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 to OSHA regulations CAUTION: Goggles and mask should be used when blowing lint from surfaces Prior to morning startup, the air filter(s) must be cleaned. Filter(s) may need cleaning several times throughout the day. 1. Shut off main electrical disconnect and lock out according to OSHA regulations. 2. Always enter the machine from the exit end. Never enter through the steam section. Remove the slide out door panel from the exit side of the machine. 3. Using a soft rag or dust mop, gently wipe the lint off of the filter(s). The lint should roll right off. There is no need to remove the filter(s) from the machine for daily cleaning. 4. Sweep out accumulated lint from the floor of the machine. 5. Check for general cleanliness throughout the machine. 6. Re-install slide out door panel. 7. Remove lock out from the electrical disconnect and proceed with normal start-up procedures. 38
Weekly Maintenance CAUTION: Goggles and mask should be used when blowing lint from surfaces. 1. Shut off main electrical disconnect and lock out according to OSHA regulations. 2. Always enter the machine from the exit end. Never enter through the steam section. 3. Remove the slide out door panels from the exit side of the machine. Remove the large steam coil access door located above the filter(s) inside the machine. 4. Steam Heated: Using a flashlight, shine the light through the fins on the Steam Coils. Check for lint blockage. If lint is present, always remove lint from the bottom of the coil. If using compressed air, always blow from the top of the coil down. Use a vacuum to suck the lint out of the fins. Gas Heated: Inspect the Burner using the following 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 5. Above the steam coils or burner in the ceiling are the intakes to the circulation blower(s). Inspect the blower wheels with a flashlight for the presence of lint. Use compressed air or vacuum to remove the lint. 6. Do a general inspection for worn or broken parts and check all piping for leaks. 7. Inspect the top of the machine for cleanliness and general appearance. Inspect for broken or missing parts, inspect all piping for leaks. 8. Check conveyor for worn or missing parts. 9. When finished, replace all door(s) and Filter(s) properly. Remove lock out from the electrical disconnect and proceed with normal start-up procedures. 39
Yearly Inspections (Gas Heated Machines) 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 40
Gas Burner Safety Testing and Inspection (Gas Heated Machine) 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 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. 41
Flame Safety Flame Monitoring Control Test Procedure (Gas Heated Machine) 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. 42