V-VTP Maintenance Manual

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V-VTP Maintenance Manual PO Box 501 Denver, NC 28037 ph: 704-483-9316 /

1 V-VTP Maintenance Manual PO Box 501 Denver, NC ph: / fx: sales@leonardautomatics.com -

Maintenance Guide Proper maintenance of the tunnel finisher is essential for prolonged equipment life and high quality garment finishing. The PLC is programmed with a maintenance schedule.

2 Maintenance Guide Proper maintenance of the tunnel finisher is essential for prolonged equipment life and high quality garment finishing. 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. Daily Inspections THE FOLLOWING SHOULD BE INSPECTED DAILY CAUTION: Lock out main panel disconnect according to OSHA regulations CAUTION: Goggles and mask should be used when blowing lint from surfaces Air Circulation Filters (Main blower & Burner Combustion blower) Note: depending upon the severity of lint accumulation, filters may need cleaning several times during the day. Filter 1. Shut off main control panel disconnect and lock out according to OSHA regulations. 2. Slide the lint filter out of the side of the tunnel. 3. Using a soft cloth or soft dust mop gently wipe off the filter screens. The lint will roll off with the wiping motion. 4. Sweep out accumulated lint from floor of tunnel. 5. Reinstall the filter. 6. Remove lock out from control panel disconnect. 7. Go into start up procedures. 63

Weekly Inspections 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

3 Weekly Inspections 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 Blowers 1. Shut off main control panel disconnect and lock out according to OSHA regulations. 2. Open rear door and remove deflector shield. 3. Check for lint accumulation on the blower wheel. Even a fine covering should be removed. 4. Clean the blower wheel with a vacuum or air gun. CAUTION: Goggles and mask should be used when blowing lint from surfaces. 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 Unit 1. Check chain for proper adjustment. Do not over tighten chain (Chain should be snug but not springy). 2. Check lubrication and cleanliness of conveyor chain. 3. Check lubrication level in gear reducer. General Clean Up 1. 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. 64

4 Burner Checklist 1. Inspect the flame sensing devices for good condition and cleanliness 2. Check for proper air and gas pressures 3. Check and clean igniter electrodes 4. Check valve motors and control valves for free, smooth action and adjustment 5. Check for the proper operation of ventilating equipment. 6. Test the manual gas shut off cocks for proper operation. 7. Clean and/or replace the combustion air blower filter if applicable 8. Inspect and clean the combustion air blower rotor 250 Hour Inspections 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. Monthly AutoFilter Inspection (If Option Equipped) Inspect the filter screen of the AutoFilter once a month for tears or holes in the screen. With the tunnel finisher burner system turned off; 1. Remove the stainless steel cover from one unit of the AutoFilter. 2. Allow the filter to complete one cycle while looking for any tears or holes in the screen. 3. If the screen is worn, contact Leonard Automatics to order a replacement screen. 4. Follow instructions on Page 67 to replace AutoFilter screen. 65

5 Yearly Inspections THE FOLLOWING SHOULD BE PREFORMED YEARLY Burner: Clean the burner: 1. The burner combustion blower is equipped with a filter assembly to remove lint from the air supply to keep itself and the burner free from lint. This filter is cleaned daily. However small amounts of lint can penetrate the filter and collect on the blower blades as well as on the underside of the burner. This can cause the flame to become yellow and produce soot. If not properly cleaned it can also cause backfire and damage to the burner combustion blower. 2. Remove the lint filter from the burner combustion blower. Measure the distance between the round air damper and the blower housing. Remove the round air damper from the blower. Inspect the blower wheel fins for lint collection. If any lint is found it should be removed. 3. Re-assemble the burner combustion blower, set the air damper back into its original position and reinstall the lint filter onto the blower housing. 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. Inspect the burner from the top looking into the flame cavity. Clean the spark plug and flame rod if necessary. 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 the flame sensors 66

6 AutoFilter Screen Replacement 1.Remove the covers from both sides of the auto filter; it is very important the new screen is 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 rewind drum. 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. 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 master drum is left. 5.Attach the screen to the master drum. 6.With the (REV/FWD) in the FWD position, jog the screen forward until there is one complete 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. 67

Gas Burner Safety Testing and Inspection Good operating practice, and in many cases insurance or regulatory requirements, prescribe testing of all flame control safety interlocks on at least an

7 Gas Burner Safety Testing and Inspection Good operating practice, and in many cases insurance or regulatory requirements, prescribe testing of all flame control safety interlocks on at 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. Note: Adjusting the Tunnel Temp Setpoint Max requires an administrative password level. The Tunnel Temp Setpoint Max is factory preset to 340 Fahrenheit and is generally reduced in the field to +/- 315 Fahrenheit. Tunnel Temp Setpoint Max is limited to a maximum 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 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. 68

Flame Safety Monitoring Control Test Procedure The burner is protected by an Flame Safety monitoring control. Eclipse has provided the following procedure to test this control.

8 Flame Safety Monitoring Control Test Procedure The burner is protected by an Flame Safety monitoring control. Eclipse has provided the following procedure to test this control. This test procedure is designed to check for a false flame signal after the start of the trial for ignition of the burner. For these tests, the terminology no indication of flame means that the red light inside the test jack on the Flame Safety is off or the voltage measured from the test jack to terminal S2 on the Flame Safety or earth ground measures below 1.5VDC. 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) CLOSE THIS VALVE The proper response of the Flame Safety is: If the burner is running, it will lose flame. The Flame Safety should have no indication of flame and will de-energize the safety shut off valves. 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 time the Flame Safety should have no indication of flame and it should de-energize the safety shut off valves. If the Flame Safety does not respond properly it failed the test. 69

Proper maintenance of tunnel finisher will prolong its life and enable the equipment to produce the best possible quality.

Maintenance Guide Proper maintenance of tunnel finisher will prolong its life and enable the equipment to produce the best possible quality. Daily Maintenance CAUTION: Lock out main panel disconnect according