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VCOMaintenance Manual

Propermaintenanceofthetunnelfinisherisessentialforprolongedequipmentlifeandhighqualitygarmentfinishing.

The PLC is programmed with a maintenance schedule. When maintenance is due, the system will automatically turn the yellow beacon above the control box on and a red banner will appear at the bottom of the touch-screen announcing the maintenance to be preformed.

The maintenance that is programmed in the system consists of:• Grease blower bearings at 250 hours.• Inspect blower and clean if necessary.• Inspect burner, burner blower, and clean if necessary.• Inspect, clean, and lubricate conveyor chain.• Change oil in conveyor drive unit.

THE FOLLOWING SHOULD BE INSPECTED DAILY

CAUTION:

CAUTION:Lock out main panel disconnect according to OSHA regulations

Goggles and mask should be used when blowing lint from surfaces

• Air Circulation Filters (Main blower & Burner Combustion blower)•Note:dependingupontheseverityoflintaccumulation,filtersmayneedcleaningseveral times during the day.

Filter (If not equipped with an AutoFilter)1. Shut off main control panel disconnect and lock out according to OSHA regulations.2.Slidethelintfilteroutofthesideofthetunnel.3.Usingasoftclothorsoftdustmopgentlywipeoffthefilterscreens.Thelintwill roll off with the wiping motion.4.Sweepoutaccumulatedlintfromflooroftunnel.5.Reinstallthefilter.6. Remove lock out from control panel disconnect.7. Go into start up procedures.

Daily Inspections

Maintenance Guide

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THE FOLLOWING SHOULD BE INSPECTED WEEKLY

• All Blowers for lint buildup and proper operation• Conveyor Drive Unit• General clean up of unit• If Auto-lint Filtration system has been purchased. Empty vacuum bag weekly

Circulation Blowers1. Shut off main control panel disconnect and lock out according to OSHA regulations.2.Openreardoorandremovedeflectorshield.3.Checkforlintaccumulationontheblowerwheel.Evenafinecoveringshouldberemoved.4. Clean the blower wheel with a vacuum or air gun.

5. Reinstall shield and close door.6. Remove lock out from control panel disconnect.7. Turn on circulation blower to insure proper operation.

Conveyor Drive Unit1.Checkchainforproperadjustment.Donotovertightenchain(Chainshouldbesnugbut not springy).2. Check lubrication and cleanliness of conveyor chain.3. Check lubrication level in gear reducer.

General Clean Up1. Wipe lint accumulation off of tunnel.2. Blow off top of tunnel with a vacuum or air gun.

CAUTION: Goggles and mask should be used when blowing lint from surfaces.

CAUTION: Goggles and mask should be used when blowing lint from surfaces.

Weekly Inspections

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THE FOLLOWING SHOULD BE PREFORMED EVERY 250 HOURS• Grease Blower Bearings

When lubricating bearings, use a #2 consistency Lithium Base grease. Add grease slowly while shaft is rotating. When grease appears at seal area, the bearing contains the correct amount of grease.

Burner Checklist1.Inspecttheflamesensingdevicesforgoodconditionandcleanliness2. Check for proper air and gas pressures3. Check and clean igniter electrodes4.Checkvalvemotorsandcontrolvalvesforfree,smoothactionandadjustment5. Check for the proper operation of ventilating equipment.6. Test the manual gas shut off cocks for proper operation.7.Cleanand/orreplacethecombustionairblowerfilterifapplicable8. Inspect and clean the combustion air blower rotor

InspectthefilterscreenoftheAutoFilteronceamonthfortearsorholesinthescreen.

Withthetunnelfinisherburnersystemturnedoff;1. Remove the stainless steel cover from one unit of the AutoFilter. 2.Allowthefiltertocompleteonecyclewhilelookingforanytearsorholesinthescreen. 3. If the screen is worn, contact Leonard Automatics to order a replacement screen. 4. Follow instructions on Page 57 to replace AutoFilter screen.

250 Hours Inspections

Monthly Auto Filter Inspections (If option equipped)

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THE FOLLOWING SHOULD BE PREFORMED YEARLY

Burner:

Clean the burner:

1.Theburnercombustionblowerisequippedwithafilterassemblytoremovelintfromthe air supply to keep itself and the burner free from lint. This filter is cleaned daily.Howeversmallamountsoflintcanpenetratethefilterandcollectontheblowerbladesaswellasontheundersideoftheburner.Thiscancausetheflametobecomeyellowandproducesoot.Ifnotproperlycleaneditcanalsocausebackfireanddamagetotheburnercombustion blower.

2.Removethelintfilterfromtheburnercombustionblower.Measurethedistancebetweenthe round air damper and the blower housing. Remove the round air damper from the blower. Inspect theblowerwheelfinsfor lintcollection. Ifany lint is found itshouldberemoved.

3. Re-assemble the burner combustion blower, set the air damper back into its original positionandreinstallthelintfilterontotheblowerhousing.

4. Remove the air duct from the bottom of the burner. Inspect through the opening into the bottom of the burner. If any lint is present remove it. Check that all the holes in the burner plate are open and free from lint. Inspect and clean duct work.

5.Inspecttheburnerfromthetoplookingintotheflamecavity.Cleanthesparkplugandflamerodifnecessary.

6. Reinstall the air duct to the bottom of the burner.

Visually check igniter cable and connectors.

Be sure the following components are not damaged or distorted: • the burner bodies and air wings • the ignitor •theflamesensors

Yearly Inspections

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1.Removethecoversfrombothsidesoftheautofilter;itisveryimportantthenewscreenis threaded in the same fashion and attached to the drums as the old one. Remove the old screen.2. Starting on the side with the vacuum, thread the new screen through the tunnel.3. Attach the screen to the drum.

4. On the touch screen: From the Main Menu screen, press the MAINTENANCE button, and then the AUTO FILTER button. With the (MAN/AUTO) in the MAN position, and the (REV/FWD) in the REV position. Press and hold the JOG button until all but enough screen to attach to the drum is left. 5. Attach the screen to the drum. 6.With the(REV/FWD) in theFWDposition, jog thescreen forwarduntil there isonecomplete wrap of screen around the drum.7. Press the SET HOME button. A screen will appear that will verify you want to set home. Press the SET HOME button, and then the BACK button. This will take you back to the AutoFilter control screen.8. Ensure the (MAN/AUTO) button is in the AUTO position, and then press the BACK button. Press the RETURN button and then FINISHER CONTROL.9. Reinstall the covers.

NOTE: The next step will require two people. One person will guide the new screen as it is being pulled through the tunnel. The second person will operate the touch screen.

AutoFilter Screen Replacement

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Good operating practice, and in many cases insurance or regulatory requirements, prescribetestingofallflamecontrolsafetyinterlocksonat least an annual basis. Follow these methods to test the safety interlocks:

1. Manual Reset High Temperature Limit Control. This limit control is most easily checked by raising the set point temperature and monitoring the actual temperature until the limit control trips out. The set point temperature is limited by Tunnel Temp Setpoint Max, which is set on the Finisher Setup screen.

The Tunnel Temp Setpoint Max is factory preset to 340° Fahrenheit and is generally reduced in the field to+/- 315°Fahrenheit.TunnelTempSetpointMax is limited to amaximum of 400° Fahrenheit. When the actual temperature equals or exceeds the setting, the machine will shut down and an alarm will sound. On PLC machines you should see a message on the screen notifying you of a High Temperature Limit failure. When the actual temperature falls below the limit control setting the limit control can be reset by pressing the reset button on the lower right hand corner of the control itself.

2. High Gas Pressure Safety Switch. This switch is factory set to approximately 17 – 18 IWC. With the burner in operation, this switch can be tested by gradually lowering the pressure set point to at or below the current actual gas pressure displayed on the gas gauge located on the gas train. When the pressure switch responds, the machine will shut down and an alarm will sound. On PLC machines you should see a message on the screen notifying you of High Gas Pressure failure. Return the switch to its original setting after testing. US machines will automatically reset while Canadian machines must be manually reset.

3. Low Gas Pressure Safety Switch. This switch is factory set to approximately 4 – 5 IWC. With the burner in operation, this switch can be tested by closing the gas supply isolation valve. As the burner consumes the gas in the gas train the actual gas pressure will fall below the switch setting. Once the pressure is below the setting, the burner should shut off and an alarm will sound. On PLC machines you should see a message on the screen notifying you of a Low Gas Pressure failure. Return the switch to its original setting after testing. US machines will automatically reset while Canadian machines must be manually reset.

Note:AdjustingtheTunnelTempSetpointMaxrequiresanadministrativepassword level.

Gas Burner Safety Testing and Inspection

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The burner is protected by a Flame Safety monitoring control. Use the following procedure to test this control. Thistestprocedureisdesignedtocheckforafalseflamesignalafterthestartofthetrialforignitionoftheburner.Forthesetests,theterminology“noindicationofflame”meansthattheredlightinsidethetestjackontheFlameSafetyisofforthevoltagemeasuredfromthetestjacktoterminalS2ontheFlameSafetyorearthgroundmeasuresbelow1.5VDC. Also, there should be no AC voltage output at either terminal 3 or 5 on the Flame Safety to the safety shut off valves.

The Gas Train is equipped with a manual valve that is down-stream of the safety shut off valves that are powered by the Flame Safety and down-stream of any limit devices that are inputs to the Flame Safety.

To test the Flame Safety: Close the downstream valve on the Gas Train.

(Please see the image below for the location of the manual valve)

The proper response of the Flame Safety is:

If the Flame Safety does not respond properly it failed the test.

• If the burner is running, it will lose flame.The FlameSafety should have noindicationofflameandwillde-energizethesafetyshutoffvalves.

• If the burner is not running, create a demand to start the burner. The Flame Safety should not keep the safety shut off valves open after the end of the trial for ignition. The valves should not remain open for more than 15 seconds. After that timetheFlameSafetyshouldhavenoindicationofflameanditshouldde-energizethe safety shut off valves.

CLOSE THIS VALVE

Flame Safety Monitoring Control Procedure

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