Ironer IM Installation and Operation Manual October 25, 2011 Revision 1.
Executive Summary The Installation and Operation manual for the IM Series of self-contained thermal fluid ironers. This manual covers the IM-800 and IM-1200 Series self contained thermal fluid ironers.
Chapter 1 Important Safety Information 1.1 FOR YOUR SAFETY - CAUTION! WARNING: For your safety the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury or death. • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. • WHAT TO DO IF YOU SMELL GAS: – Do not try to light any appliance – Do not touch any electrical switch; do not use any phone in your building.
1.2 A Note of Caution There is a protective coating applied to the chests of the ironer that MUST BE REMOVED prior to initial startup of the machine. Remove this protective coating prior to padding or applying heat. Failure to remove the coating can damage or destroy the chest and padding and will require difficult cleaning and replacement. Not heeding these instructions will certainly ruin you day.
Contents 1 2 3 Important Safety Information i 1.1 FOR YOUR SAFETY - CAUTION! . . . . . . . . . . . i 1.2 A Note of Caution . . . . . . . . . . . . . . . . . . . . . ii Important Instructions 1 2.1 Before Attempting Repairs . . . . . . . . . . . . . . . . 1 2.2 Operator Safety Notes . . . . . . . . . . . . . . . . . . 3 2.3 Parts Ordering Information . . . . . . . . . . . . . . . 4 2.3.1 Nameplate Location . . . . . . . . . . . . . . . 4 2.4 Key Symbols . . . . . . . . . . . . . .
3.3 3.4 3.5 Work Rates . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.3.1 1 Roll 48”x118” . . . . . . . . . . . . . . . . . . 11 3.3.2 1 Roll 32”x118” . . . . . . . . . . . . . . . . . . 12 3.3.3 2 Roll 48”x118” . . . . . . . . . . . . . . . . . . 12 3.3.4 2 Roll 32”x118” . . . . . . . . . . . . . . . . . . 12 3.3.5 Moisture Retention Correction Factors . . . . . 12 3.3.6 Calculating Moisture Retention . . . . . . . . . 13 Site Requirements . . . . . . . . . . . . . . . . . .
3.6 Compressed Air Connections . . . . . . . . . . . . . . 21 3.6.1 Internal Connections . . . . . . . . . . . . . . . 21 3.6.2 External Connection . . . . . . . . . . . . . . . 21 Electrical Connections . . . . . . . . . . . . . . . . . . 21 3.7.1 Internal Electrical Connections . . . . . . . . . 21 Exhaust Installation . . . . . . . . . . . . . . . . . . . . 23 3.8.1 Exhaust Connection . . . . . . . . . . . . . . . 23 3.8.2 Internal Duct Work . . . . . . . . . . . . . . . . 23 3.8.
4.2 5 4.1.3 Shutdown Procedure . . . . . . . . . . . . . . . 34 4.1.4 Waxing Procedure . . . . . . . . . . . . . . . . 34 Running the Ironer . . . . . . . . . . . . . . . . . . . . 36 4.2.1 Cotton Sheets . . . . . . . . . . . . . . . . . . . 36 4.2.2 Poly-Cotton Blend Sheets . . . . . . . . . . . . 36 4.2.3 Dryness . . . . . . . . . . . . . . . . . . . . . . 36 4.2.4 Taking A Break . . . . . . . . . . . . . . . . . . 37 4.2.5 Running Small Pieces . . . . . . . . . . . . . . 37 4.2.
5.6.2 5.7 5.8 5.9 6 Roll Pad Discoloration (Yellowing) . . . . . . . 54 Guide Tape . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.7.1 Securing Tapes . . . . . . . . . . . . . . . . . . 55 5.7.2 Materials . . . . . . . . . . . . . . . . . . . . . . 56 5.7.3 Routing The Guide Tapes . . . . . . . . . . . . 56 5.7.4 Gearbox Lubrication . . . . . . . . . . . . . . . 57 5.7.5 Pump Setup and Alignment . . . . . . . . . . . 58 5.7.6 Typical Pump Problems . . . . . . . . . . . . .
6.1.5 Conclusion . . . . . . . . . . . . . . . . . . . . 75 6.2 Paratherm HE MSDS . . . . . . . . . . . . . . . . . . . 77 6.3 Shell Thermia MSDS . . . . . . . . . . . . . . . . . . . 82 6.4 Thermal Fluid Pump . . . . . . . . . . . . . . . . . . . 90 6.5 Riello Burner Manual . . . . . . . . . . . . . . . . . . . 117 6.6 Riello Burner Parts Manual . . . . . . . . . . . . . . . 138 6.7 North American Riello Burner Parts Manual . . . . .
Chapter 2 Important Instructions 2.1 Before Attempting Repairs Rollers and other moving parts can cause serious injury or death. Before attempting repairs, follow proper shutdown procedures, remove power, and allow the machine to fully cool before commencement of service. Before electrical service begins, allow at least 5 minutes after power has been removed to allow the AC inverter drive to discharge. Safety is of primary concern with any maintenance or repair operation.
Never attempt to clean or service any area of the machine without removing power at the main disconnect and allowing time for the machine to cool completely. There are certain jobs that must be performed with the ironer running at the slowest possible speed. In this instance, another person must be stationed at the disconnect to immediately remove power if needed. Always avoid moving rolls and be especially aware of pinch points where two or more rolls come together.
2.2 Operator Safety Notes NEVER ATTEMPT TO REMOVE OR ADJUST JAMMED LINEN WHILE THE MACHINE IS IN OPERATION. Attempting to reposition or free jammed linen while the machine is under power can result in machine damage (best case) or serious injury or death (worst case). REMOVE POWER TO THE MACHINE and allow it to cool before attempting removal of jammed goods. Ironer surfaces can reach temperatures well in excess of 400 degrees Fahrenheit (205 degrees Celsius), not something you want to touch.
Figure 2.1: Serial Decal 2.3 Parts Ordering Information If you require literature or spare parts, please contact your local distributor. If a local distributor is unavailable, you may contact B&C Technologies directly at (850) 249-2222 for the name of your nearest parts dealer. For technical assistance in the United States, contact B&C Technologies: (850) 249-2222 Phone (850) 249-2226 FAX parts@bandctech.com www.bandctech.com 2.3.
2.4 Key Symbols Anyone operating or servicing this machine must follow the safety rules in this manual. Particular attention must be paid to the DANGER, WARNING, and CAUTION blocks which appear throughout the manual and shown in figures 2.2 on page 6 and 2.3 on page 7. 2.5 2.5.
Figure 2.
Figure 2.3: Key Symbols 7. Read, understand, and follow all safety instructions. Do not come close to moving parts and hot surfaces. Do not wear loose clothing, jewelry, neckties, or any other garment that could become caught in the machine while operating or near the machine. 8. Only a qualified technician should attempt to service or repair the machine. 9. Do not install the machine in an area where it could be exposed to water or weather. 10. Do not alter or tamper with the control system. 11.
Chapter 3 Machine Installation 3.1 3.1.1 Installation Receiving Inspection Upon receipt of the equipment, visually inspect for shipping damage and note any damage with the carrier before signing the shipping receipt, or advise the carrier of the damage as soon as it is noted. If damage is discovered, a written claim must be filed with the carrier as soon as possible. Note: Warranty is VOID unless the equipment is installed according to instructions.
3. Heating System The ironers can be ordered for the following heating systems: • High Pressure Steam • Hot Oil / Thermal Fluid 4. Drive System General The heavy-duty ironer is driven by a variable speed gear drive or a variable electric drive for the multi-roll units. The power is directed to a slip-on gear box on each roller and in feed conveyor through a high-performance V-belt system. The required in feed speed can be adjusted at the right control panel and can be monitored with the rate meter display.
module, controls the pressure which is monitored via a pressure gauge on the left control panel. As an option, individual pressure control of each roll is available. 10. Linen Infeed The infeed of linen occurs on the front side of the ironer via wear and temperature resistant flat belts. The belts are driven by a textured infeed roller. A finger guard, located at the end of the belts, stops the ironer and lifts the first roller immediately if activated. 11.
sults will be obtained with a properly sized incoming gas line. Undersized gas lines will cause performance and burner issues. Table 3.1: IM Electrical & Gas Requirements 3.
3.3.2 Realistic Work Rates for 1 Roll 32”x118” (800mm) Ironer Goods g/m2 Working Temperature lb/yd2 m/min 170C / 338F ft/min kg/h lb/hr m/min 180C / 356F ft/min kg/h lb/hr m/min 188C / 371F ft/min kg/h lb/hr m/min 200C / 390F ft/min kg/h lb/hr Sheets @ 80% Bed Coverage 130 0.2400 9 160 0.2954 7.5 190 0.3508 6.5 30 25 21 175 175 175 386 386 386 10 8.5 7.5 33 28 25 195 195 195 430 430 430 11 9.5 8.5 36 31 28 215 215 215 474 474 474 13 11.5 10.
3.3.6 Calculating Moisture Retention Percent Moisture Retention is a measure the water remaining in the goods being processed. To determine the water retention of flatgoods being processed do the following: 1. Pull a sample of 10 pieces from the middle of the pile (goods on top tend to be dryer and will give false results). 2. Immediately weigh your sample of 10 goods and record that weight as ”W1”. 3. Pass them through the ironer once and wait 5 minutes. 3.
Figure 3.1: Machine Clearances 3.4 3.4.1 Site Requirements Service Clearance Figure 3.1 shows the recommended minimum service clearances. The dimensions shown are needed to adequately service and operate the machine with maximum efficiency. Reducing this clearance is not recommended. You must allow space around the machine for maintenance. 3.4.2 Floor Requirements The installation site must have flooring capable of supporting the weight of the machine without flexing.
3.4.3 Gas Requirements The ironer requires a significant gas service capable of providing the volume and pressure needed to achieve the BTU rating of the particular machine. Typical gas pressure ranges from 1/2 to 2 PSI with ratings up to 2.5 million BTU. Refer to the previous section for gas connection sizing, gas pressure requirements and BTU ratings. 3.4.4 Thermal Fluid Requirements The ironer is shipped with a minimal amount of thermal fluid.
Note! Do not use phase adders (roto-phase) on inverter driven equipment! The machine should be connected to an individual branch circuit not shared with lighting or other equipment. A lockable, load break rated, visible break disconnect switch with safe working clearances is required for all installations. A disconnect plug is also acceptable, so long as it is able to safely break the load, is in an accessible location, and can be locked.
3.5.2 Clean Gap Pieces Before placing the ironing modules, the gap piece(s) must be cleaned. There is a protective coating applied during the manufacturing process that protects the finely polished surface during shipping. Carefully remove the plastic covering, making sure that all plastic covering has been completely removed. Thoroughly wipe down the entire gap piece using a clean, dry lint-free cloth. Do not use solvents or abrasives during this process.
Figure 3.2: Module Bolting NOTE: The fork lift used must have the required capacity and be fitted with appropriate forks. The modules can be picked up at the I-Beams at the front side. If using a fork lift, then one side of the ironer is to be lifted and skid rollers are to be used for the opposite side. Lift the ironer and move it slowly to its destination. The passage of the load should be clear of any obstruction on the floor or overhead, such as power lines, ceiling beams and others.
Figure 3.3: Flange Cover Detail 3.5.6 Center/Front Module Placement With the module still on its skid, move it near its final position, about 12 inches (300mm) from the already placed module and remove the skid bolts. Place drip pans under the flange shipping covers (painted red). Note: Thermal Fluid may cause a skin reaction in sensitive individuals. Wear protective clothing. Refer to the Material Safety Data Sheet in the Appendix of this manual.
Figure 3.4: Thermal Fluid Flange Bolt Tightening edge of the chest. The endframes must rest firmly on the floor. • After the modules are set in location, bolt the lower I-Beams together using the hex bolts (M20 x 50). Do not tighten the bolts yet. • Bolt the upper connecting brackets between the modules using the hex bolts (M8 x 35). Do not tighten the bolts yet. • Level the modules by using sheet metal shims. The shims are to be used only under I-Beam at the chest support.
Install the drive motor assembly at the rear right-hand side of the ironer. Align the drive pulleys with the driven pulleys using a steel straight-edge. Anchor the drive unit to the floor. Install the V-Belts between the drive pulleys and the driven pulleys. Secure the machine to the floor or foundation if required by local codes. *ACCESS LADDER (OPTIONAL) Install the access ladder to the rear mounting position.
Figure 3.5: Compressed Air Connection Figure 3.
3.8 3.8.1 Exhaust Installation Exhaust Connection Separate venting of the machine into suitable exhaust systems is required for operator safety, ironer operation, and ironer reliability. Incorrect installation can lead to an unsafe environment for operators and damage to the ironer or padding. Labor and materials needed to properly vent the ironer must be locally sourced. Comply with all local codes regarding installation of the duct work. 3.8.
3.9 3.9.1 Gas Connection Gas Pressure Requirements The nameplate specifies the gas inlet pressure and BTU requirements of the machine. In order to perform reliably, the machine must be provided with the correct gas pressure and volume. Gas pressures provided outside of the range indicated on the nameplate will likely cause performance issues or malfunction of the machine. Verify before installation that the gas supply is sufficient to meet the requirements of the nameplate.
3.10 Thermal Fluid Connection & Filling 3.10.1 Thermal Fluid Familiarization Refer to the system diagrams on pages 28 and 29 for details on item nomenclature. 1. Thermal Fluid - The thermal fluid used is either Paratherm HE, Shell Thermia B, or an equivalent Fluid. Also referred to as ”thermal oil”, ”heat transfer fluid”. Formulations vary with different suppliers, but in general these fluids are not highly hazardous. See Appendix for detailed information and MSDS. 2.
10. PS3 (Pressure Switch 3) - This normally closed switch is connected to the outlet of the boiler. It protects the chests and transfer plates from excessive pressure and helps to confirm oil flow through the system. On some machines there is an isolation valve feeding this pressure switch branch line if present this valve should never be closed. 11. PS4 (Pressure Switch 4) - This is an optional normally closed pressure switch that goes open in the event of excessive system pressure.
5. Connect a 3/8” copper tube or other suitable tubing to the top of Valve D (bleed valve). The tube should be long enough to reach a clean 5 gallon bucket containing 1 gallon of oil. 6. Make certain that valves A, C and D are fully open. Valve B should be fully closed. 7. Open Valve E and begin pumping fluid into the system. Continue until a steady stream of fluid with little or no air comes out of the bleed tube into the 5 gallon bucket. 8.
Figure 3.7: Thermal Fluid System Digram 21. Set the main temperature control setpoint to 300o F (150o C). 22. Repeat step 16 until no air is released and the pump no longer cavitates. 23. The degassing procedure should now be complete.
Figure 3.
3.11 Riello Burner Setup IM Thermal Fluid Ironer, Initial burner setup procedure: NOTE: For LP Gas you must install an LP Gas kit in the burner and follow the kit instructions. Note that with LP gas the required pilot pressure, main regulator pressure, and delivery pressure for max firing rate are very different. 1. Set air bypass screw and gas disk at according to the guidelines in the Riello Manual for the maximum required firing rate.
14. When a good ”crossover” from pilot to main burn occurs regularly, continue. 15. Run the burner up to high fire, set the main regulator pressure for a clean burn with less than 50 ppm CO at 3% to 6% O2 on a combustion analyzer inserted in the flue get the CO as low as possible. A CO level of 10 ppm or less can be achieved very easily. 16.
Ignition electrode should be 1/8” from diffuser disk surface. Pilot tube face should be 5/16” from diffuser disk surface. Flame rod should be 1/8” from diffuser disk down stream surface. See Chapter 5, section 5.7.7 for full details on settings.
Chapter 4 Operation 4.1 4.1.1 Operating Procedure Perform Daily Inspection 1. Walk around machine and look for oil leaks, make sure the folder is in place, look for any loose parts and hazards. 2. Check the guide tapes. If there are many broken they should be replaced when the machine is cold. 3. Check the oil level. When the ironer is cold the level should be in the bottom 1/4 of the sight glass. When the machine is hot the oil will expand to 3/4 on the sight glass. 4.
10. When the Temperature on the upper display reaches about 270o F the machine is warm enough to be waxed. 11. Wax the ironer EVERY DAY according the waxing procedures. 12. After waxing the ironer is ready for work when the Temperature on the upper display is close to (10o F under) the temperature on the lower display. 4.1.2 Operating Tips Leave the ironer at a set working temperature and adjust the speed so that your goods come out just dry.
7. Open the wax pocket and spread a 10 – 12 inch (25 – 30 cm) wide, 1/8 inch deep band of wax across the width of the sheet starting from the front edge of the wax pocket. 8. Lay the wax pocket flap down on top of the wax (this prevents too much from getting in the roll padding). 9. Push the green on button to restart the machine and make sure the roll switches are in the down position. The machine will start up, lower the rolls and begin pulling the wax cloth into the first roll. 10.
7. Take the wax cloth out of the folder and let it rest and cool for a minute to make it safer to handle. 8. Move the wax cloth back to the front of the ironer. Position the front edge to the left side of the in-feed and feed the wax cloth again. 9. Again, make sure the wax cloth comes out of the folder evenly - it will be very hot so wear thick fabric or leather gloves to protect your hands. 10. Take the wax cloth out of the folder and let it rest and cool for a few minutes.
4.2.4 Taking A Break Standard practice with all chest ironers is to raise the rolls and turn off the roll vacuum during breaks. The roll padding wears much faster when turning in an uncovered chest so its important to raise the rolls when no work is being done. It has been said (and is probably true) that leaving the rolls down for a 15 minute break produces equivalent roll padding wear as 4 hours of working time. 4.2.
Chapter 5 Maintenance 5.1 Wrinkle Patterns The following figures will help to troubleshoot ironing problems based upon the types of wrinkles left in the flatgoods upon exiting the ironer.
Figure 5.
Figure 5.
Figure 5.
Figure 5.
Figure 5.5: Wrinkle Pattern caused by residue in the first chest. This is characterized by wrinkling across the leading edge. There is often a yellow stain at the front edge as well.
5.2 Lubrication All bearings should be lubricated with a high quality high temperature grease . Shell Darina EP2 or compatible is required. Mixing grease types can lead to catastrophic failure. Many types of grease bases (or soaps) are not compatible and can chemically react and fail. Lubricate bearings monthly, or every 200 hours of operation. 5.3 Chest Adjustment The chests are supported at each corner by two rollers (see figure 5.6 on page 45).
Figure 5.
Figure 5.7: Drive Belt Deflection Tester Table 5.1: Drive Motor to Intermediate Pulley Belt Deflection Table Ironer Size Working Width Deflection mm in mm in 1x800 4000 157 7 9/32 2x800 4000 157 7 9/32 3x800 3500 138 7 9/32 3x800 3700 145 7 9/32 3x800 4000 157 7 9/32 1x1200 4000 157 7 9/32 2x1200 4000 157 7 9/32 3x1200 2700 106 7 9/32 3x1200 3000 118 7 9/32 Force N 16-24 24-36 17-25 21-31 21-31 24-36 17-25 21-31 35-37 lb 3.6-5.4 5.4-8.1 3.8-5.6 4.7-6.9 4.7-6.9 5.4-8.1 3.8-5.6 4.7-6.9 7.8-8.
Figure 5.8: Drive Motor, Tensioner Pulley 5.4.1 Drive Motor to Intermediate Pulley Tension Adjustment To adjust the belt tension between the drive motor and intermediate pulley, proceed as follows (refer to figure 5.8 on page 47 and the tension chart, table 5.1 on page 46: 1. Move the main power switch to the off position. 2. Remove last side cover on right hand side of ironer. 3. Loosen bolts at drive motor frame, tension to required value using the tensioning bolts. 4. Retighten all fasteners. 5.
Table 5.2: Intermediate pulley to Variable pulley belt tension Ironer Size Working Width Belt Size Deflection Force mm in mm mm in N lb 800 3000+ 118+ 1500 5 5/16 16-24 3.6-5.4 1200 3000+ 118+ 1500 5 5/16 24-36 5.4-8.1 Table 5.3: Slip on gear to Infeed Roll Tension Chart Ironer Size Belt Size Deflection Force mm mm in N lb 800 3350 15 19/32 4-5 0.9-1.1 1200 4120 17 16-Nov 4-5 0.9-1.1 2. Move the main power switch to the off position. 3. Remove side covers on right hand side of ironer. 4.
Figure 5.
Figure 5.10: Roll to Roll Tension Adjustment 5.4.4 Roll to Roll Tension Adjustment To adjust the roll to roll belt tension proceeds as follows (refer to figure 5.10 on page 50 and the tension chart, table 5.4 on page 51): 1. Move the main power switch to the off position. 2. Remove side covers on right hand side of ironer. 3. Loosen nuts of tensioner idler located on a turnbuckle. 4. Adjust tension in belts as required. 5. Retighten all fasteners. 6. Replace covers and restart operation.
Table 5.4: Roll to Roll Tension Chart Ironer Size 2x800 3x800 2x1200 3x1200 Belt Size Module Numbers Deflection Force mm mm in N lb 3150 1 to 2 13 1/2 12-18 3.6-5.4 3150 1 to 2 13 1/2 9-13 2.0-2.9 3150 2 to 3 13 1/2 16-22 3.6-4.9 4000 1 to 2 16 5/8 13-19 2.9-4.2 4000 1 to 2 16 5/8 15-20 3.3-4.5 4000 2 to 3 16 5/8 26-39 5.8-8.7 Figure 5.11: Infeed Belt Tension Adjustment 5.4.
Figure 5.12: Measuring Roll Procession Table 5.5: Roll Procession Chart Ironer Size Turns Procession Length mm in 800 10 100-150 4-6 1200 10 150-200 6-8 1. Raise the rolls 2. Place a mark on the edge of each roll, and a corresponding mark on the frame of the machine, or a strip of metal near the roll, see figure 5.12 on page 52 3. Run the machine so that the first roll rotates 10 complete times, coming to rest at the mark 4.
Figure 5.13: Roll Procession Adjustment 1. Move the main power switch to the off position. 2. Remove side covers on the drive side. 3. Loosen nuts at tension idler between the intermediate pulley and the variable pulley. 4. Loosen set screws at the variable pulley outer flange. 5. Turn outer flange as required in 30 degree (rotate 12 o’clock to 1 o’clock for 30 degrees of rotation) steps. See figure 5.13 on page 53 6.
Figure 5.14: Correct overlap for roll pad trimming Single roll ironers are particularly sensitive to improper padding overlap because they don’t have a second roll to press the gap left by the first roll. If the padding is overlapped, goods will typically show a highly polished strip followed by a damp or wrinkled strip across the width of the roll. In this case the padding should be trimmed. If too much is trimmed an underlap condition will result.
Table 5.6: Replacement padding dimensions Model IM800x3000 IM800x3300 IM1200x3000 IM1200x3300 Width 130” (3.3m) 142” (3.6m) 130” (3.3m) 142” (3.6m) Length Replacement Wt. 197” (5.1m) 24 oz (800g/m2) 197” (5.1m) 24 oz (800g/m2) 295” (7.5m) 24 oz (800g/m2) 295” (7.5m) 24 oz (800g/m2) Factory Wt. (Break-in) 21 oz (700g/m2) 21 oz (700g/m2) 21 oz (700g/m2) 21 oz (700g/m2) 2. High alkalinity – this is usually from adding too much sour to get the pH down to 6.0.
Figure 5.15: The surgeon’s knot 5.7.2 Materials Guide tapes come in various materials and widths and materials. All IM chest ironers use 3/4” width material should be used for guide tapes. Guide tapes for ironing machinery are primarily available in 3 versions of 2 materials – Polyester and Nomex. Nomex is a Dupont trade name for a type of Aramid fiber with a maximum service temperature of 220o C, perfect for high temperature ironing.
Figure 5.16: The guide tape feed route existing one adjacent to the location where the tape is missing. You can then lower the rolls and jog the machine slowly to pull or ”thread” the new tape into the machine with an old one... with some practice you will become adept at keeping the tapes from becoming tangled. The new tape is then threaded through the tensioner at the location missing the tape. 5.7.
4. Loosen filler cap and flush gear box with flushing oil. 5. Tighten drain plug (use new gasket). 5.7.5 Pump Setup and Alignment When a new machine is started up, a new pump is commissioned, or when service involving draining the pump is performed the following procedures must be followed. 1. The pump and motor shafts must be properly aligned. The pump shaft must be set 0.010”0.015” lower than the motor shaft to allow for thermal expansion of the pump body (see formula below). 2.
Figure 5.17: Riello Cleaning diagram 3. Another normal path of failure of the mechanical seal is failure to observe the fill and vent requirement for the main bearing bracket. If this operation is overlooked or not carried out properly the seal will start up dry as will the main bearing and failure is only a matter of time. 5.7.7 Burner Cleaning To clean the blower cage on Riello Burners do the following: 1.
To clean the flame holder and flame rod assembly: 1. Disconnect power, Gas, and Air services from the machine. 2. Remove the pilot gas line from the top of the burner and put it in a safe place. 3. Remove the cover screw (1) and remove the burner cover (2). 4. Remove the head bolt (5) and disconnect the damper linkage (3) from the gas butterfly (4). 5. Slide the burner head back about 2 inches on the rods (6) and then disconnect the flame sense and ignition electrode connectors. 6.
Figure 5.18: Riello burner dissasembly Figure 5.
5.8 5.8.1 Thermal Fluid Maintenance Fluid Life The thermal fluid should be sampled and analyzed 1 to 2 times a year to monitor it for deterioration. However, in many settings the best practice is to change the thermal fluid annually. For analysis contact you thermal fluid supplier. Remember, the higher the working temperature, the shorter the fluid life will be. Careful and conservative laundry managers can potentially have fluid life of 2 years or more. 5.8.
5. Remove the screen, examine any particulate that have accumulated and clean the screen thoroughly with a wire brush. 6. Reinstall the screen, cover (use a new gasket), screws, and plug. Open valves A, B, and C. Refer to the thermal fluid system diagram for valve nomenclature details. 7. Purge the air from the system as described in the Thermal Fluid Filling procedure starting at step 10, found earlier in this manual. 5.8.
Figure 5.20: Typical thermal pump assembly 2. Close Valve A. 3. Connect a suitable hose barb and hose to the fluid outlet at Valve E. An oil rated inline pump may be needed. 4. When all connections are made and secured open Valve E and then Valve A. Fluid will flow into the pump. 5. Energize the pump and pump the oil out of the ironer and into your containers. 6. Remember that these containers will become very heavy so make provisions for getting them on a barrel truck of some type - think ahead! 7.
Table 5.
Table 5.
1. Infeed Safety Barrier - Test Daily - Test the bar by starting the machine and then pushing the barrier so that the bottom edge swings back 1-2 inches. The machine must shut down in this travel. 2. Left Front E-Stop - Test by starting the machine and then pressing the button. The machine must stop. 3. Right Front E-Stop - Test by starting the machine and then pressing the button. The machine must stop. 4. Left Rear E-Stop - Test by starting the machine and then pressing the button. The machine must stop.
13. Temperature High Limit Reset - After the previous step press the High Limit reset button to verify that it clears the high limit condition. 14. Burner Fault Lamp - At the rear of the machine press the button in the cover of the Riello Burner. The burner will fault and the button will be illuminated. At the front of the machine verify that the Burner Fault Lamp illuminates and audible alarm sounds if installed. 15.
oxidation. If the conductor is heavily oxidized, remove it, clean it, and replace using oxgard paste to prevent future oxidation in the connection. Verify that there is no paint between the lug and the panel. 26. Pump Current – While the machine is running and the oil pump is on with the oil at a temperature lower than 50o C, use a calibrated reliable AC Current clamp meter to measure the operating current in each conductor to the motor.
35. Low Pressure Switch - verify operation of the low gas pressure switch by recording its setting in the log sheet and then increasing the setting dial to a pressure above the regulator setting while the burner is operating. When the switch trips the low gas pressure light on the front of the ironer should light and the burner should shut down. Restore the switch to its original setting and press the reset button on the switch body.
45. Lock Pins - have an assistant operate the lift cylinders and pay attention to the lock pin on each cylinder. When the rolls are lowered the lock pins should pull out quickly and smoothly with no sticking 4 to 6 seconds before the rolls lower. If the time is shorter check the setting of timers KT2 and KT3.
Table 5.9: Burner Startup Report Form Date: Tested By: Customer: Location: Machine Model: Machine Serial Number: Voltage: Test Equipment: Calibration Date: Burner Model: Burner Serial Number: Fuel: Service Pressure Max: Min: Flame Sense Type: Pilot Regulator Setting: Main Regulator Setting: Gas Ring Setting: Air Screw Setting: Parameter Cam Position (deg.) O2 (%) CO (PPM) Stack Temp ( C ) Comb. Eff. (%) Stack Pressure (inWC) Flame Sense I.
Chapter 6 Appendix 6.1 6.1.1 Proper Drum Storage Recommended Storage Life Most lubricants have supplier recommended shelf lives based largely upon the lubricant’s additive package. For example, lubricants containing rust inhibitors may lose performance after as little as six months in storage. Conversely, some turbine fluids with a light additive dose may be shelved for up to three years. Shelf life information is available from your lubricant supplier and/or manufacturer for each product used.
6.1.2 Storage Indoor Storage – Pails, drums and totes must be stored in a clean and dry location. Storage temperatures should remain moderate at all times. Lubricants in storage should be located away from all types of industrial contamination including dust and humidity. Bungs must be kept tight at all times and drum covers should be used whenever drums are stored in the upright position (bungs at 3 and 9 o’clock positions).
• It is recommended that the oil be cycled through a high efficiency filter element with a beta rating matching your equipment requirements. If your storage method exposes the lubricant to moist environments, two-stage filtering with a water absorbing filter element is highly recommended.
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6.2 Paratherm HE MSDS Paratherm Corporation Material Safety Data Sheet SECTION 1 PRODUCT AND COMPANY IDENTIFICATION Product Name: Paratherm HE® Heat Transfer Fluid Company Identification: Paratherm Corporation 4 Portland Road West Conshohocken, PA 19428 USA Product Information: 610-941-4900 info@paratherm.
SECTION 5 FIRE FIGHTING MEASURES Extinguishing Media: Water fog, foam, dry chemical, or carbon dioxide (CO2) should be used. Do not use direct water stream Fire Fighting Instructions: Do not enter any enclosed or confined fire space without proper protective equipment, including self-contained breathing apparatus. Water spray may be useful in minimizing or dispersing vapors and to protect personnel. Cool equipment (including drums) exposed to fire with water if it can be done with minimal risk.
SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES Appearance: Almost water white before use Odor: none pH: NA Density: 7.18 lb/gal @ 75 ºF Flashpoint: > 440ºF Cleveland Open Cup Vapor Pressure: <1mm @70F Vapor Density (Air = 1): >1 Evaporation Rate (BuAc = 1): <1 Boiling Point: >500ºF Solubility: Insoluble in water. Pour Point: -10ºF SECTION 10 STABILITY AND REACTIVITY Chemical Stability: Stable under normal storage and handling conditions.
SECTION 15 REGULATORY INFORMATION United States RCRA Hazardous Waste Number and Classification: Not applicable TSCA Inventory Status: Included SARA Title III Section 313 and 40 CFR 372: Not subject to reporting requirements Clean Air Act Section 112: Not classified as a Hazardous Air Pollutant (HAP) California Proposition 65: This product does not contain materials which the state of California has found to cause cancer, birth defects, or other reproductive harm.
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6.3 Shell Thermia MSDS Thermia® Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 Material Safety Data Sheet 1. MATERIAL AND COMPANY IDENTIFICATION Material Name Uses : : Thermia® Oil C Heat transfer oil. Manufacturer/Supplier : SOPUS Products PO Box 4427 Houston, TX 77210-4427 USA 877-276-7285 MSDS Request : Emergency Telephone Number : 877-242-7400 Spill Information : 877-504-9351 Health Information 2.
Thermia® Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 Material Safety Data Sheet : Under normal conditions of use or in a foreseeable emergency, this product does not meet the definition of a hazardous chemical when evaluated according to the OSHA Hazard Communication Standard, 29 CFR 1910.1200.
Thermia® Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 Material Safety Data Sheet : Additional Advice Prevent from spreading by making a barrier with sand, earth or other containment material. Reclaim liquid directly or in an absorbent. Soak up residue with an absorbent such as clay, sand or other suitable material and dispose of properly. Local authorities should be advised if significant spillages cannot be contained. 7.
Thermia® Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 Material Safety Data Sheet Hand Protection : Eye Protection : Protective Clothing : Monitoring Methods : Environmental Exposure Controls : practices, precautions should be taken to avoid breathing of material.
Thermia® Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 Material Safety Data Sheet Water solubility n-octanol/water partition coefficient (log Pow) Kinematic viscosity Vapour density (air=1) Evaporation rate (nBuAc=1) : Negligible. : > 6 (based on information on similar products) : Typical 30 mm2/s at 40 °C / 104 °F : > 1 (estimated value(s)) : Data not available 10.
Thermia® Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 Material Safety Data Sheet organisms. Expected to be practically non toxic: LL/EL/IL50 > 100 mg/l (to aquatic organisms) (LL/EL50 expressed as the nominal amount of product required to prepare aqueous test extract). Mineral oil is not expected to cause any chronic effects to aquatic organisms at concentrations less than 1 mg/l.
Thermia® Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 Material Safety Data Sheet Notification Status EINECS TSCA DSL All components listed or polymer exempt. All components listed. All components listed. SARA Hazard Categories (311/312) No SARA 311/312 Hazards.
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6.4 Thermal Fluid Pump Etanorm SYA Operating Instructions 1220.8-10 G2 Thermal Oil / Hot Water Pumps Works No.: Type Series: Etanorm SYA These operating instructions contain fundamental information and precautionary notes. Please read the manual thoroughly prior to installation of unit, electrical connection and commissioning. It is imperative to comply with all other operating instructions referring to components of individual units.
Etanorm SYA Contents Page 1 General 4 2 2.1 2.2 2.3 2.4 2.5 2.6 4 4 4 4 4 4 2.8 Safety Marking of Instructions in the Manual Personnel Qualification and Training Non-compliance with Safety Instructions Safety Awareness Safety Instructions for the Operator / User Safety Instructions for Maintenance, Inspection and Installation Work Unauthorized Modification and Manufacture of Spare Parts Unauthorized Modes of Operation 3 3.1 3.
Etanorm SYA Index Section Page Section Page Accessories Admissible ambient temperature Aligning the Pump/Drive Auxiliary connections 4.6 7.2.1 5.3.1 5.4.1 6 11 7 9 Bearing temperature 7.2.1 11 Checking the direction of rotation Commissioning Commissioning, start-up Connecting the piping Connection to power supply Contact guard 5.7.3 6.1 6 5.4 5.7 5.
Etanorm SYA 1 General This KSB pump has been developed in accordance with state-of-the-art technology; it is manufactured with utmost care and subject to continuous quality control. These operating instructions are intended to facilitate familiarization with the pump and its designated use. The manual contains important information for reliable, proper and efficient operation.
Etanorm SYA Work on the machine must be carried out only during standstill. The shutdown procedure described in the manual for taking the machine out of service must be adhered to without fail. Pumps or pump units handling media injurious to health must be decontaminated. Immediately following completion of the work, all safety-relevant and protective devices must be re-installed and/or re-activated.
Etanorm SYA 4.4 Permissible Forces and Moments at the Pump Nozzles t = 20 C FVmax FHmax Mtmax Etanorm SYA 32-125.1 32-160.1 32-200.1 32-160 32-200 32-250 40-160 40-200 40-250 40-315 50-160 50-200 50-250 50-315 65-160 65-200 65-250 65-315 80-160 80-200 80-250 80-315 100-160 100-200 100-250 100-315 125-200 125-250 125-315 125-400 150-315 150-400.1 4.5 t = 300 C FVmax FHmax Mtmax [kN] [kN] [kNm] [kN] [kN] [kNm] 3.65 3.56 3.60 3.56 3.65 3.65 3.81 3.81 4.21 4.09 3.97 4.21 4.58 4.54 4.42 5.27 5.27 5.
Etanorm SYA 5 Installation at Site 5.1 Safety Regulations Electrical equipment operated in hazardous locations must comply with the explosion protection regulations. This is indicated on the motor rating plate. If the equipment is installed in hazardous locations, the applicable local explosion protection regulations and the regulations of the test certificate supplied with the equipment and issued by the responsible approval authorities must be observed and complied with.
Etanorm SYA The pump set is correctly aligned, if a straight-edge placed axially on both coupling halves is the same distance from each shaft at all points around the circumference. Make sure to turn the measuring point by hand all the time. In addition, the distance between the two coupling halves must remain the same all around the circumference. Use a gauge to verify, for example (see Figures 5.3-4 and 5.3-5). Straight-edge 5.
Etanorm SYA If required, connect the PTC resistors as per DIN 44081/ 44082 with the tripping unit in accordance with fig. 5.7.3. 5.5 Final Check Re-check the alignment as described in section 5.3.1. It must be easy to rotate the coupling/shaft by hand. The alignment check must be repeated at operatCaution ing temperature. Check the integrity and proper functioning of all connections. Fig. 5.7-3 Connecting the PTC resistors 5.
Etanorm SYA 6.1.4 Start-up Always make sure that the shut-off element in the discharge line is closed before the pump is started up. Only after the pump has reached full rotational speed shall the shut-off element be opened slowly and adjusted to comply with the duty point. 6.2.4 Minimum Permissible Speeds If the system is completely primed, start-up can take place with the shut-off valve on the discharge side open even when commissioning a new pump. 6.2.
Etanorm SYA 7 7.2.2 Lubrication and Lubricant Change Maintenance / Repair 7.1 General Instructions The operator is responsible for ensuring that all maintenance, inspection and installation work is carried out by authorized, duly qualified staff who are thoroughly familiar with these operating instructions. A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pump with a minimum of maintenance expenditure and work.
Etanorm SYA 7.4 Dismantling Before dismantling, secure the pump so as to Caution make sure it cannot be switched on accidentally. The shut-off elements in the suction and discharge lines must be closed and absolutely tight. Hot oil escaping or spurting out may self-ignite. The operator is responsible for the perfect functioning of the shut-off valves. Special care must be taken when repairing pumps installed in an on-duty system. The pump must have cooled down to ambient temperature.
Etanorm SYA Additional instructions: - Place joint ring 411.4 on discharge cover sealing face, to prevent it from slipping out of position. - Replace all joint rings and gaskets affected by dismantling. - Use specified deep-groove ball bearing 321 only. - Pack bearing with grease (see 7.2.2.3) - When fitting the deep-groove ball bearing, ensure the side with the cover plate points towards the pump side (see figs. 7.5-1, 7.5-2, 7.
Etanorm SYA 7.5.3 Tightening Torques 7.5.3.1 Pump G 1215:5/2 F Fig. 7.5-6 Bolt tightening points, spacer-type coupling Pump on baseplate Position Fig. 7.5-4 Bolt tightening points, pump Part No. 901.1 901.2 902.1 / 920.1 902.2 / 920.2 920.
Etanorm SYA Bearing housing 2) Bearing cover 1) Mechanical seal Seal cover 2) Seat ring holder 1) 210 230 310 321 330 350 360 433 471 476 502.1 502.2 25 25 25 25 25 25 25 25 25 35 25 25 25 35 25 25 35 35 25 35 35 35 35 35 35 35 35 35 55 55 55 55 32-125.1/. 32-160.1/. 32-200.1/. 32-160/.. 32-200/.. 40-160/.. 40-200/.. 50-160/.. 50-200/..
Etanorm SYA 7.6.2 Ordering Spare Parts When ordering spare parts please always quote the following data stated on the pump name plate, e.g.: Type series: Etanorm SYA 80-160 Works No.: 4-919-451 777 60 SYA or on the volute casing, e.g. EN 80-160 7.6.3 Recommended Spare Parts Stock for 2 Years’ Continuous Operation Part No. Description 210 230 321 330 433 502.1 - Shaft Impeller (incl. casing wear ring 502.2) Deep-groove ball bearing Bearing bracket cpl.
Etanorm SYA Vibrations during pump operation Excessive rise of temperature inside the pump Increase in bearing temperature Leakage at the pump Excessive leakage at the shaft seal Trouble-shooting Pump delivers insufficient flow rate Motor is overloaded Excessive pump discharge pressure 8 * * * * * * * Cause Remedy 1) Pump delivers against an excessively high discharge Re-adjust duty point. pressure. Excessively high back pressure. Check plant for impurities. Fit a larger impeller.
Etanorm SYA 9 Related Documents 9.1 General Drawing and List of Components of Etanorm SYA, SU 25 1) Version with non-balanced impeller (pump size 32-125.1) 1) For shaft unit / pump size combinations refer to section 7.6.1. Part No. 102 163 183 210 230 310 321 330 360 Description Volute casing Discharge cover Support foot Shaft Impeller Plain bearing Deep-groove ball bearing Bearing bracket Bearing cover Part No. 411.1/.3/.4/.5 412.1/.2 433 476 500 502.1/.2 550.1-/.4 901.1/.2 902.1/.
Etanorm SYA 9.2 Exploded View and List of Components of Etanorm SYA, SU 25 1) 330 210 550.3 920.3 930 940.1/.2 210 102 102 411.5 502.1 902.1 903.2 920.1 930 502.1 902.1 411.4 920.3 230 230 502.2 932.3 550.4 500 550.3 502.2 411.5 903.2 163 500 550.4 932.3 163 902.2 920.2 920.1 411.3 310 901.1 903.3 916 932.1/.2 330 310 321 360 411.1 412.1/.2 433 476 550.1/.2 903.3 411.1 6D 901.1 6D 1M 901.2 183 8B 902.2 920.2 411.5 903.2 6B 99-20 1215 : 14/6 940.1 210 210 550.3 920.3 930 940.
Etanorm SYA 9.3 General Drawing and List of Components, Etanorm SYA, SU 35, 55 1) 2) Pump size of shaft unit 55 1220:2 1) For shaft unit / pump size combinations refer to section 7.6.1 2) Not fitted on pump size 150-400.1 Part No. Description Part No. Description Part No. Description 102 163 183 210 230 310 321 330 360 400 411.1/.3/.4/.5 412.1/.2 433 476 500 502.1/.2 2) 550.1/.2/.4/.5 901.1/.2 Gasket Joint ring O-ring Mechanical seal Seat ring holder Ring Casing wear ring Disc Hex.
Etanorm SYA 9.4 Exploded View and List of Components of Etanorm SYA, SU 35, 55 1) 330 210 102 102 411.5 502.1 902.1 903.2 920.1 930 502.1 902.1 411.4 920.3 230 500 502.2 411.5 903.2 163 932.3 550.4 230 502.2 3) 500 550.4 932.3 210 920.3 930 940.1/.2 920.1 310 411.3 903.3 411.1 310 321 360 400 411.1 412.1/.2 433 476 550.1/.2 901.1 902.2 903.3 920.2 932.1 330 6D 6D 1M 902.2 920.2 8B 901.2 183 411.5 903.2 99-20 1215 : 17/6 6B 932.4 940.1 210 210 920.3 930 940.1/.2 550.5 940.
Please select the applicable declaration on the basis of the explanations below, depending on the criteria indicated and the actual delivery situation. ________________________________________________________________________________ Declaration of Conformity as per EC directive “Machinery“ 98/37/EC Please note: The declaration of conformity, in combination with the CE symbol, is only valid for machinery which is operative by itself (i.e.
Bl. 1 0045.
Bl. 2 0045.009--90 Machine-- richtlijn 98/37/EG, Bijlage II A, de richtlijn 89/336/EEG i.v.m.
Bl. 1 0045.
Bl. 1 0045.
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6.
CONTENTS TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packaging - Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. dimensions. . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA Model Output (1) MAX. MIN. Fuel - Max delivery - Pressure at maximum delivery (2) natural gas Operation Standard application Ambient temperature Combustion air temperature Main power supply (+/-10%) Fan motor MBtu/hr kW MBtu/hr kW RS 28/M 617 - 1232 181 - 361 198 58 SCFH “ WC 1232 2.
BURNER DESCRIPTION (A) 1 2 3 4 5 6 7 8 9 10 11 D2256 12 13 14 15 16 17 18 19 20 D2257 21 22 23 24 25 26 D2258 (A) inch A B C Two types of burner failure may occur: • FLAME SAFEGUARD LOCK-OUT: if the flame relay 22)(A) pushbutton lights up, it indicates that the burner is in lock-out. To reset, press the pushbutton. • MOTOR TRIP (RS 38 - 50 three-phase): release by pressing the pushbutton on thermal overload 20)(A).
FIRING RATES (A) Combustion chamber pressure “WC During operation, burner output varies between: • MAXIMUM OUTPUT, selected within area A, • MINIMUM OUTPUT, which must not be lower than the minimum limit in the diagram.
GAS PRESSURE RS 28/M The adjacent tables are used to calculate manifold pressure taking into account combustion chamber pressure. ∆p (“ WC) MBtu/hr kW Column 1 Pressure loss at combustion head. Gas pressure measured at test point 1)(B), with: • Combustion chamber at 0” WC • Burner operating at maximum output • A = Gas ring 2)(B)p.8 adjusted as indicated in diagram (C)p. 8. • B = Gas ring 2)(B) adjusted to zero. 1 2 624 699 795 891 986 1078 1174 1232 183 205 233 261 289 316 344 361 A B 0.98 1.
INSTALLATION inch A B RS 28/M 69/32“ 813/16“ 3/8 W RS 38/M 69/32“ 813/16“ 3/8 W RS 50/M 69/32“ 813/16“ 3/8 W BURNER MOUNTING (A) Drill the combustion chamber mounting plate as shown in (A). The position of the threaded holes can be marked using the head gasket supplied with the burner.
COMBUSTION HEAD ADJUSTMENT Installation operations are now at the stage where the blast tube and sleeve are secured to the boiler as shown in fig. (A). There are two possible cases: A - The MIN burner output is not in the values of table (D). In diagram (C), depending on the MAX output, find the notch to use for adjusting the air and the gas, and then proceed as follows: Air adjustment (A) Turn screw 4)(A) until the notch identified is aligned with the front surface 5)(A) of the flange.
GAS PIPING • The main gas train must be connected to the gas attachment 1)(A), using flange 2), gasket 3) and screws 4) supplied with the burner. • The main gas train can enter the burner from the right or left side, depending on which is the most convenient, see fig.(A). • Gas safety shut-off valves 5)-6)(B) must be as close as possible to the burner to ensure gas reaches the combustion head within the safety time range.
LOW GAS PRESSURE SWITCH AIR PRESSURE SWITCH D2548 D2547 (A) ADJUSTMENTS BEFORE FIRST FIRING Adjustment of the combustion head, and air and gas deliveries has been illustrated on page 8. In addition, the following adjustments must also be made: - open manual valves on the gas train. - Adjust the low gas pressure switch to the start of the scale (A). - Adjust the air pressure switch to the zero position of the scale (B). - Purge the air from the gas line.
BURNER CALIBRATION 1 The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet. 2 Adjust successively: 1 - First firing output 2 - Max. burner output 3 - Min. burner output 4 - Intermediate outputs between low and high fire 5 - Air pressure switch 6 - Minimum gas pressure switch D791 (A) 1 - FIRING OUTPUT Pilot adjustment has been illustrated on page. 7. 2 - MAXIMUM OUTPUT Maximum output of the burner must be set within the firing rate range shown on page 5.
Adjusting air delivery Progressively adjust the end profile of cam 4)(A) by turning the cam adjustment screws as they appear through the access opening 6)(A). - Turn the screws clockwise to increase air delivery. - Turn the screws counter-clockwise to reduce air delivery. 3 - MINIMUM OUTPUT Minimum output must be selected within the firing rate range shown on page 5. Press switch 2)(A)p.
5 - AIR PRESSURE SWITCH (A) - CO CHECK Adjust the air pressure switch after having performed all other burner adjustments with the air pressure switch set to the start of the scale (A). With the burner operating at min. output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out. Then turn the dial anti-clockwise by about 20% of the set point and repeat burner starting to ensure it is correct.
MAINTENANCE FLAME INSPECTION WINDOW Combustion The optimum calibration of the burner requires an analysis of the flue gases. Significant differences with respect to the previous measurements indicate the points where more care should be exercised during maintenance. Gas leaks Make sure that there are no gas leaks on the pipework between the gas meter and the burner. Flame inspection window Clean the flame inspection window (A).
Factory Wiring Diagram RS 28/M - RS 38/M single-phase With Siemens LFL control Continuous fan operation Change the wire connection from terminal 6 to terminal 1, move the jumper from terminals 12-13 to terminals 4-12 and remove the wire from terminal 13 of control box as indicated below.
ELECTRICAL CONNECTIONS Field Wiring Diagram RS 28/M - RS 38/M Single-phase with burner mounted Siemens LFL control Use flexible cables according to local Regulations. LAYOUT (A) - The RS 28/M - RS 38/M models electrical connection single-phase power supply LAYOUT (B) - The RS 38/M - 50/M models electrical connection three-phase power supply Fuses layout (A) - (B), see table (C). Wire size when not indicated: AWG18.
Factor Wiring Diagram RS 28/M - RS 38/M single-phase with Remote Panel D2396 (A) Factory Wiring Diagram RS 38/M - RS 50/M three-phase with remote panel D2403 (B) Key to Layouts (A) - (B) C - Capacitor CMV - Motor contactor DA - Siemens LFL Control box MB - Burner terminal strip MV - Fan motor PA - Air pressure switch RT - Thermal overload S1 - Switch for following operations: MAN = manual AUT = automatic OFF S2 - Button for: - = power reduction + = power increase SM - Servomotor SO - Ionisation probe (f
APPENDIX - Burner firing rates according to air density CORRECTION FACTOR F above sea level average barom. pressure Air temperature °F (°C) ft m “ W.C.
BURNER OPERATION Full Modulation BURNER STARTING • Operating closes. Fan motor starts. • Servomotor starts: 90° rotation to right, until contact is made on red cam. The air damper is positioned to MAX. output. • Pre-purge stage with air delivery at MAX. output. • After pre-purge stage, servomotor rotates to left up to the angle set on blu cam for MIN. output. • The air damper and the gas butterfly are positioned to MIN. output. • Ignition electrode strikes a spark. • Pilot valve opens.
BURNER FAULTS Control program under fault conditions and lock-out indication In case of any disturbance, the sequence mechanism stops and with it the lock-out indicator. The symbol above the reading mark of the indicator gives the type of disturbance: No start, e.g. because one contact is not closed. Lock-out during or after control program sequence due to extraneous light (e.g. non-extinguished flames, leaking fuel valves, defects in the flame supervision circuit, etc.
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6.6 Riello Burner Parts Manual Catalogo ricambi Spare parts list Catalogue pièces détachées Ersatzteile Katalog Catálogo recambios Bruciatori di gas ad aria soffiata Blown gas burners Brûleurs gaz à air soufflé Gebläse-Gasbrenner Quemadores de gas Funzionamento bistadio progressivo o modulante Progressive two-stage or modulating operation Fonctionnement à 2 allures progressives ou modulant Gleitend-zweistufiger oder modulierender Betrieb Funcionamiento a dos llamas progresivas o modulante COD. MOD.
139 8173
300 3760 300 3761 300 3762 301 2063 300 3830 301 2077 300 3879 301 2078 300 3843 301 2064 300 3841 300 3763 300 3842 300 3765 300 3766 300 7627 300 3768 300 6090 300 5285 300 3781 300 3782 301 2079 300 3847 301 2080 300 3816 300 3772 300 3773 300 3778 300 3891 300 7444 301 2089 300 3848 300 3794 300 3844 300 3845 300 3846 300 3854 300 3855 300 3856 300 3857 300 3858 300 3859 300 3860 N. COD.
300 3861 300 3862 301 2081 301 2082 301 2083 300 3868 300 3869 300 3849 300 3865 300 3866 300 3867 301 2174 301 2177 300 3850 300 3851 301 2129 301 2130 300 3409 301 2191 300 7166 300 3864 300 3660 300 6953 300 3873 300 3797 300 3798 300 3799 300 3800 300 3801 300 3802 300 3803 300 3804 300 3805 300 3806 300 3807 300 3808 300 3809 300 3810 3003811 300 3812 300 3817 300 3893 300 3875 300 3874 300 3876 N. COD.
142
6.
144 70 C6505066 - 2918310
1 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 17 17 18 18 19 19 20 21 22 23 23 23 23 24 25 26 27 27 28 29 30 30 30 3012985 3012986 3003760 3012063 3003830 3003890 3003879 3012988 3003843 3012064 3003841 3003763 3003842 3012987 3013873 3003766 3007627 3013009 C5830008 3012955 3012989 3012990 20006633 3012991 3013123 3012079 3013871 3012956 3012080 3013008 3012993 3012994 3013057 3013869 3003778 3003891 3012948 3012089 3013872 3003848 3012995 3003844 3003845 3003846 • • • • • • • • • • • • • • • • • •
31 32 33 33 33 34 34 34 35 35 35 36 36 36 37 38 39 40 41 42 43 44 45 46 47 48 48 48 49 49 50 50 50 51 52 53 54 55 56 57 58 59 60 C5360002 3003854 3013129 3003857 3003859 3003861 3012081 3002082 3002083 3012997 3012998 3012999 3003865 3003866 3003867 3012174 3013136 3013001 3013002 3007166 3003863 3013007 3012085 3003873 3003797 3003798 3003799 3003801 3003803 3003805 3003806 3003807 3003809 3003811 3013010 3003893 3003875 3003874 3013003 3003878 3005483 3013004 3003780 3003829 • • • • • • • • • • • • • •
C9522350 (3781470) C9522351 (3781475) C9523300 (3781670) C9523301 (3781675) (3781676) 3013005 3003888 3003883 3006098 3003203 3003881 3012062 3013006 3013478 3013874 C9522300 (3781270) 61 62 63 64 65 66 67 68 69 70 CODE C9521300 (3781070) N.
