Chest heated ironers - Alliance Laundry...
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CFFS500/2000 CFFS500/2500 CFFS500/3000 CFFS500/3300 Technical specifications Installation instructions Operating instructions Maintenance (Gas heating) Chest heated ironers Instruction manual Part No D1481
Transcript of Chest heated ironers - Alliance Laundry...
CFFS500/2000CFFS500/2500CFFS500/3000CFFS500/3300Technical specificationsInstallation instructionsOperating instructionsMaintenance
(Gas heating)
Chest heated ironersInstruction m
anual
Part No D1481
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- The padding
- The feed bands.
- Chains
- Pump seals.
- Oil change.
- Transport damage.
- Components damaged by poor maintenance.
- Spare parts who are placed by a technician who is not trained or schooled by
--LACO.
WE CAN’T GIVE ANY WARRANTY TO THE FOLLOWING ELEMENTS:
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FOREWORD
This manual contains information on installation, use and maintenance.
The machine operator should read this manual carefully in order to get to know the machine
before starting it up.
In this document, we have tried to answer questions which might arise. For further
information or an explanation, please contact the After-Sales Service department.
The photos, drawings and text are as up-to-date as possible. Deviations may arise as a result
of technical improvements or special options chosen by the owner. The drawings may only be
used to explain and clarify how the machine works.
Under no circumstances should these be used for any other purposes.
This manual will also help you to get the best out of your machine.
If you require information or wish to order certain parts, it is important to always
specify the machine registration number.
LOCATION OF MACHINE REGISTRATION PLATE
Machine number plate + CE plate
can be found on the front in the
bottom right-hand corner.
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PART 1: INSTALLATION INSTRUCTIONS 6
1.1 HANDLING THE MACHINE 6 1.2 LAYOUT AND CONNECTIONS 7 1.3 TECHNICAL DATA AND DIMENSIONS 8 1.4 INSTALLATION 9 1.5 GENERAL. 14
PART 2: OPERATING INSTRUCTIONS 15
2.1 POINTS TO BE CHECKED ON A DAILY BASIS BEFORE START-UP 15 2.2 NORMAL USE – ABNORMAL USE 15 2.2.1 NORMAL USE 15
2.2.2 ABNORMAL USE 16 2.3 CONTINUOUS RISKS ASSOCIATED WITH THE MACHINE – MEASURES TO BE TAKEN 16 2.4 OPERATING PANEL 17 2.5 OPERATING INSTRUCTIONS 18 2.5.1 ADDITIONAL POINTS 18 2.6 SAFETY INSTRUCTIONS 19 2.6.1 THE HAZARD POINTS 19
2.6.2 SAFETY DEVICES 19 2.6.3 THINGS YOU SHOULD DEFINITELY NOT DO 19 2.6.4 RULES 19
2.6.5 MEASURES TO BE TAKEN IN AN EMERGENCY SITUATION 20
PART 3: MAINTENANCE INSTRUCTIONS 21
3.1 MAINTENANCE INSTRUCTIONS 21 3.2 OTHER MAINTENANCE INSTRUCTIONS 21 3.3 RISKS WHICH MAY ARISE AS A RESULT OF POOR MAINTENANCE 22 3.4 TYPES OF OIL 23 3.5 HYDRAULIC PRESSURE REGULATION 24 3.6 REPLACING AND SETTING THE TENSION OF THE FEED BELTS 25 3.7 SETTING THE SAFETY THERMOSTAT 25 3.8 PROBLEM SOLVING 26 3.8.1 THE MACHINE DOES NOT HEAT UP TO ANY TEMPERATURE AFTER SELECTING THE
PREHEATING FACILITY (TOUCHSCREEN) 26 3.8.2 THE MACHINE IS UP TO TEMPERATURE BUT THE IRONING BED WILL NOT CLOSE 26
3.8.3 THE IRONING BED IS CLOSED BUT THE ROLLER IS NOT ROTATING 27 3.8.4 THE EXHAUST SYSTEM IS NOT WORKING 27
3.8.5 NO CONTROL VOLTAGE 27 3.8.6 FOLDS IN LINEN 28
3.8.7 THE SAFETY THERMOSTAT DROPS OUT 28 3.8.8 MACHINE STARTS UP READY FOR HEATING BUT THE GAS BURNER IS NOT WORKING 28 3.8.9 CARRIAGES DO NOT OPEN 29
3.8.10 CARRIAGES REMAIN LIVE 29 3.8.11 GRIPPERS LET GO TOO EARLY 29
3.8.12 POOR LONGITUDINAL FOLD 30 3.8.13 MACHINE DOES NOT CARRY OUT THE FIRST CROSSFOLD 30
3.8.14 MACHINE DOES NOT CARRY OUT THE SECOND CROSSFOLD 31 3.8.15 MACHINE DOES NOT CARRY OUT THE THIRD CROSSFOLD 31 3.8.16 STACKING GRIPPER IS NOT HANDLING SHEETS PROPERLY 32
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3.8.17 STACKING GRIPPER REMAINS ON TOP 32 3.9 OIL CHANGE IN REDUCTION GEARBOX 33 3.10 THERMAL OIL CHANGE. 34 3.11 CLEANING OF THE BED. 37 3.12 ROLL PADDING REPLACEMENT. 38
PART 4: SCHEMATIC DIAGRAMS 45
4.1 CROSS-SECTION OF CROSSFOLD COUPLING 45 4.2 CROSS-SECTION OF STACKER 47 4.3 CROSS-SECTION OF EXIT BELT 48 4.4 DRIVE FOR FEED ROLLER TO IRONING ROLLER 49 4.5 HYDRAULIC CIRCUIT 50 4.6 METHOD OF FOLDING 51 4.7 CROSS-SECTION OF LONGITUDINAL FOLDING 52 4.8 DRIVE FOR CROSSFOLDER. 53 4.9 SET-UP FOR CONTACT FINGER GUARD. 54 4.10 VALVE ISLAND 55 4.11 PNEUMATIC DIAGRAM 56
PART 5 : FACTORY SETTINGS AND OPTIONS. 60
5.1 ALTIVAR 60 ALTIVAR 312 : 60 5.2 THERMAL OVERLOAD 71 5.3 LOADING BACKUP PROGRAMS ONTO THE B&R SCREEN WITH USB STICK. 71 5.4 ADJUSTABLE SUCTION VALVE (OPTION). 72
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PART 1: INSTALLATION INSTRUCTIONS
1.1 Handling the machine
NEVER LIFT THE MACHINE USING A FORKLIFT TRUCK
(This can cause irreparable damage) -
- Remove any obstacles under machine placement area.
- Fasten the lifting cables to the supplied lifting eye bolts on the top.
- Lift machine.
- Make sure cable is positioned correctly so that machine hangs horizontally.
- Make sure nobody walks under the load.
- Lift and relocate machine carefully, without sudden shocks or movements.
- Place machine on ground, as close to the permanent location as possible.
- If the machine needs further moving, use rollers.
Important: To use rollers, place rollers in four corners, distributing weight evenly.
- Once machine is in final position open hydraulic valve to release chest.
- Remove all packing materials.
- Level machine.
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1.2 Layout and connections
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1.3 Technical data and dimensions C500/2000 C500/2500 C500/3000 C500/3300
Roll Diameter
Length
500 mm
2000 mm
500 mm
2500 mm
500 mm
3000 mm
500 mm
3300 mm
Dimensions Height
Width
Depth
1430 mm
3833 mm
2155 mm
1430 mm
4333 mm
2155 mm
1430 mm
4833 mm
2155 mm
1430 mm
5133 mm
2155 mm
Speed Minimum
Maximum
1.5 m/min
5-12 m/min
1.5 m/min
5-12 m/min
1.5 m/min
5-12 m/min
1.5 m/min
5-12 m/min
Temperature Minimum
Maximum
150°C
175°C*
190°C*
150°C
175°C*
190°C*
150°C
175°C*
190°C*
150°C
175°C*
190°C*
Motors Roll
Fan
Hydr. pump
Circulation
pump
0.75 / 1.5 kW
0.25 kW
0.37 kW
2.2 kW
0.75 / 1.5 kW
0.25 kW
0.37 kW
2.2 kW
0.75 / 1.5 kW
0.25 kW
0.37 kW
2.2 kW
0.75 / 1.5 kW
0.25 kW
0.37 kW
2.2 kW
Electr.
Connection
(D curve)
Cable section
220 V 50 Hz
380 V 50 Hz
230 V
400 V
80 A
40 A
3 x 16 mm² +PE
3 x 10 mm² + PE + N
80 A
40 A
3 x 16 mm² +PE
3 x 10 mm² + PE + N
80 A
40 A
3 x 16 mm² +PE
3 x 10 mm² + PE + N
80 A
40 A
3 x 16 mm² +PE
3 x 10 mm² + PE + N
Weight kg 1560 kg 1660 kg 1950 kg 2050 kg
Packaging H x D x W 1.5 x 1.7 x 3.9 m 1.5 x 1.7 x 4.4 m 1.5 x 1.7 x 4.9 m 1.5 x 1.7 x 5.2 m
Noise Decibels 65 dB 65 dB 65 dB 65 dB
Capacity
burner
kW 16 - 52 16 - 52 35 - 91 35 - 91
Gas inlet Pressure Min. 20mBar Min. 20mBar Min. 20mBar Min. 20mBar
Diameter ½” ½” ½” ½”
Gas outlet m³/h 80 80 135 135
°C 260 260 260 260
Throughput
Diameter
90 mm
90 mm
90 mm
90 mm
Gas
consumption
m³/h 1,48 – 4,81 1,48 – 4,81 3,24 – 8,41 3,24 – 8,41
Gas setting kcal/h 13800 - 44700 13800 - 44700 30100 - 78200 30100 - 78200
Vapour outlet m³/h 650 650 650 650
°C (temp
170°C)
100°C 100°C 100°C 100°C
Throughput
Diameter
75 mm 75 mm 75 mm 75 mm
Air intake (100% dry air! )
l/min. 450 450 450 450
Pressure Min. 6 Bar Min. 6 Bar Min. 6 Bar Min. 6 Bar
Diameter ½” ½” ½” ½”
Air supply m³/h 2300 2300 2300 2300
Capacity Residual
moisture
50% temp.
175°
75 kg/h 95 kg/h 115 kg/h 125 kg/h
* All gas calculations are with
a gas type with a calorific value of 9300 kcal/h.
Example: gas consumption = 44700 / 9300
= 4,81m³/h
*Max. temperature for polyester is 175°C
Max. temperature for nomex is 190°C
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1.4 Installation
1. Unload the machine as described. (See 1. Handling the machine)
The best way to move the ironing machine is using a loading platform. The ironing
machine should be set up so that it is perfectly level.
There should be a space of at least 50 cm on the left and right of the machine in order
to enable installation and maintenance activities to be carried out.
The walls through which the air outlet pipes are routed should be made of non-
flammable material.
The ironing machine should have a sufficient air supply (2300 m²/h approx.)
(an insufficient air supply can cause the machine to overheat!)
Move the machine using the
lifting holes provided Do not lift the machine using
a crow bar
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2. Remove all packaging materials such as plastic and cardboard from the machine and
clean the ironing bed before heating up the machine.
Do not use explosive products to do this.
3. Remove the wooden blocks from underneath and set down the machine in such a way
that it is level.
4. Remove the lifting aids.
Packaging material
See also the drawings provided!
Remove wooden
blocks
Lifting eyes for cables
Screw the plugs provided
into the lifting holes.
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5. Electrical connection
Compare the type of cables and voltage with the machine data and bear the guidelines
in mind.
It is important for the electrical connection to be carried out by a technical specialist in
order to ensure that the installation complies with the standards and directives which
apply at the site where the machine is being installed.
The nominal cross-section of the line connection selected should be suitable for the
nominal electrical load specified on the ironing machine.
The ironing machine should be earthed in order to ensure that it operates correctly and
safely.
The main cable should be routed inside via the adapter sleeve which sits in the frame
at the side of the electrical battery.
The connecting cable can be connected to the main switch (L1-L2-L3-N-PE) in the
left-hand battery.
Once the main connections have been made, the main switch can be set to position 1
and the direction of rotation of all the motors should be checked! (to prevent damage)
6. Air connection
The connection to the machine is ½". The air pressure should be 6Bar with a flow of
450 l/min. The air must be 100% dry air!
7. Exhaust connection
The exhaust is located at the back on the right-hand side and has the following
dimensions:
Gas exhaust outlet: diameter 90 mm
Ironing roll exhaust: diameter 75mm
Connection of the main
switch:
Ironing roller
exhaust
Air connection
Sortie gaz
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The law requires that the steam outlet be completely separate in order to prevent fire.
The vapour outlet should consist of a heat-resistant pipe (150°C).
In order to ensure that it works properly, this pipe should always be kept as short as
possible and should have as few bends as possible.
If an outlet duct is connected to a main duct, the angle of incidence should not exceed
45°.
If the distance from the outlet duct is greater than 5 metres, a series of exhausters
should also be fitted underneath the outlet duct or the pipe diameter should be
increased! (e.g. 125 mm instead of 75 mm)
Insulate both the gas and steam outlet pipes in order to prevent fire.
8. Raccordement au gaz
Comparez le type de gaz (gaz naturel, propane) avec les informations de la machine, et
tenez compte des directives indiquées.
Il est important de faire faire les raccordements au gaz par un spécialiste agréé
afin de s'assurer que l'installation réponde aux normes ainsi qu'aux directives
qui sont en vigueur là où la machine est installée.
Le gaz alimentant la machine doit correspondre au type de gaz qui est spécifié
sur la plaque de la machine.
La pression du gaz naturel et du propane doit se situer entre 20 m/bar et 65 m/bar. Si la
pression dépasse 65 m/bar, un pressostat de gaz doit être installé en amont du
robinet de gaz.
Faites également attention au diamètre du conduit de gaz. Le raccordement à la
machine est ½.
Si la distance entre le compteur de gaz et la machine est supérieure à 10 mètres, il est
recommandé d'utiliser une conduite de gaz d'une diamètre supérieur (par ex. 1'' au lieu
de ½“).
Note :
Le non-respect des directives d'installation peut entraîner une résistance dans le
conduit d'évacuation qui peut nuire au bon fonctionnement et à la qualité.
9. Lorsque le câble de connexion est relié, l'interrupteur principal peut être placé en
position 1 et le sens du mouvement des moteurs doit être contrôlé (pour empêcher tout
dommage).
Raccordement au
gaz 3/4”
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10. Tighten the felt around the roller as described later on in the manual.
11. Burner adjustment.
On startup of the machine on location, burner settings have to be adjusted by an
recognized or competent person and be inspected on standards in the concerned
region. Burner settings also have to be adjusted every 12 months for optimal burning
and efficiency, also by a recognized or competent person.
12. The machine is now ready for use.
The heating system must be fully bled the first time the machine is warmed up.
This bleeding is done by removing the existing teflon hose.
There is another supplied hose at the top of the machine.
Fit this where the other hose was removed and take a metal bucket and put the hose
into the bottom of the bucket so the moisture can be captured.
Once the machine has warmed up, the supplied hose can be removed again and the
existing teflon hose replaced.
Existing
teflon hose
Size of metal bucket
+ supplied teflon
hose
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13. Install the bench horizontally at the back of the machine.
1.5 General.
- The service life of an ironing machine with a steel ironing bed is approximately 15
years with normal maintenance.
This is an estimate.
It is not binding.
No compensation may be claimed for a shorter service life.
- Noise level: 60-65 db depending on speed.
Undo bolts and rotate bench 90° so that you can
screw the same bolt back in and place the bench flat
(spirit level). Then tighten both bolts well.
Dismantle the protective plate at the back.
Allow the machine to warm up (adjust the temperature setting to 175°) and press
start and at the same time press against the finger guard so that the bed closes and
the roll does not turn. Loosen the tensioning screws and adjust the distance between
the bed and bench so that they are 2 mm apart. Then tighten the tensioning screws
again.
Tensioning screws at the
bottom of the bench
Distance between
bed and bench 2
mm
Fit and secure the protective plate.
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PART 2: OPERATING INSTRUCTIONS
2.1 Points to be checked on a daily basis before start-up
- Check the direction of rotation of all the motors.
- Check that all safety guards are in position and closed.
- Check that the finger guard is working properly and adjusted correctly.
This means that the opening between the finger guard and the feed belts should not be
more than 15 mm.
- Check that the emergency stop devices are working properly.
- Before starting, make sure that all the hazard areas are clear.
- Check that there are no foreign objects between the roller and the bed of the ironing
machine.
- Check the condition of the felt.
If the wire attaching the felt is exposed, it will have to be replaced.
- Check the condition of the feed belts.
- Clean the machine to remove any dust.
- Check the machine for leaks.
2.2 Normal use – Abnormal use
2.2.1 Normal use
- The machine is designed to be used for ironing all types of flat linen such as sheets,
double sheets, hand towels, pillows, handkerchiefs, etc. (No shorts or sheets with
loose-hanging ribbons!!)
- The maximum temperature is 190°C.
- The minimum temperature is 150°C.
- The temperature will have to be adapted to the felt (polyester up to 175°C and Nomex
up to 190°C)
- The machine settings for installation, the pressure of the felt, etc. should be in
accordance with the specifications in the manual.
- Maintenance should be carried out on the machine at regular intervals as described in
the manual.
- Only spare parts supplied by the manufacturer should be used.
The manufacturer will not accept any liability for defects or accidents due to improper
use of the machine or spare parts not supplied by the manufacturer.
- Do not allow hard objects to be fed between the roller and the bed.
- Do not allow meltable materials to be fed between the roller and the bed.
- Take account of all safety measures.
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2.2.2 Abnormal use
- Items to be ironed are not flat.
- Allowing the machine to operate under no-load conditions (without feeding in linen).
- Temperatures above 175°C if polyester felt is used and 190°C if Nomex felt is used.
- Cleaning the bed with hard materials (can cause irreparable damage).
- Operating the machine without taking precautionary safety measures.
- Failing to comply with safety measures.
2.3 Continuous risks associated with the machine – measures to be taken
- All the external pipes from the machine for the exhaust outlet and gas outlet pose a
real risk of burn injury.
For that reason, all these pipes should be insulated properly against direct contact and
protected.
- The personnel operating the machine should be trained so that they know what to do in
emergency situations, e.g. what to do if someone becomes trapped, what to do in the
event of a fire, how to analyse the machine, etc.
- The hot linen which comes out of the machine can cause burn injuries.
For that reason, it is necessary to wear personal protection such as gloves when
handling the linen.
- When the machine is in operation, keep inflammable materials as far away as possible.
There are still flammable materials present in the form of the felt, feed belts and the oil
in the machine.
The greatest risk is presented by dust.
In certain circumstances, dust can form a highly explosive mixture.
That is why it is essential to clean the machine regularly.
- Also create an equipotential connection so that no differences in potential can arise
between the machine and the surrounding metal structures in order to prevent flash-
over.
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2.4 Operating panel
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2.5 Operating instructions
See appendix to B&R manual.
Note:
- If the emergency stop button "S1" is activated, all the motors and the heating system
will be deactivated and the ironing bed will open automatically. The only way to
restart the machine is by turning the emergency stop button clockwise and pressing
button "S6" (RESET) again.
- If pressure is applied to the finger guard, the roller will stop immediately but the
temperature will remain constant and the bed will remain pressed against the roller.
- The machine can be restarted by pressing button "S6" (RESET).
Note:
- If the finger guard is activated, the bed will remain pressed against the roller. That is
why you are strongly advised to rotate the roller again or switch off the machine
completely.
2.5.1 Additional points
- Feed a piece of waxed fabric through the ironing machine 2 to 4 times a day in order
to wax the bed. If you do not do this, the bed will not provide a sufficiently smooth
surface and static electricity can be created, resulting in poor ironing quality.
- Never let the roller press against the bed unless it is rotating. Otherwise it will cause
damage to the felt.
- Clean the ironing bed regularly using a special cleaning cloth (available as an option
with the machine).
Finger guard
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2.6 Safety instructions
2.6.1 The hazard points
- Hot ironing bed.
- The entry point between the roller and the ironing bed.
- Hot linen at the exit point from the roller.
- Feed belts.
- Rotating elements (brush system).
- The carriage bar.
- Third crossfold.
2.6.2 Safety devices
- Emergency stop button at each corner and in the middle of the machine.
- Finger guard at the point of entry to the roller.
- Emergency stop relay.
- Controlled supply of 24 VDC.
- Thermal insulation around the cables and the ironing bed.
2.6.3 Things you should definitely not do
- Do not stick your hands under the finger guard, between the feed belts or under the
carriage bar.
- Do not try to pull out items which have already been fed into the machine.
- Do not wear loose clothing, bracelets or rings. Tie long hair back.
- Never use the machine without the protection of safety equipment. Make sure that the
safety devices are closed before starting to use it.
- Never sit on or crawl onto the machine.
2.6.4 Rules
- Check that the safety devices are working properly on a daily basis.
- Stop the machine if any intervention is required or if any abnormality occurs.
- Train your employees so that they know what to do in an emergency situation.
- Do not wear loose clothing. Tie long hair back.
- Do not wear any jewellery.
- Wear gloves when handling hot linen.
- Read the operating instructions before working on the machine.
- Switch off the motors when working on the machine.
- Prevent the machine from starting up again while maintenance or repairs are being
carried out.
- Report any damage immediately.
- If you are working on hot components, wear protective clothing.
- Only clean the machine if it is completely cold and has been switched off.
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2.6.5 Measures to be taken in an emergency situation
Situation 1: Emergency stop function fails
- Stop the machine by operating the main switch.
- Check that the emergency stop facilities and other safety devices are working properly
on a regular basis.
Situation 2: A person becomes trapped between the roller and the ironing bed.
- Press the emergency stop button "S1".
- The ironing bed will be lowered automatically and the person can be freed.
- Call the emergency services and administer first aid.
Situation 3: Getting caught in the feed belts.
- Press the emergency stop button "S1".
- Cut away the feed belts.
Situation 4: Electrocution
- Disconnect the principal voltage immediately and only then free the person. Otherwise
there is a risk that you will be electrocuted. Administer first aid. Call the emergency
services immediately.
- Check earth leakage circuit breaker.
Situation 5: Fire
- Press the emergency stop button and switch off the principal voltage immediately.
- Put out the fire using a CO extinguisher if necessary!
Situation 6: Broken pipes
- GAS: Close the gas tap immediately. Open all windows and doors.
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PART 3: MAINTENANCE INSTRUCTIONS
3.1 Maintenance instructions
Check that the safety equipment is working on a daily basis!
3.2 Other maintenance instructions
On a daily basis
- Feed a piece of waxed fabric (cleaning cloth) through the ironing machine some 2 to 4
times a day. (4 times when the linen doesn’t enters smoothly the chest, or when there
are creases in the linen.) (1 x wax ± 5min.)
- Clean the machine with a vacuum cleaner or with air pressure. (1 person ± 10min.)
12 x per year
- Clean the burner. (1 person ± 20min.)
4 x per year
- Clean the turbines on all the motors including those for the exhaust, circulation pump,
brush system, carriage bar, roll drive motor and the hydraulic pump.
(1 person ± 30min.)
2 x per year
- Check the tension of the chain and feed belts.
Every year
- Replace the gear oil. (1 person ± 30min.)
- Lubricate the chain. (1 person ± 5min.)
- Lubricate the roll drive bearing at the suction side. (Only 600 – 800)
(1 person ± 10min.)
Every 2 years:
- Change thermal oil every 2 years or every 3500 hours.
(1 person ± 6 hours)
Every 5 years:
- Change hydraulic oil every 5 years. (1 person ± 30 min.)
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Other instructions
- Drain the water in the tank pressure regulator (pneumatic air). (Min. once a week)
(1 person ± 10min.)
- Cleaning the chest and changing the roll padding.
(1 person ± 5 hours) (2 persons ± 4 hours)
- Changing the foldingbands.
(All the bands ± 8 hours) (1 band ± 20 – 60min.)
- If rust appears on the bed (water-salt deposits at the point of entry to the bed), then the
ironing bed should be cleaned using a special cloth which is available (cleaning cloth).
- Maintenance should be carried out in accordance with the maintenance schedule
enclosed. It should be carried out after the machine has been stopped and is cold.
The manufacturer will not accept any liability for defects or accidents due to failure to
carry out maintenance or poor maintenance resulting from or due to the use of
additional parts not supplied by the manufacturer.
3.3 Risks which may arise as a result of poor maintenance
- Rapid wear to gear wheels or bearings if they are not lubricated sufficiently.
- If the bearings are not lubricated sufficiently, this can cause a fire hazard.
- If the safety equipment is not checked on a daily basis, faults in the machine can lead
to serious accidents.
- If you wait too long before replacing the felt, this can cause irreparable damage to the
ironing bed.
- Dust on the machine can cause a fire or even an explosion.
- Worn or missing feed belts can pose a risk to fingers or the linen may get caught.
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3.4 Types of oil
ATTENTION:
Each mechanical drive uses its own specific type of oil. Therefore the
correct type of oil should be used when the oil is changed.
Roller drive gearbox
- Type of oil GOYA 220
- Oil changes The first time, after 6 months and then every year.
- Volume 1.2 litres
Alternative oil:
Q8 Goya 220
BP Energol GR XP 220
CASTROL Alpha Sp 220
ESSO Spartan Ep 220
FINA Giran 220
MOBIL Mobilgear 630
SHELL Omala EP 220
Chest
- Type of oil TEXATHERM HT 22
- Oil changes Every 2 years or every 3500 hours.
- Volume 50 litres
Alternative oil:
SYNLUBE Lubriplate
TRANSCAL BP Marine
SHELL CASSIDA Fluid HT
Hydraulic pump
- Type of oil HYDRO 46
- Oil changes Every 5 years
- Volume 2.5 litres
Alternative oil:
Q8 Hayden 46
BP Energol HLP 46
CASTROL Hyspin AW5 46
ESSO Nufo H 46
FINA Hydran 46
MOBIL DTE Medicure
SHELL Turbo T oil 46
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3.5 Hydraulic pressure regulation
Manometer
Set pressure
Max. 30 Bar
Recommended:
20 – 25 Bar
Oil tank drain
Oil: 2.5 litres
The oil filler
To adjust the hydraulic pressure of the ironing bed,
undo the black blind nut (using a no. 13 spanner).
Then undo the tensioning nut (the no. 13 spanner)
using an Allen key and turn it to the left (to reduce the
pressure) or right (to increase the pressure). (The
pressure can be read off on the manometer).
The max. pressure which can be set is 30 Bar.
Then tighten the nut again.
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3.6 Replacing and setting the tension of the feed belts
- Undo the two bolts using an M8 spanner.
- Move the guide plates towards the feed trough.
- Open the feed belts by removing the locking pin between the connecting hooks.
- Once the feed belts have been replaced, move the guide plates towards the ironing bed
and retighten the bolts on both sides.
The guide plates should be fitted so that the feed belts are firmly held under tension
and positioned as close as possible to the ironing bed.
3.7 Setting the safety thermostat
- Heat up the machine first of all (175°C) in order to set the safety thermostat.
- Wait 20 minutes so that the ironing bed is fully up to temperature.
- Use a flat-headed screwdriver and slowly turn the adjusting screw to the left until you
hear a click. This click means that the safety thermostat is open and the machine
cannot be heated up any further.
- Then use the flat-headed screwdriver and slowly turn the adjusting screw to the right
until you can press the red pushbutton so that the machine can be heated up again.
- This means that the safety thermostat is set approximately 10°C higher than the actual
ironing temperature set. Iron a few pieces of linen in order to check that the thermostat
does not take over.
- If the safety thermostat unexpectedly takes over during ironing, the linen (more than
55% relative moisture) may be too wet or the speed may be too high.
- To restart the machine, press the red pushbutton again.
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3.8 Problem solving
3.8.1 The machine does not heat up to any temperature after selecting the preheating
facility (touchscreen)
Possible causes
A. Failure of fuse F8.
B. Safety thermostat S8 is off.
C. Emergency stop has been activated.
D. No gas.
E. Gas burner defective.
F. Air in the gas pipe.
G. Card module defective.
Solution
A. Reset or replace fuse F8.
B. Reset safety thermostat S8
C. Unlock the emergency stop.
D. Check the gas supply.
E. Press the burner reset button.
F. Vent the gas pipe.
G. Replace card module.
3.8.2 The machine is up to temperature but the ironing bed will not close
Possible causes
A. Contactor is defective.
B. Pump motor is defective.
C. No oil in the pump.
D. Cylinder defective.
E. Card module is defective.
F. Thermal overload had failed.
Solution
A. Replace the contactor K8.
B. Check motor M2.
C. Check oil pump level or for leaks.
D. Replace the cylinder.
E. Card module defective.
F. Reset or replace the thermal overload Q8.
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3.8.3 The ironing bed is closed but the roller is not rotating
Possible causes
A. Foot pedal has been pressed.
B. Pressure has been applied to the finger guard.
C. Frequency converter is defective.
D. Card module defective.
Solution
A. Check or replace contact FDC4.
B. Check or replace contact FDC2.
C. Replace the frequency converter.
D. Card module defective.
3.8.4 The exhaust system is not working
Possible causes
A. Motor is defective.
B. Contactor is defective.
C. Thermal overload has failed.
D. Card module defective.
Solution
A. Replace the motor.
B. Replace contactor K9
C. Reset or replace the thermal overload Q9.
D. Card module defective.
3.8.5 No control voltage
Possible causes
A. Motor protection is off.
B. Main switch is defective.
C. Fuse has failed.
D. Transformer defective.
E. No primary voltage.
Solution
A. Activate motor protection.
B. Replace the main switch.
C. Reset or replace the fuse F2,F3,F4 or F5.
D. Replace the transformer.
E. Find problem with primary voltage.
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3.8.6 Folds in linen
Possible causes
A. Temperature of the ironing bed is too low (below 150°C).
B. The ironing bed is very dirty.
C. Linen has not been rinsed properly.
Solution
A. Increase the operating temperature (normal 175°C).
B. Clean and wax the ironing bed.
C. Check the results after rinsing.
3.8.7 The safety thermostat drops out
Possible causes
A. Temperature of the ironing bed is set too high (+ 175°C).
Solution
A. Reduce the temperature setting (max. 175°C).
3.8.8 Machine starts up ready for heating but the gas burner is not working
Possible causes
A. Not enough gas.
B. Safety thermostat is defective.
C. Gas pressure regulator not adjusted or defective.
D. Gas valve defective.
E. Air in the pipe.
F. Fuse defective.
Solution
A. Check the gas supply.
B. Replace safety thermostat S8.
C. Check or replace the gas pressure regulator.
D. Replace the gas valve.
E. Vent the gas pipe.
F. Replace the fuse F8.
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3.8.9 Carriages do not open
Possible causes
A. Proximity switch Z5 is poorly adjusted.
B. No program has been set.
C. MC1 and/or MC2 not adjusted properly.
D. Emergency stop button has been pressed.
E. Carriage bar belt is defective.
Solution
A. Readjust proximity switch Z5.
B. Set program.
C. Readjust MC1 and/or MC2.
D. Reset emergency stop facilities to rest function.
E. Repair the carriage bar belt.
3.8.10 Carriages remain live
Possible causes
A. Photocell FC8 not adjusted properly.
B. Sheet is not being fed in properly.
C. Fault in frequency converter.
Solution
A. Readjust photocell FC8.
B. Feed in the sheet in the correct manner.
C. Set the frequency converter correctly.
3.8.11 Grippers let go too early
Possible causes
A. Program not set properly.
B. Not enough pressure on the clamp pistons.
C. Photocell FC8 not adjusted properly.
D. No voltage being supplied to the photocells.
Solution
A. See appendix to O&M manual for the settings.
B. Apply more pressure to the clamp pistons (max. 3 bar).
C. Readjust photocell FC8.
D. Replace fuse F3 inputs.
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3.8.12 Poor longitudinal fold
Possible causes
A. Sheets still too wet.
B. Temperature too low.
C. Belts are lying on top of each other.
D. Sheets not being fed in properly.
E. Pressure too low.
F. Static electricity in linen.
Solution
A. Rotate at slower speed.
B. Increase temperature.
C. Check the belts.
D. Feed in correctly.
E. Check air compressor.
F. Increase pressure.
3.8.13 Machine does not carry out the first crossfold
Possible causes
A. Sheet is too big.
B. Photocell FC3 or FC5 defective.
C. Bypass cross 1 is on.
D. Air valve is broken.
Solution
A. If possible, make several longitudinal folds.
B. Replace photocell FC3 or FC5.
C. Remove bypass cross 1 from program.
D. Replace air valve.
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3.8.14 Machine does not carry out the second crossfold
Possible causes
A. Sheet is much too thick.
B. Bypass cross 2 is on.
C. Photocell FC2 defective.
D. Air valve is defective.
Solution
A. Make fewer longitudinal folds in sheets.
B. Remove bypass cross 2 from program.
C. Replace photocell FC2.
D. Replace air valve.
3.8.15 Machine does not carry out the third crossfold
Possible causes.
A. Sheet much too thick for longitudinal folding.
B. Sheet much too thick for crossfolding.
C. Photocell FC1 defective.
D. Air valve is defective.
E. The blade is not adjusted properly.
Solution
A. Make fewer longitudinal folds in sheets.
B. Make fewer crossfolds in sheets.
C. Replace photocell FC1.
D. Replace air valve.
E. Readjust the blade.
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3.8.16 Stacking gripper is not handling sheets properly
Possible causes
A. Valve is defective.
B. Air cylinder braking is too strong.
B. Proximity switch Z1 defective.
C. Sheet too thick.
Solution
A. Replace valve.
B. Reduce air cylinder braking.
B. Replace proximity switch Z1.
C. Make fewer longitudinal folds or crossfolds.
3.8.17 Stacking gripper remains on top
Possible causes
A. Valve is defective.
B. Proximity switch Z2 defective.
C. Linen stack too high.
Solution
A. Replace valve.
B. Replace proximity switch Z2.
C. Adjust number of sheets on exit belt in program.
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CAUTION!
A. It is better just to crossfold big, thick sheets.
B. Whenever any work has to be carried out on the machine, it should be stopped by
activating an emergency stop. The purpose of this is to switch off all the moving parts
connected with the ironing, feeding, folding and stacking process.
C. On restarting, all protective doors, plates or Perspex screens are to be closed or fitted
again.
D. When the machine is restarted, mechanical movements can occur immediately.
3.9 Oil change in reduction gearbox
Note: Switch off the main switch..
Only change oil when the machine is cold.
Undo the screw at the bottom of the
reduction gearbox so that you can
drain the oil into a receptacle. N.B.: content see Oil types
Once the oil has completely drained from the reduction gearbox,
replace the screw at the bottom and tighten securely! (When
changing oil, it is better to replace the seal from the screw.)
Unscrew the filling plug at the top and
fill the reduction gearbox with new oil.
Note:Oil type GOAYA 220
Content: see Oil types
Then replace the filling plug and tighten
securely! (When changing oil, it is better
to replace the seal from the screw.)
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Disconnect the plug from the valve
Valve open
Close valve on pressure line.
Plug on pressure line.
3.10 Thermal oil change.
Attention : Oil change can only happen when the oil got a temperature
of appr. 40 - 50°C, then the oil circulates better.
1. Shut the machine off with the main switch.
2. Close the stopcock at the bottom of the expansion tank and replace the stopper (for
safety).
3. Open the stop valve and collect the oil thermal oil in a container.
Leave the valve open until all the old oil is out of the system
3. Close the stop valve on the pressure line of the oil pump.
4. Remove the plug mounted on the pump pressure line.
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Open stop valve
Stop valve + plug
Filling plug oil on top
Oil level cold
Remove existing teflon hose and
attach the extra hose
5. Connect a pressure hose to the plug hole and open the compressor air valve (max 6
bar) in several jets till all the old oil is totally out of the system (repeat this several
times). Take off the air line and put the plug back in the connection. Open the stop
valve on the pressure line.
6. Close the stop valve at the bottom of the expansion tank and mount the plug. (as a
safety).
7. Remove the filling plug at the top of the boiler. Fill the boiler with thermal oil up to
the indicated level while the circulation pump is activated regularly.
Attention: Do not let the circulation pump turning without oil!
8. When the oilpump is able to turn continuously, fill the oil up to the indicated level
9. Heat machine up and constantly check the oil level.
When filling the machine with new oil there is always some moisture in it
(condensate). To avoid problems it is necessary to use the teflon hose on top of the
expansion tank. This the condense moisture can be removed from the system.
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Remove existing teflon hose and
attach the extra hose
Bed vent
10. After heating up the machine it is ready to work. The extra teflon hose can be taken
away and the existing one mounted again.
Please vent the bed at the top and the bottom! Just to be sure there is nothing but oil in
the bed. Vent while the circulation pump is working.
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3.11 Cleaning of the bed. - There is no doubt that the life of all ironer clothing depends largely on the condition of the
beds. A clean smooth bed increases the life of any clothing and improves the quality of the
ironed linen.
A typical ironing problem like creasing on the leading edge is almost always due to a dirty
bed. Though not always visible residuals and salts will build up on the bed surface.
- Before cleaning the bed the causes of the deposit should be located. These are usually to be
found in the washing process :
- too hard water (lime deposit)
- PH value higher or lower than the ideal 6.5
- too high rest moisture (too much water to evaporate)
- bad rinsing (soap residuals).
- Cleaning of the bed :
1. When there is only build-up at the bed inlet, it can be removed by hand and with Scotch-
Brite (only when bed is cold).
2. When there is build-up on the whole bed:
- Drop the bed.
- Let the machine cool down ( 100°C).
- Open the scrapers.
- Wrap a cloth around the roll which will protect the padding against dust.
- Wind strips of Scotch-Brite around the rollers in wide lanes.
- Lower hydraulic pressure to 15 Bar.
- Push the slightly heated ( 100°C) bed against the roll and turn the roll for 2 to 3
hours.
- Keep watching to make sure the Scotch-Brite does not get loose.
- Remove all dust, then the Scotch-Brite and the cloth.
- Restore the original hydraulic pressure.
- Heat the bed and pass a wax cloth to grease the bed.
* Wax should be applied regularly but then sparingly (not too much) so as not to clog up the
suction clothing. Always use the cloth and never apply wax between roll and bed. It may
cause spots in the ironed items as then the padding takes the wax.
- For long time storage (seasonal work) prepare machine as follows :
- let the padding dry out
- Pass a wax cloth with much wax to prevent rusting
. - keep carrying out the annual maintenance (oil change, greasing...).
Before starting the ironer again : clean the bed!
Attention: On oil heated ironers (temperatures higher than 185° C)
too much wax constitutes a fire hazard.
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3.12 Roll padding replacement.
If the ironing machine is delivering reduced output and poorer ironing quality after a period of
time (1 year), this means the padding is worn.
The old padding is easily removed using a reversing switch located in the electrical
connection box.
- First clean the bed. ( See cleaning of the bed).
- Open the bed. ( machine at rest)
- Disassemble the feedingthrough.
- Disassemble the covers.
- Cut or detach the cords on the side of the padding.
- Turn the scrapers away of the padding as shown in the drawing.
- Let the roll turn backwards (with the switch) and take the padding so it rolls of the roll. Note
that the scrapers don’t falter in the padding, and that the padding doesn’t damages the
feedingplate.
- Check dimensions of the new delivered padding. ( length, width)
Mod.500 Padding
Ø Length (mm) Width (mm)
2000 3200 2200
2500 3200 2700
3000 3200 3200
3300 3200 3500
- Put a knot in the rope at both sides, so the rope can’t get out of the padding.
- Set the temperature at min. 120°C.
Knot in the rope ( 1 knot)
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- Then press preheating.
Glue ( type Vitabond VB100)
- Put the padding straight on the roll + push the padding against the roll. Place the padding on
the roll with the ropes at the bottom.
- Lower speed ( potentiometer) , then let the roll turn with the switch in the power box
( clockwise).
Spray glue over the
entire length with a
width of 10cm.
Preheating / Tension
± 10cm
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- While turning, make sure the padding is tensionned.
- When the padding enters the bed, stop the roll.( position switch “0” ). Close the bed (
working pressure max. 15Bar!) and let the roll turn. You can do this by pushing the start
button. Check that nothing rolls bad or keeps faltering. If you want to stop the roll, push the
fingerscreen or the footpedal. ( option)
- Make sure the ropes are not on the padding when the roll turns.
- Press the sides with a stump object. That prevents that something should halter / hang.
Startbutton
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- When the padding is completely on the roll ( 2 turns), increase working pressure and let the
roll turn for 15min. at a temperature of min.120°C and a higher speed.
Let the roll turn when the padding is too short ( max. 1 hour) If the padding is too long, stop
the roll and cut the padding. ( Cut when 3rd turn begins.) You can feel where the padding is
laying double. It is recommended to check the length of the padding after 1or 2 weeks and if
necessary cut the padding.
- Brush the padding ( positioning of the padding by turning the roll with the switch). Make
sure the bed is open. The brushing happens best with a steelbrush or a drill with a radial
steelbrush. Put something under the padding, like a wooden plank. So you can’t damage other
things.
Ideal length.
The padding is too
long. ( cut)
The padding is too short. ( Turn the roll
longer or change the padding.)
Wooden plank
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- Then use the steelbrush to create a smooth transition.
- Turn the roll.
- Stop the roll, and make 3 knots in the ropes at the sides of the padding. ( Tighten the knot as
hard as possible.)
Take the ropes.
Make 3 knots in it.
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- Let the roll turn and place the scrapers back in the correct position.
Cut the ends.
Push het ends and the knots back
with a stump object.
Too much pressure.
Too little pressure.
Good ( slight pressure)
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- Mount the feedingthrough.
- Mount the covers.
- If there are no comments, the padding is ready for use.
Never turn the roll whit pressure on the bed when the bed is cold!
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PART 4: SCHEMATIC DIAGRAMS
4.1 CROSS-SECTION OF CROSSFOLD COUPLING
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4.2 CROSS-SECTION OF STACKER
M8 type: 43900187
JOUCOMATIC type: C20 AS 25 DM
JOUCOMATIC type: C20 AS 25 SER
M8 TYPE: 43900187
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4.3 CROSS-SECTION OF EXIT BELT
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4.4 DRIVE FOR FEED ROLLER TO IRONING ROLLER
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4.5 HYDRAULIC CIRCUIT
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4.6 METHOD OF FOLDING
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4.7 CROSS-SECTION OF LONGITUDINAL FOLDING
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4.8 DRIVE FOR CROSSFOLDER.
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4.9 SET-UP FOR CONTACT FINGER GUARD.
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4.10 VALVE ISLAND
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4.11 PNEUMATIC DIAGRAM
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PART 5 : FACTORY SETTINGS AND OPTIONS.
5.1 Altivar
Altivar 312 :
Factory settings for Frequency invertor from Schneider. (ATV312)
( Push 2 sec. )
‘ESC’ ( Push 3 times )
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Factory settings for Frequency invertor from LACO. (ATV312 0.18kW)
- First enter factory settings from Schneider. ( As described on the previous page.)
- Then change the following parameters:
70
‘ESC’ ( Push 2 times )
L
‘ESC’ ( Push 2 times )
‘ESC’
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0.1
0.0
70
‘ESC’
‘ESC’
‘ESC’
0.1
‘ESC’
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0,8 (0.15 kW)
‘ESC’ ( Push 2 times )
L i2
‘ESC’
‘ESC’
‘ESC’ ( Push 2 times )
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L3
‘ESC’
Push 3 seconds
Push 3 seconds ‘ESC’ ( Push 2 times)
‘ESC’
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L12
‘ESC’ ( push 3 times)
3.0
‘ESC’
500
‘ESC’ ( push 3 times)
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Factory settings for Frequency invertor from LACO. (ATV312 0.75 – 1.5kW).
- First enter factory settings from Schneider. ( As described on the previous page.)
- Then change the following parameters:
0.1
70
‘ESC’ ( Push 2 times )
‘ESC’
3.0
‘ESC’
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0.0
70
3,5 (0.75 kW) or 3,6 (1.5kW)
‘ESC’
‘ESC’
‘ESC’ ( Push 2 times )
L i2
‘ESC’
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‘ESC’
‘ESC’ ( Push 2 times )
L3
‘ESC’
Push 3 seconds
Push 3 seconds ‘ESC’ ( Push 2 times)
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‘ESC’
L12
‘ESC’ ( push 3 times)
2.0
‘ESC’
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How to reduce the roll drive motor noise with the frequency invertor. (ATV312)
Tune between 2 and 10
Tune the parameter between 2 and 10.
When you find the best parameter with the lowest
noise, you may push ‘enter’.
ATTENTION: When you tune the parameter
higher than 10, the motor can burn!
‘ESC’ ( Push 3 times )
500
‘ESC’ ( push 3 times)
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5.2 Thermal overload Adjust with a screwdriver.
Q8 => 1.2A (380V) 2A (230V)
Q9 => 0.7A (380V) 1.2A (230V)
Q10 => 4.5A (380V) 8A (230V)
Q11 => 0.4A (380V) 0.75A (230V)
Q12 => 0.4A (380V) 0.75A (230V)
Q13 => 0.6A (380V) 1A (230V)
Q14 => 0.6A (380V) 1A (230V)
5.3 Loading backup programs onto the B&R screen with USB stick.
Place the files “recept” and “settings” on the USB stick. They may not be in a folder on the
USB stick. This means, that you see the files when you open the USB stick on the computer.
Then we go with the USB stick to the machine and plug the USB stick into the USB input that
is the most backwards of the B&R screen.
Then we go on the B&R screen to “settings” “copy” “MEM” “MEMORY”
“restored from USB”. Shut the machine down, and put the machine on after 5 sec. The backup
programs are now loaded onto the B&R screen.
USB input
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5.4 Adjustable suction valve (option).
An adjustable suction valve allows the suction throughput to be regulated so that the roll is
not subject to cold suction but is still dry. The ideal temperature of the roll when the padding
returns to the ironing bed is approximately 40° C.
Valve can be adjusted
with a flat-head
screwdriver.
