with the allowable
limits for worker exposure to air contaminants as mandated by OSHA and/or
any other workplace regulations that apply at your facility. To ensure
compliance, we recommend that you test your indoor air quality.
The most common airborne emissions released by printing media include,
but are not limited to, the compounds listed in Table 1. Where applicable,
the U.S. Occupational Safety and Health Administration (OSHA) standard
(U.S. Document 29 CFR, Part 1910, Subpart Z) concerning the individual
compound is also listed.
Table 1: List of chemical compounds
Compound OSHA Standard
Acetaldehyde
Benzene 1910.1028
1,3-Butadiene 1910.1051
Carbon monoxide
22 Chapter 2 鈥? System Description
Compound OSHA Standard
Formaldehyde 1910.1048
Hydrogen cyanide
Nitric oxide
Nitrogen dioxide
Particulates
Note that not all of these compounds are released by each medium. For a
list of emissions (if any) that might be released by a particular medium, see
the manufacturer鈥檚 MSDS or contact the manufacturer or distributor
directly.
WARNING: Particulate and gaseous emissions that are not properly filtered can
endanger your health. For a list of airborne emissions that pertain to the media
you are using, see the manufacturers鈥? MSDSs or contact the manufacturer or
distributor directly.
For more information on airborne emissions and ventilation, see the Site
Preparations & Requirements Document for your output device. You
received this document from a Creo service representative when the output
device was initially installed.
Consumables
Replacement filters are the only consumables required for the UDRC.
Each UDRC configuration uses different filters. The part numbers for the
correct replacement filters are listed on the configuration label, which is
located on the back of the UDRC. See UDRC Configuration Labels on
page 72 for an illustration of this label.
For general information on UDRC filters, see Filters on page 13.
For information on replacing the particulate filter only, see Replacing the
Particulate Filter on page 32.
Supported Media 23
For information on replacing the particulate and chemical filter
combination, see Replacing the Particulate Filter on page 32 and Replacing
the Chemical Filter on page 35.
CAUTION: Use only Creo-authorized particulate and chemical filters. Your
output device will not operate properly if you try to use a substitute or
unauthorized particulate or chemical filter.
Supported Media
You must image only Creo-qualified media in your output device. The
imaging parameters for these media were determined and preset by Creo
for optimum performance. Overexposure may result in a substantial
increase in airborne emissions.
If you attempt to image unqualified media, the filter(s) may not remove all
airborne emissions. For the latest information on qualified media, contact
your service representative.
WARNING: Imaging unqualified media may result in the release of unknown
airborne emissions that are not properly filtered. Imaging unqualified media may
result in exposure to airborne emissions in excess of applicable regulatory limits
and in possible discomfort, illness, injury, and/or disability.
Odor thresholds for some chemical compounds may be extremely low. For
example, the odor threshold for cresols is around 0.6 ppb (0.0006 ppm),
while the exposure limit (ACGIH TLV, 2003) is 5 ppm, almost 10,000 times
higher. Although odors present at the levels lower than exposure limits
generally do not pose a health hazard, we recommend that sensitive
individuals wear respiratory protection.
WARNING: Some media may release strong odors when imaged. Some odors
may not be completely filtered. If you are concerned about a particular medium,
see the manufacturer鈥檚 MSDS or contact the manufacturer or distributor directly.
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